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By S. Ersayin

In 1998, the Concentrator Modeling Center was established within the Coleraine Minerals Research Lab, Coleraine, Minnesota, to develop models for simulation of iron ore processing plants, and to assist plant operators in improving performance of their aging plants. The short-term objective was to develop necessary models for reliable simulation using conventional techniques, while the long-term objective was set as liberation-based modeling and simulation of these plants. The short-term objective was achieved in 2002 after the development of models for magnetic separators, hydro-separators and fine screens. A project funded by the U.S. Department of Energy was carried out to demonstrate the capability in improving iron ore processing at the Minorca plant. As a result of this study, a 10% improvement in throughput at the plant was obtained, and simulation became a desired tool for plant operators. A significant step in the long-term objective was reached in 2005 with the development of a liberation model. This was followed by incorporation of models capable of processing liberation data into the software. By early 2007, the Concentrator Modeling Center had the capability of performing liberation-based simulation of entire plants.

Jan 1, 2009

By S. Ersayin

In 1998, the Concentrator Modeling Center was established within the Coleraine Minerals Research Lab to develop models for simulation of iron ore processing plants, and to assist plant operators in improving performance of their aging plants. The short-term objective was to develop necessary models for reliable simulation using conventional techniques, while the long-term objective was set as liberation-based modeling and simulation of these plants. The short-term objective was achieved in 2002, after the development of models for magnetic separators, hydroseparators and fine screens. A project funded the US Department of Energy was carried out to demonstrate the capability in improving iron ore processing at the Mittal plant. As a result of this study, a 10% improvement in throughput at the plant was obtained, and simulation became a desired tool for plant operators. A significant step in the long-term objective was reached in 2005 with the development of a liberation model. This was followed by incorporation of models capable of processing liberation data into the software. By early 2007, the Center had the capability of performing liberation-based simulation of entire plants.

Jan 1, 2008

By J. J. Schwoebel, M. J. Mavor

Rapid coal extraction techniques in gassy mines may strain a ventilation system if a degasification approach is not utilized. Design of mine ventilation systems requires estimates of gas emission rates from unmined coal into the existing mine workings. A degasification system for a specific property can be properly engineered to improve mining economics if the proper geologic and reservoir information is collected. This paper describes methods to determine the degasification rates for horizontal boreholes and vertical (stimulated and unstimulated) wells and the rate of gas emissions into the mine workings. The methodology is demonstrated by a specific example. Horizontal boreholes drilled in advance of mining are demonstrated to be the most effective means of coal seam degasification and reduction of gas emissions into mine workings. The significance of the paper is that few published methods for these estimates are available

Jan 1, 1991

By H. P. Cole

A team of researchers at the University of Kentucky, working under a USBM contract, developed over 65 simulation exercises for teaching and testing problem-solving and decision-making skills to miners and mining engineers. These skills involve both improving judgment and decision making in mine emergencies and enhancing the learning of real-world engineering design principles. The exercises are ideally suited for either latent image format or for computer-aided instruction. Exercise features are summarized, the structure and field testing of typical exercises described, and sample frames of individual exercises presented. Empirical data are summarized that describe the effectiveness of using these short, time-efficient performance tasks that simulate real problems and that provide immediate corrective feedback for teaching and testing critical skills. I

Jan 1, 1991

By A. Rousselet, H. Gilbert-Tremblay, A. Berton

"Robex Resources interrupted production at the Nampala Mine in September 2014 following throughput and gold recovery results which were below expectations during the first months of operation. After a thorough plant audit, an important brainstorming took place in order to identify an economical path to resume production. It was clearly identified that a significant investment was necessary at the concentrator prior to restarting the plant, namely the addition of a ball mill and a new elution system.The mineral processing simulation software USIM PAC was used in order to simulate the grinding circuit in design. The simulations’ outputs allowed the ball mill characteristics and the surrounding classification devices to be designed with more accuracy. Many ball mills available from second hand retailers were therefore studied in the simulated circuit. The chosen ball mill, which was in perfect condition, had the advantage of being available for rapid delivery on site.The paper first describes the ball mill sizing method in comparison with the conventional Allis Chalmers method. It then describes the phase 2 concentrator start-up (that took place in 2016) with the commissioning of the ball mill, the classification circuit, the gravity concentration, the four (4) new carbon-in-leach (CIL) tanks, and the Zadra elution system (The phase 1 start-up took place in 2014). It finally provides production data compared to expected simulation data, as commercial production was reached in January 2017.IntroductionDesigning a new concentrator or new equipment within an existing concentrator requires significant efforts to identify possible bottlenecks and their causes (i.e. limiting equipment or sectors) and accurate sizing of major equipment can have a tremendous impact on the economy of the whole project. In the presented case study, the ball mill was the critical equipment and oversizing it could have brought the Capex to a level where the project would not have gone through. Inversely, undersizing the mill could have resulted in lower production and therefore no economic viability for the project once it is in operation.During engineering studies, equipment sizing often relies on a static mass balance and one-by-one sizing of all pieces of equipment. The sizing is then left to the equipment manufacturer or in the case of mills, evaluated with empirical models mostly relying on the Bond equations (Allis Chalmers method) [Rowland and Kjos, 1978]. This methodology shows the disadvantage of not considering interaction between equipment in a mineral processing circuit, especially when recirculation occurs. Also, it has the disadvantage of not using the more advanced grinding models that include the use of the whole particle size distribution as well as phenomenological components by only using limited parameters in the ore particle size distribution (i.e. the P80). This can be explained by the lack of data that sometimes needs to be gathered in order to tune the more advanced models but also by the conservative mindset in mineral concentration engineering which does not always favor the use of process simulation. In many aspects of process engineering, Soutex has demonstrated its affinity to using simulation in order to size equipment with more accuracy, consider process variability, simulate complex systems, and study supply chain management (Berton et al., 2015)."

Jan 1, 2018

A discussion on simulation tools to aid the development of robotics platforms is presented. The focus of the work is towards mining robotics platforms where operations are typically in unstructured, unpredictable environments and a high degree of dependability in their operations is required. It is argued that a test-based development approach leads to more robust solutions and faster development cycles than traditional single-track field-only development and that the key enabling technology for this development paradigm is the judicious use of simulation tools. The future direction of simulation for use in online applications such as active planning and as a means to assist tele-operation in high latency communication applications is also brief y considered together with the requirements for a useful simulation environment in terms of the simulator architecture. Finally, a case study is presented on the application of the discussed methodologies to an unmanned ground vehicle (UGV) for earth-moving tasks, which is being developed in an accelerated time frame with a transient development team.

Dec 6, 2010

By A. J. Lynch

Mineral processing models have been discussed for many years but it was not until digital computers became available about 1960 that serious attempts at circuit simulation could be carried out. Even then the work was primarily academic until PCs could be used by engineers in plants and design offices in the mid-1980s. Since then simulation has moved quickly and it is now at the point that most processes can be simulated reasonably accurately for purposes of design and optimization. There are still some significant deficiencies, notably in dry grinding and separation, and in the chemical interactions in flotation. Future work will involve: ?improvements of existing models ?dynamic simulation for automatic control and, in particular ,for training which is a weak link ?using advanced simulation models to predict liberation and separation from data acquired from SEM-based liberation analysers. Eventually mineral processes models will be part of total simulation systems which will incorporate mining and downstream processes including all environmental impacts.

Jan 1, 1999

By J Guo, K Williams, J Y. Guo, A W. Roberts, M Jones, B Chen

Numerical simulations using the discrete element method (DEM) were carried out to investigate the flow patterns and stress field redistribution at the hopper and feeder interface. The influences of different filling heights, belt speeds and clearances between the hopper bottom and feeder surface on feeder loads were studied. Meanwhile, experiments were conducted by utilising wedged plane-flow hoppers with different configurations and horizontal feeders with various clearances. The simulation results were compared with theoretical values and experimental measurements. In terms of the cases presented in this study, simulation results reveal good agreements with experimental observations regarding the flow pattern. Being similar to the theoretical values, the simulations provide close predictions on vertical feeder loads for steady flow states, but they may show significant overestimations for initial states. Additionally, suggestions are given for relevant simulation parameters based on the comparisons shown in this investigation.CITATION:Guo, J, Roberts, A W, Williams, K, Jones, M, Chen, B and Guo, Y J, 2017. Simulation investigation of flow patterns and feeder loads at hopper/feeder interface, in Proceedings Iron Ore 2017, pp 173–182 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 24, 2017

By Kesser Z, Vincze T

The Western Mining Corporation mining lease on the Bendigo Goldfield measures 5krri x 18km with more than 20 anticlinal folds parallelling th long north-south boundaries. Numerous closely spaced shafts and extensive underground workings on the reef lines along the folds flooded with groundwater following the progressive abandonment of the field. Preliminary water sampling and assessment demonstrated that a major dewatering programme and acceptable disposal methods were necessary to dewater interconnected old workings in areas of interest prior to any underground work taking place. A field wide geohydolic investigation was undertaken to establish geohydraulic parameters, groundwater recharge rates and water qualities. Data from the field investigation together with estimates of the volume geometry of the submerged workings as obtained from old mine plans, production history, and limited pump testing results were used with an appropriate analytical model to obtain estimates of water discharge rates required to reach various dewatering targets. Water disposal options were limited by relatively high salinities, arsenic levels, contained hydrogen sulphide, and the mine locations within the urban areas surrounding Bendigo. Direct disposal to the surface drainage system could not be considered, treatment to acceptable discharge standards was not economically feasible, and it was necessary to adopt a strategy of collection, containment, and evaporation.

Jan 1, 1988

By Wayne Taylor, Martyn Dawborn

Simulation modeling of portions of two platinum mines using General Purpose Simulation Software (GPSS/H™) is presented in this paper. Both mines, located in the Bushveld Igneous Complex PIC) of South Africa, exploit Merensky and UG2 reef horizons, which are processed separately and therefore handled individually from the stope face to surface, requiring duplication of storage arrangements and batch operation of transport facilities. The first simulation assignment concerns the upgrading of a shaft system operating exclusively on Merensky ore, to hoist UG2 ore and increase production. The second assignment comprises a simulation of rock flow from the stope face to surface by way of tramming, inclined conveying and vertical hoisting. Development ends and stope boxholes were modeled down to individual hoppers (cars) demonstrating the versatility of the GPSS/H™ language.

Jan 1, 2002

By W. L. Jacobsen, T. L. Dyer

Cortez Gold Mines completed a feasibility study for a new openpit gold mine in north central Nevada. The production schedule calls for a peak in material movement. This schedule is based on current operational efficiencies and equipment parameters observed at the company’s existing openpit operation. To mitigate risks of over/under predicting production, simulation modeling was used to validate the loading and haulage requirements during the peak production period. The advantage of simulation is the ability to provide a realistic model of a mining operation based on scheduled and unscheduled random events during the period under analysis.

Jan 1, 2007

By K Jupp, T J. Howard

Cliffs Natural Resources Pty Ltd (CNR) operates iron ore mines in the Koolyanobbing region of Western Australia, about 50 km north of the town of Southern Cross. Ore is trucked from three geographically isolated sources to the crusher at Koolyanobbing, where it is blended before and during crushing. Lump and fines products are produced and railed to Esperance for ship loading and export to Asian customers. CNR is examining alternative processing paths, from mining to ship loading, with the aim of improving efficiency and reducing costs. Modifications to the system must be consistent with potential future expansions and maintain the low inter-shipment grade variability on which CNR prides itself and has built a strong relationship with its customers. In searching for the optimum process design, many options from mine face to ship loading must be evaluated and compared. Pilot plant studies are infeasible, while complex mineralogical interactions, competing goals and numerous possible system configurations limit the applicability of theoretical analysis. It was therefore concluded that simulation modeling would provide the confidence to take the next step into production trials. This paper describes techniques applied at CNR to simulate grade variability resulting from potential process design changes. The simulation models are easily run Excel-based modules, with each module representing a different part of the process. The modules use extensive Visual Basic macros driven by Excel's user-friendly interfaces. Presentation of the results is enhanced by Excel's excellent graphical capabilities. The simulation software stores and graphically presents time-stamped data from a run, enabling detailed analysis of different process configurations. Final success of a simulation run is measured by inter-shipment variability (standard deviation and process capability) and in-process ore tonnages. Meaningful results from the simulations require the initial input data contain the same correlations present in the real production environment, between the mineral components, production linkages and across time. The data also have to allow simulation of potential changes to mining method and introduction of new pits into the blend. Mining data from the real operations under study are therefore used, with average grades and variability adjusted to match potential future development proposals. It is also necessary to filter out medium and long-term variations from the production data as this variability is best controlled through the conventional medium to long-term mine planning process, not by the process design being studied. The filtering was carried out using a Fourier transform technique, which is described.

Jan 1, 2009

By J. W. Merks

"Simulation is the process of designing a computerized model, of a system or procedure, for the purpose of understanding its behaviour and developing strategies to control its operation. Simulation models are rapidly becoming an effective tool for mineral processing plants. Powerful software and fast hardware are more readily available than a basic understanding of the theory of mathematical probability and applied statistics that process simulation models demand.Simple spreadsheet software can be used to develop simulation models that take into account any set of conditions at a mineral processing plant. In addition to an unbiased estimate for each variable in the set on which two-and three-product formulas are based, reliable variance estimates for all variables are required. How to estimate variances, effectively and at the lowest possible cost, and how to compute variances for simple functions such as the metal content of a quantity of ore or concentrate, or more complex functions such as the percentage recovery at a mineral processing plant, are the key to useful simulation models.IntroductionSimulation models for systems and procedures have become one of the most powerful and effective applications for computers( 2.6). Simulations are applied to a wide range of scientific and engineering disciplines. Generally, a model is designed to investigate the effects of changes in and interactions between a set of variables before a system is in operation or a procedure is implemented, by simulating weeks, months, and even years of operation, in a few minutes of computer time. Along with practical and useful applications always comeabuse and misuse. For a simulation process cannot be more reliable than the methodology that was applied to design the model, to estimate variables and variances, to check performance, and to verify validity. A mineral processing plant is a dynamic system that changes continuously as a function of time but within probabilistic constraints that can be estimated by applying statistical tools and techniques to the variables and variances that interact in the system.A model should be designed to simulate not only the set of variables but also the variance for each variable. Models in which constant variances are used to generate normally distributed random numbers, are less realistic than models in which the variances are simulated first, and then used to simulate the variables."

Jan 1, 1991

By Dr. Jack M. Gillette

A system of models which simulate surface coal mining operations has been developed for use in mine planning and economic evaluations. Micromodels simulate individual mine operations for equipment selection and mine planning. Macromodels simulate all operations in the complete mine for economic evaluation of reserves. A cash flow analysis model makes a complete discounted cash flow analysis to deter-mine a required coal sales price or return on investment for evaluation of any mining project.

Jan 1, 1978

By René Lefebvre

Numerical simulations of the physicochemical processes related to acid rock drainage (ARD) in the Sugar Shack South rock pile of the Questa Mine were performed with the TOUGH AMD simulator. The objectives were to 1) identify the main processes responsible for observed present-day conditions, 2) provide an estimate of gas phase humidity transfer, and 3) give a preliminary indication of the potential impact of closure involving the installation of an alluvial soil cover. Modeling results indicated that the mine rock geometry (thin layers placed along steep mountain slopes) favors the onset of strong thermal air convection. Simulations also indicate that resloping the piles would not significantly reduce convection and oxidation. For simulation purposes, a potential cover with the permeability range of a local alluvium was investigated and found to be of questionable effectiveness since its permeability can exceed the value of 3x10-13 m2 required to prevent thermal air convection and reduce ARD.

Nov 1, 2002

By R. V. Ramani

"A computer simulation model of a dragline has beer developed for the study of alternative dragline deployment schemes for varying geological and mining conditions. In this paper, the mathematical aspects of the model, the input data and output results are discussed. An application of the model to a coal mine in eastern Kentucky is presented.IntroductionDraglines are very productive machines. To extend their operating ranges, they are operated in several modes such as advance benching, key cut, extended benching and pullback. Unfortunately, these variations result in low machine productivities. Appropriate methods to operate these machines must be developed on the basis of detailed analyses of dragline performance under varying geological and mining conditions. There are several standard engineering procedures for the selection of dragline, and design of a dragline pit (Ramani, Iroegbu and Manula, 1976). However, the complex interrelationship which exists among equipment, methods and natural conditions can be quantified only through orderly and systematic experiments.Computer simulation is well suited to studying these types of equipment selection and method layout problems. Several alternatives can be analyzed in a relatively short time by the modification of input variables. Also, the application of computer simulation models can significantly reduce the manpower and cost required for such analysis."

Jan 1, 1985

A digital computer program has been developed to mathematically simulate the effect of limited changes in feed rate on the grinding circuit of an operating mill. The data on which the program is based was supplied by the staff of the mill in question. Samples taken around the complete grinding circuit were analyzed for solids content and particle size distribution for two feed rates. Matrix models were used to represent the grinding units: rod mill and pebble mills. Parameters for these models were computed using a method developed by Mular(l). Classifier parameters were computed by the Powell search method(2) for the Plitt model (3) . The simulation program, which permits the computing of the size distributions in the circuit resulting from the changes in feed rate between the two measured values, assumes that a linear relationship exists between the corresponding parameter coefficients. The program uses an iteration method to bring the simulated grinding circuit to a steady-state material balance for any specified' feed rate between those measured. The program is, in addition, extremely fast and economic in computing time. The results show that the simulations are not everywhere consistent with practice. For example, higher feed rates on simulation predict finer products. These errors are shown to be attributable to anomalies in data gathering techniques. An improved sampling procedure for grinding-circuit data gathering is suggested for future simulations of this type. It is concluded that the

Jan 1, 1971

By J. Ramirez-Castro, J. A. Finch

"Galena is the finest component of the product of a closed-circuit grind treating a lead-zinc ore, largely due to preferential recycling of this high-density mineral by the cyclone. For example, at the Pine Point Mines concentrator, for ~ 55% -200 mesh over-all, the galena will be close to 95% -200 mesh. This sliming of the lead can limit recovery, selectivity and dewatering. A proposed circuit modification to reduce the sliming is to incorporate a unit cell. A simulator was constructed to study the No. 3 grinding circuit at Pine Point modified by a unit cell on ball mill discharge (BMD).The simulator used a cumulative size basis rate-of-breakage with plug flow ball mill model, the parameters being obtained by laboratory grinding tests. Flotation and the cyclone models used a cumulative recovery/size matrix. The behaviour of each mineral, galena, sphalerite, pyrite and calcite/dolomite, was simulated. Simulation was adapted to a programmable calculator. A close fit to the existing circuit performance at two tonnages and mineral mixes was established.The simulator showed that the modified circuit could significantly coarsen the Pb grind, from 95% to —50% -200 mesh, depending on recovery, without substantially altering the size of the other minerals. The other principal findings were: compared to laboratory flotation tests on existing circuit BMD, the unit cell concentrate (CONC) will be coarser and markedly lower in grade; relatively low unit cell stage recoveries are desirable, because the cyclone scavenges the tail to give a circuit recovery which is higher than the unit cell stage recovery; unit cell stage recovery should not exceed the cyclone stage recovery, as the latter is the maximum circuit recovery; low unit cell stage recovery helps offset the disadvantage of the high flow at BMD; other high-density minerals will also be scavenged into the CONC, as illustrated by pyrite, making CONC quality difficult to maintain; density control of BMD flotation does not greatly alter feed density to the cyclone or ball mill.Possible plant metallurgy is forecast for a CONC diverted to final lead concentrate."

Jan 1, 1980

By Sukumar Bandopadhyay, Arunapuram Sundararajan

"For the last three decades, the application of network planning has provided a basis for a formal and general approach to the discipline of project management. For fixed activity duration, a very simple algorithm commonly known as critical path method (CPM), gives the length of time required for the total project as well as indicates the activities which are vital to the completion of a project. Project Evaluation Review Techniques (PER T) on the other hand, generalize the above approach to recognize uncertainty in the activity durations by allowing them to be random variables. One of the misleading aspects of current "" PER T"" solution method is, however, the implication that there is a unique critical path. In general, any number of paths could be critical, depending on the particular realization of the random activity durations that actually occur. In this case, simulation can be utilized to estimate completion time of a project.In this paper, the concept of criticality indexing is discussed, and a simulation model application which defines the critical path based on the criticality indexing concept, to a longwall development - extraction network, is presented. The model also provides suitable scheduling of resources based on the resource constraints and smooth s out period-t o-period assignments. IntroductionThe successful management of large-scale projects require careful planning, scheduling , and coordinating numerous interrelated activities. To aid in these task s, formal procedures based on the networks and network techniques (variously called PERT or CPM) were developed. In its original form the completion time for individual activities of a project was assumed fixed and known in advance: this in turn led to the familiar algorithms for computing the critical path, earliest start time, slack, and so forth. The unreality of such an assumption is, of course , apparent in many contexts. Consequently, attempts were made to introduce probalistic activity completion times, allowing representation of the stochastic nature of most projects."

Jan 1, 1987

By Sukumar Bandopadhyay, Arunapuram Sundararajan

"Unique production and environmental problems are associated with multiple seam mining where dragfines are used for overburden and interburden removal. On the production side, the problems are decreased dragfine efficiency in chopdown operations, the general need for spoil rehandle, complications in sequencing stripping and coal handling operations, and potential stability problems in highly stacked spoil. Many variations of dragline methods have been reported in the literature to encounter these problems. Because of the physical properties and peculiar hydrology of sub-arctic region mining of multiple seams in such areas probably could not be done with the methods used in temperate regions.The properties of thawed material would make spoil hard to place in a stable manner and thus would influence the mini sequence. For instance, multiple seam mining which requires some rehandling of spoil and prolonged exposure of overburden and interburden material might be precluded by the instability of thawed spoil and therefore mining techniques have to be modified. Since the deployment and operation of a dragline in modes different from conventional schemes will affect productivity, it will be necessary to study the effects on production of changing the dragfine operational schemes. This paper presents a heuristic simulation model of multi-seam dragline operation of a sub-arctic mine that can be used to analyze the handling of overburden and detailed study of the dragfine performance."

Jan 1, 1986