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By Walter Meintrup

On Nov. 4, 1981 the newly installed 1000tph wet-process iron-ore ball mill of A/S Sydvaranger completed its first four months of uninterrupted, successful full-load operation in Kirkenes/Norway. This 6.5m diameter mill is driven by a gearless ring or wrap-around motor of 8100kW at 13.1RPM - a first of a kind in this segment of industry. (Fig. 1) This paper analyses the reasons that have led to the selection of this type of drive over more conventional schemes, lists specific advantages of such large mills, and describes in some detail the installation in Norway. General aspects of possible design variations, and application information for designers and users of such mills conclude the presentation.

Jan 1, 1982

By Daniel Rossi

Em aciarias elétricas, o consumo dos insumos tem impacto importante na composição do custo final do aço, dos quais se destaca o consumo de energéticos utilizados no forno elétrico a arco, que pode representar até 30% do custo operacional de uma aciaria. Para quantificar o aporte desses diferentes tipos de energia é utilizado o indicador de consumo de energia total FEA + FP, que associa fatores de equivalência a cada tipo de energético de forma a transformar sua unidade de medida para a unidade base de kWh/t. Nesse trabalho foi realizado um teste no formato de projeto de experimentos, variando-se as vazões de gás natural e/ou oxigênio em um dos modos de queimador e em três modos de lança a fim de modificar suas proporções O2/GN e avaliar o impacto no consumo de energia total.

Jul 30, 2018

By Shawna Munn, Carol Dounitch, Erika Acton

The EQ Bank Tower, a 24-storey office tower with 4 levels of underground parking, is currently under construction at 25 Ontario Street in the downtown core of Toronto, Canada. The tower geometry required an 18 m (60 ft) deep excavation inside an existing 3-storey 100-year-old façade, to be retained in place throughout construction. This presented a variety of design challenges that required several innovations and a customized monitoring program. In this paper, we will discuss two major challenges, and highlight the innovative and adaptable solutions carried out using performance-based design leveraging the observational method. The first was installation of a shoring system in a 500 mm (20 in) gap between the historical façade and a live gas main. The second involved excavating 10 m (33 ft) into expansive shale bedrock adjacent to a sensitive neighbouring building.

Oct 1, 2022

By Muttharam M, Karthick Kumar V

Helical piles foundation systems have been extensively used in engineering application. It is commonly adopted to resist the compression, uplift force, overturning moment and lateral forces. Helical pile system is extensively used in many structures such as Transmission towers, Wind farms and other offshore structure because it is easy and quick to install. Realizing the importance of helical pile, an attempt is made in the present investigation to bring out the effect of spacing between the helix, blade thickness, and shaft thickness through numerical analysis. To validate the finite element model experimental investigation was carried out. In this investigation model steel piles with dual helical plate embedded in clay bed with the consistency of 0.4 was tested to study the effect of uplift loading on the behaviour of piles in tensions. Model helical pile with 12.5 mm diameter circular shaft and helix diameter of 25 mm. The model pile embedded in clay bed for a depth of 400 mm. Parametric analysis of helical pile by varying blade thickness, shaft thickness, and the spacing of helix was carried out by using Finite Element tool Plaxis 3D. From this analysis, an increase in thickness from 4 mm to 10mm increase the uplift load. Similarly, an increase in spacing of helices from 0.5 m to 1.5m increase the uplift capacity beyond that it decreases the uplift capacity. By keeping the contact area of the helix as constant as the number of a helix and helical spacing was varied, the critical number of the helix was found as 2 and the critical spacing of helix was found as 1.5 m for this study.

Nov 1, 2022

By Chris Leach, Lucie Spencer

This case study describes the geotechnical aspects of the basement construction for a multi-storey, residential and hotel complex located in the newly developed Elizabeth Quay precinct in Perth, Western Australia. The development included a three-level basement for car parking covering the full site area which was constructed using the top-down construction sequence. Soil conditions generally comprised 2m of fill overlying medium to dense clayey sands that in turn were generally overlying a very stiff clay stratum at approximately 13m depth. Bedrock level was generally encountered at approximately 22m to 35m below ground level. The ground water table was at a depth of approximately 1m below the existing ground surface level. A site boundary basement wall was constructed using a diaphragm wall retention system. The majority of the vertical loads from the building were transferred to the Kings Park Formation (KPF) bedrock through the use of foundation piles constructed by the CFA method. The CFA piles were installed from existing ground level, resulting in approximately 9m sacrificial concrete length from pile platform level to basement 3 (B3) level. The permanent column loads are such that a single CFA pile was not structurally adequate. To allow a full CFA foundation system to be adopted, an innovative design and construction approach was developed for these heavily loaded columns. This paper discusses the site technical details and the design and construction aspects required to meet the challenges offered by this project.

Nov 1, 2022

By Muhammad Azeem Raza, Samuel Frimpong

Underground mining environments are inherently hazardous and can lead to emergencies where effective rescue and self-escape become critical. Missouri University of Science and Technology is pioneering new technologies for effective self-escape. The rescuers and miners need to be trained in these new technologically driven environments. Previous research in fields like aviation, medical surgery, and oil and gas drilling has demonstrated the effectiveness of virtual simulation training, but the mining sector has yet to fully adopt advanced tools such as eye-tracking and immersive training modules. This research proposes a comprehensive training infrastructure incorporating these technologies to enhance situational awareness and decision-making during emergencies. The novelty lies in the application of advanced miner escape and communication technologies, specifically designed to monitor and enhance cognitive responses in high-stress situations. By leveraging these technologies, the proposed training infrastructure aims to prepare the next generation of underground miners and operators, by equipping them with the necessary skills to manage emergencies effectively.

Feb 1, 2025

By M. Brändström, R. Dube, J. Moyo, T. Perkins, G. Bermudez, L. Bartsch, C. Smith, R. Sorensen

The Kennecott Copperton concentrator is currently the bottleneck for the Kennecott operation and several projects have been initiated to increase throughput. This increase in grinding circuit throughput has resulted in a coarser grind size which has impacted flotation circuit recovery. Metso Outotec 300m3 forced air tank flotation cells are currently utilized in the rougher flotation circuit at the Copperton concentrator. Higher overall recoveries have been observed on the newer Outotec tank cells compared to the original 85m3 self-aspirated flotation cells they replaced. However, coarse particle flotation response on these large, forced air cells did not show encouraging results when compared to smaller previously installed cells. This coarse recovery loss has been attributed to the longer froth transport duration and transport distance on large cells (100m3 and larger). Cell manufacturers addressed the risks of additional coarse particle losses in large cells by installing concentric circumferential launders and crowders (also called center launders). These are designed to reduce froth transport time and distance in the last cells in rougher stages where low residual floatable minerals causes a lack of froth mobility. The center launders also increase froth crowding, which also helps to increase froth transport velocity and increases copper and molybdenum recoveries. A trial set of the center launder retrofits were installed on the last three tank cells in one of the parallel rougher flotation rows at Copperton. The launder retrofits were installed at the end of October 2020 and monitored until March 2021. This six-month trial showed statistically significant improvements in copper and molybdenum flotation recoveries through the rougher circuit.

Mar 2, 2022

By Stephen Mansfield, Saran Sankar

The Sentinel open pit copper mine, operated by First Quantum Minerals Ltd, is located in the North West province of Zambia. The Sentinel orebody is a sediment-hosted, structurally modified deposit in which mineralisation is contained in the phyllite formation, which occurs as a series of layered, continuous sheets having a northerly 20 to 30⁰ dip. The persistent nature of the geological structure can lead to the generation of large slabs when joints are relatively close together or very large blocks when joints are more widely spaced. With standard blasting methodologies, the challenging fragmentation most commonly occurs in the stemming zone and blast interfaces, reducing excavation rates and increasing the risk of crusher bridging events and reduced throughput. A generalised approach to increase powder factor would increase in drill and blast costs and would not be sufficient to target the specific cause of the challenging fragmentation. Implementing differential blast energy based on post blast requirements for different material type, such as ore and waste, and rock mass characteristics is not new in the mining industry. High-energy blasts for ore aim to produce finer materials, enhancing downstream processes such as crushing and grinding, while reducing power consumption and increasing throughput. Conversely, waste rock often requires less energy in order to deliver optimised fragmentation for loading and hauling efficiency. Identifying and applying optimum blast energy to specific material type and geological domains will not only ensure smoother and efficient operations throughout downstream processes, but will have a direct impact on overall profitability of the entire operation. This paper will describe the methods used to model and implement differential blasting across a range of material types in order to deliver the required blast outcomes for ore and waste and the impact on downstream processes and drill and blast unit cost.

Jan 21, 2025

By Viswanadham B. V. S., Babu K. V

Wind energy is one of the most economical renewable energy sources. In order to support wind turbines onshore or offshore open-ended monopile foundations are widely used. Unlike conventional structures, wind turbine foundations experience a large magnitude of lateral loads in the order of 20 % to 30% of total vertical loads. The presence of soft clayey layers at shallow depth along the coastal region, offers lesser lateral load resistance to monopile foundations. One option to enhance lateral load capacity is by introducing fins to the outer surface of the monopiles. Studies pertaining to lateral load response of finned piles in clayey soils are very sparse. This paper presents some of the numerical model studies on the lateral load response of monopiles and finned piles in soft and stiff clay. In the present study, three-dimensional finite element analyses were performed on monopiles as well as finned piles. Analyses were performed in clay with different consistency varying from soft to stiff. Pile material is mild steel for all analyses. The pile section modeled as linear elastic material whereas soil was modeled as Mohr – Coulomb constitutive model with non-associated flow rule. Monopiles and finned piles having four and eight fins with different fin sizes and configurations are considered during the analyses. Finned piles advantage over monopiles to resist lateral load is highlighted in the present study. The results have shown that fins are effective to enhance the lateral load carrying capacity of monopiles and also it reduces the bending moment in monopiles for a given design load.

Sep 1, 2022

By Javankhoshdel Yacoub

Piles are often used to reinforce slopes as they increase the available restoring force when calculating the factor of safety against sliding. In this paper, a 3D model of a slope containing multiple modes of failure is reinforced using pile elements. The results of the 3D Limit Equilibrium analysis containing piles are obtained using a newly introduced coupled approach which combines the results of finite element analysis (to obtain the displacement of soil along the pile) with the traditional limit equilibrium iterative formulation. The multiple modes of failure are obtained using the novel Multi-Modal Optimization (MMO) metaheuristic method which adapts the Particle Swarm Optimization (PSO) method to search for multiple local minima in a single slope model.

Oct 1, 2022

By Guillermo Lazcano Ríos, Jorge Parvez Aguirre, Alejandro G. Díaz Berríos, Felipe Rodriguez Alveal

Codelco's Chuquicamata Underground Division (DCHS) faces issues due to collapses in its subsidence streets, which hinders the advancement of the subsidence front and leads to the loss of areas and reserves. To address these issues, DCHS and Orica have developed a new excavation methodology based on pre-loading explosives in high drawbell. This methodology involves creating a high drawbell extending from the floor of the production level to the ceiling of the subsidence level, divided into two phases: upper and lower. A resin stemming is used to separate these phases. The excavation strategy adjusts to variables such as reception volume, fluffing, and excavation geometry, involving vertical pre-loading of the explosive and the use of a separating element between the phases. The test aims to validate the new excavation methodology and the retaining element in the rock mass, evaluating aspects such as drawbell geometry, impact on the rock mass, damage to the retaining element, and fragmentation. Wireless electronic detonators are used in the upper phase to improve safety by eliminating the need for physical connections, while traditional electronic detonators are employed in the lower phase. Low-density bulk emulsion is applied to minimize the impact on the Crown pillar and extraction point, and higher-density explosives are used above the subsidence level to ensure good caving. Results showed that the blast achieved 86% conformity with the theoretical design. Resin stemming allowed for 100% effective detonation in the upper columns, and the fragmentation obtained was 5.44 inches, which was less than expected. No damage to the Crown pillar was observed, and the explosive quality met standards. This technique has proven to be effective and viable, suggesting the possibility of eliminating the subsidence level in future levels, resulting in savings, and providing greater stability to the rock mass.

Jan 21, 2025

By Marcus Francisco Gonçalves Mesquita

As mudanças no plano estratégico de uma organização reverberam por todos os seus setores, gerando demandas de alinhamento estratégico. Entre estes setores estão os de planejamento e programação da manutenção. O presente estudo de caso descreve uma iniciativa de alinhamento estratégico realizada pela equipe de planejamento de manutenção da unidade Ubu da Samarco Mineração S/A, uma empresa de mineração e pelotização de minério de ferro, localizada no estado do Espírito Santo. A partir de uma revisão na estratégia corporativa foram derivados a missão, visão e valores da equipe. Esses por sua vez, serviram de base para uma revisão dos processos de trabalho e para a definição de ações de melhoria. Por fim foram estabelecidos indicadores para mensurar a realização da visão. Os resultados apresentados por esses indicadores comprovam que as equipes de planejamento podem obter e demonstrar resultados significativos através de técnicas elementares de planejamento estratégico.

Aug 7, 2018

By Pablo Altoé Amorim, Bruno Sellitti Borges, Otávio Lube dos Santos, Arthur Pizetta David, Matheus Diogo Penido da Silva

Automation is in everywhere nowadays, including within companies and industries, and is therefore fundamental and essential for production, quality and process control of them. There are many ways to automate a production line or a machine can be through relay logic, Programmable Logic Controllers (PLCs), and even more modern microcontrollers with native Internet of Things (IoT) support can be used. What are the advantages and disadvantages of each approach? A PCB was created using more modern microcontrollers programmed in C, C ++ and Whiting language to simulate a replacement of a PLC in an actual machine. Having a very positive result, being able to handle the machine manually via Wi fi besides being able to also perform a real-time monitoring of the machine's motors through the mobile phone, thus entering the IoT and fitting into the Industry 4.0.

Oct 1, 2019

By R Kroukamp, G Rech

CRONIMET Australia in cooperation with Speciality Metals International, the mining lease holder of the Mt Carbine Tungsten mine, have demonstrated the preconcentration and processing of large (>12 million tonnes) tailings and mine waste dumps on site in far north Queensland. The first stage of this project has proven the economic viability of preconcentration using sensor-based particle sorting whilst ensuring high recovery of industry critical tungsten minerals – wolframite and scheelite. Sensor-based sorting technology have enabled the production of a sorter product to feed the existing wet gravity plant ensuring higher recoveries and increasing concentrate production. Processing of 1,000 tonne low grade samples using the TOMRA x-ray transmission (XRT) ore sorter installed on site, has reduced the volume of material entering the downstream wet processing plant by up to 60%. The sorted 10-25mm size range produced the highest upgrade ratio (product/feed) of 24:1 and achieved sorter concentrate grade of 1.52% WO3, sorter waste grades below 0.014% WO3 and metal recoveries of up to 93.4%. The appropriately sized, barren sorter waste material is also sold as aggregate and other quarrying products and thus adding to the overall economic benefit of the project. The utilisation of the sorting technology on site has produced an economically viable project, significantly reduced capital cost, and reduced the time to market of the final tungsten concentrate. The next phase of the project includes design and installation of a larger two sorter plant capable of over 150t/h feedrate.

Nov 10, 2020

By M Bond, R R. Hargreaves, G W. Booth

There are numerous causes of speculative mineral resource and reserve inflation. Traditionally, these are linked to issues of data accuracy or misinterpretation, the use of overly optimistic estimation parameters or assumptions, an absence of independent expert verification, or the simple pressure to increase company value, covert or otherwise. Owing to its subjective nature, classification of resources and reserves remains an opaque process. Of necessity, Competent Persons rely on personal heuristic interpretations, ideally underpinned by appropriate estimation and classification experience across commodity and deposit types. Whereas independent verification of individual resource and reserve statements remains impractical, publicly available data can be interrogated for potential category inflation, particularly when viewed with exploration expenditure statistics included in annual company reports. Abrupt changes in category tonnages and market capitalisation without concomitant expenditure can aid in outlier detection. Consequently, a comparison of common exploration and resource reporting parameters offers a basis for risk assessing classification robustness, over time. In this introductory study, an analysis of globally listed companies was undertaken over a multi-year period, examining base and precious metal projects in both preproduction and operational asset classes. From these, a series of exploratory decision tree trigger points were generated against which target companies were anonymously identified and risk-ranked.

May 24, 2023

By Alessandro Marques

Based on a short overview regarding steel defects in the final product, several refractory approaches to maintain or increase steel cleanliness are reviewed in this publication. By applying a ladle to mold approach, one potential to maintain cleanliness is to reduce the probability of air ingress by selection of a suitable slide gate system. Following this path, also the influence of a special configured impact pot is presented to maintain steel quality. Finally, higher productivity as well as cleanliness can be provided by selection of PROIL as a revolutionary product at the casting machine.

Oct 30, 2017

By C. Guo, R. J. Chalaturnyk, M. MacKinnon, J. D. Scott

The Mildred Lake Settling Basin (MLSB) is the largest disposal site for mature fine tailings (MFT) at the Syncrude Canada Ltd. oil sands plant. Over the past years (since 1996), there has been a marked change in the densification behaviour of MFT in the MLSB. Methane-producing microorganisms, known as methanogens, have become very active, and large amounts of biogas (mainly methane) have been produced. Continued field monitoring of the MLSB has provided convincing evidence of the rapid densification process (rapid water drainage from the tailings) at the area with intense microbial activity. This rapid densification has caused pumping challenges in the transfer of fine tailings from the Mildred Lake Settling Basin for the creation of composite tailings. It may also have potential positive effects in accelerating the reclamation of the oil sands fine tailings. A field and laboratory research program was carried out to study the mechanism leading to the rapid densification phenomenon. A review and discussion of the research program is given and some results from the field investigations and small-scale column tests are presented in this paper.

Jan 1, 2007

By Anup Kumar Mandal, Sanjoy Chowdhury, Biswajit Das

"Tailing pond of an iron ore mine necessitated raising the height of its embankment to create additional storage capacity. The tailing pond is located in eastern India and raising the height of embankment was going on during the month of January, 2014. Upstream method of construction was adopted since there was no space available at the downstream side. During the construction, about 200 m stretch of the north east embankment of height about 5.5 m failed forming a classical slip circle on the upstream side involving about half the top width of the embankment. To find out the root cause of the slope failure, detail geotechnical investigation work was carried out within the embankment as well as in the adjacent areas within the pond. About 7.5m thick very soft tailings were detected below the constructed embankment. Shear strength of the soft tailing was very low and was inadequate to sustain imposed embankment load. This resulted in the failure of the embankment. Analysis of the tailing deposit revealed that even after failure, settlement was continuing due to imposed embankment load. Under normal onedimensional consolidation, the tailing deposit would have taken about 5.7 years for 90% of primary consolidation. However, in order to mitigate the scarcity of storage space, mining plan required raising the height of the embankment within next six to eight months. Therefore, despite the fact that there was a failure, it was necessary to continue the construction on the underlying weak stratum. The system was redesigned with installation of prefabricated vertical drains (PVDs) to accelerate the consolidation process thereby gaining the in-situ strength. Strength was additionally enhanced by installing geogrids in multiple layers. It stabilized the existing embankment and also ensured construction of additional height over and above the existing embankment.INTRODUCTIONBeneficiation plant in the Iron mines enhances the mineral content by separation of contaminants and fines. The residue (waste material) is called tailings/tailings depending upon the grain sizes. These tailings in a slurry form are generally disposed in a pond called as tailing pond/tailing pond. Height of embankment of such ponds is increased either by upstream or by downstream or by centrally raising methods in different phases as quantum of deposition in the pond increases with time."

Jan 1, 2015

By Garland Likins, Gray Mullins, George Piscsalko

"Quality control of drilled shafts is greatly dependent upon the practices of the site personnel. For drilled shafts cast under slurry, inspection of the hole prior to concreting is very difficult or impossible. There are numerous non-destructive test (NDT) methods currently available to assess the integrity of drilled shafts. This paper will discuss the theory and use of an emerging NDT technology known as Thermal Integrity Profiling (TIP). The Thermal Integrity Profiling method measures the elevated concrete temperatures that occur during the hydration process. These temperature measurements are made along the length of the pile and can determine the integrity over 100% of the pile cross section, both inside and outside the reinforcing cage. With the known shaft volume information, TIP can evaluate the effective shaft radius at each measurement location. With the increased use of TIP on highway projects, there is a need to have standard criteria for shaft acceptance. Shaft acceptance criteria can be based upon thermal measurements and subsequent analysis of the data to determine the average shaft radius, local concrete cover, and cage alignment. With this additional information obtained via the thermal testing method, acceptance methods based upon concrete cover can be developed. In this paper the Thermal Integrity Profiling method will be described, results from a case history will be discussed, and an acceptance criteria based upon concrete cover will be proposed.INTRODUCTIONDrilled shafts are an attractive foundation element in many applications due to their large axial and lateral capacities. When drilled shafts are cast in a dry hole, it is possible to inspect the hole prior to casting, allowing for very basic level of quality control, although the shape of the completed element is still unknown without some form of post construction testing. When drilled shafts are installed where soil conditions are unstable, the shafts will often be cast under slurry to support the surrounding soils during the construction process. When casting a drilled shaft under slurry, it is very difficult to impossible to accurately and efficiently inspect the hole prior to casting concrete and it is equally difficult or impossible to inspect the shaft during the casting process"

Jan 1, 2016

By James L. Christensen, Gregory Sanchez, Michael P. Walker

The Fogg Museum expansion project required excavation and construction in a congested urban area in Cambridge, Massachusetts. A soldier pile tremie concrete (SPTC) wall provided the support of excavation and now serves as the permanent basement wall of the new expansion of the museum. The existing Fogg museum had a single basement level. The new expansion has a two-level basement for new exhibit space and an amphitheater. The east side of the site is about 20 feet above the basement level of the existing Fogg structure which resulted in a significant unbalanced load that needed to be resolved without damaging the original Fogg structure. The SPTC wall was supported with a combination of tiebacks and internal bracing. The final depth of the excavation was about 40 feet below street level. Strict movement control was imposed because the existing museum contained an Italian Renaissance-style courtyard. The southeast corner of the SPTC wall had to accommodate underpinning of an historic concrete ramp which was ultimately incorporated into the expansion. Challenges during construction included excavating the SPTC wall panels up to 12 feet into argillite bedrock which had occasional diabase dikes and sills. The following topics are discussed in more detail after a general project.

Jan 1, 2015