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By J. Andersen

The very large quantities of energy used for size reduction in the minerals processing industry necessitate the accurate prediction of comminution machine power draw for optimum plant design. The JKMRC has developed effective models for predicting ball mill, autogenous mill, semi- autogenous mill and crusher power draw. When combined with comminution models they provide a powerful tool for evaluating not only the size reduction performance of a plant design, but its power utilization efficiency as well. This paper describes the structure of the mill and crusher power models. Data from a wide range of equipment types are presented which illustrate the accuracy of these models.

Jan 1, 1992

By Felicia F. Peng, Lili Li

The dispersion model of nonideal flow was applied to describe the hydrodynamic state within the flotation column. Residence time distribution (RTD) data of a laboratory flotation column were measured to determine the parameters of the model. The effects of operating variables and column geometry on the Peclet number which reflects the extent of axial dispersion were investigated and a semi-empirical expression of Pe was formulated. The dispersion model was validated for the column flotation of ultrafines coal. Under the conditions of sufficient aeration rate and frother addition, a good agreement between the measured recoveries and predicted data was obtained. The dispersion model with first-order flotation rate process of the flotation column developed in this study is useful in predicting the collection zone recovery of fine coal, and for the flotation column scale-up.

Jan 1, 1995

By R. R. Klimpel

The efficiencies of plant-scale comminution processes are often evaluated by various indices calculated and/or measured somewhat independently of the performance of any associated downstream froth flotation processes. To compare specific comminution factors, such as energy utilization, media consumption and equipment utilization time, comparisons of comminution efficiency independent of flotation behavior are appropriate. However, as increasingly detailed plant-level information is gathered on the joint and highly interactive nature of comminution and froth flotation, it is becoming even more obvious that knowing and using simple efficiency indices are not enough. What is needed are more performance-related measures of the efficiencies of the combined size reduction froth flotation system for effective plant-level economic optimization to occur. The purpose of this paper is to present examples of some of the important interactions that influence the joint efficiencies of size reduction and froth flotation processes.

Jan 1, 1999

By Frank W. Bowdish

During the early 1960's, a method was developed for refining sand from the Arkansas River to produce a feldspathic product that was proposed for use in making colorless glass. Because of the need for chemical uniformity, a cooperating glass manufacturer specified certain ranges of percentages for each chemical constituent of the sand. These specifications were met by fulfilling the single requirement that alumina vary by no more than 20.1 percent from the specified value. This translated to a total variation of only about 1 percent in the feldspar content of the mixed quartz-feldspar products. Because the feldspar was lighter than the quartz, the average density of refined sand varied depending on composition. Densities, determined to five significant figures, of several samples were correlated with their chemical analyses, and the correlation could then be used with density determinations to more reliably indicate compositions than by chemical analyses only. The effects of several variables on the composition of refined sands were studied. There was a regular variation in the proportion of feldspar with screen size. A series of samples with their natural size distributions were more nearly uniform in composition than the same sands after screening and recombination. The screening and recombination process was done so that the sands had identical size distributions. Variations in the refining showed little effect on composition. A pile of flow-back sand from a construction sand washer was found to be severely segregated. However, samples taken from many points in the river near the sand plant and from the flow-back discharge pipe over several weeks very nearly met the uniformity specification. If care was taken to avoid segregation either before or during processing, it should be possible to meet the uniformity specifications for a feldspathic glass sand.

Jan 1, 1978

To simplify programming, image analyzers commonly measure either linear intercepts or the areas of particles and grains to determine liberation based on polished section mounts. However, the concentration of minerals by flotation is based on reagents that interact with the exposed surfaces of the minerals. Thus, it is often perceived that image analyzers should measure the perimeter of the mineral of interest in the ore particles. A comparative liberation study of thirteen samples collected from a flotation plant processing a complex base metal sulfide ore showed that the liberation of the ore minerals determined by area measurements is very similar to the liberation determined by the exposed perimeters. The liberation determined by exposed perimeters is more appropriate only for those cases where the mineral texture is so complex that it is retained in the small particles generated in conventional grinding operations. Key words: Mineral liberation, Flotation, Image analyzers

Jan 1, 2003

By D. Greene

The close integration of mine planning and mine operation continues to be the goal of mine operators. Depending upon the complexity, size and sophistication of the mine, limited success has been achieved in this area. Despite tremendous strides in the development of computer-aided mine planning, digital plans must usually be converted to error-prone paper maps and physical ground surveys for actual excavation and reclamation. However, advances in global positioning systems (GPSs), operator displays and mobile computers now enable equipment operators to work directly from on-board digital plans. A computer-aided earthmoving system (CAES) offers reduced survey costs, faster field transition time and improved excavation accuracy, coupled with faster, more informed decision making regarding key mining operations.

Jan 1, 2000

By Carlos E. Avila, Ronald D. Evans

The results of an experimental research program to measure the non- Darcy flow coefficient as a function of temperature and overburden pressure are presented. The experimental values of the non-Darcy flow coefficient were measured over a temperature range of 70-200°F (21°-93"C)and overburden pressures of 1000-4000 psia (68-272 atm). The data obtained confirm that the non-Darcy flow coefficient is a function of rock and fluid properties and is not solely dependent upon the former has been routinely assumed in the literature.

Jan 1, 1986

By R. W. Hughes, R. Koopmans

This paper investigates the effect of varying stress levels on the determination of deformation moduli and examines the sensitivity of the borehole dilatometer in measuring rock mass scale features and its ability to represent rock mass characteristics. Cubical blocks of sandstone, limestone and granite were tested in the laboratory under triaxial stress conditions. Field programs were conducted in both granite and sandstone rock masses surrounding underground openings. The dilatometer's zone of influence was determined by conducting tests within an instrumented concrete cylinder and by performing a finite element analysis. Laboratory and field results suggest that the deformation modulus of a rock mass can be substantially affected by the stress field and that the borehole dilatometer is sensitive enough to profile deformation moduli as dictated by the in situ rock mass characteristics.

Jan 1, 1986

By G. M. Wali Ullah, Micah Nehring, MEHMET KIZIL, PETER KNIGHTS

In operations that use the sublevel stoping mining method, production scheduling takes into account factors — including ore reserve envelopes, ore grade averages, equipment capacity, feed controls to the mill, and geotechnical restrictions — across the scheduling horizon. Mathematical programming is one of the most effective methods for enhancing the decision-making process in regard to the most viable production schedule in light of a given set of limitations. The majority of research on sublevel stope mining focuses primarily on a single objective of optimization, which is to maximize the net present value (NPV). Environmental, social and governance (ESG) considerations are becoming more prevalent in the mining industry. This includes aspects relating to deforestation, land disturbances, gas emissions, community relations and water usage, among many others. Institutional and other kinds of investors are becoming more interested in the work that resource companies do regarding their ESG obligations. This review article identifies the gap in the existing literature and proposes to simultaneously optimize the production schedule around three objectives. Two of these relate directly to ESG aspects

Jul 1, 2024

By A. Unal

Coal resource characterization usually calls for estimating more than one variable over a block or node simultaneously. Within the realm of geostatistics, each variable has been evaluated independently from the others assuming a lack of significant correlation. Research conducted with coal seams, however, has shown that the variables of immediate interest, such as seam thickness, ash, sulfur content, and density depict some correlation schemes in distinct zones, if not throughout the entire area. The above findings have two immediate consequences : (1) correlation analyses provide guidelines to determine the geologically distinct zones, and (2) where possible, cokriging should be used instead of kriging. This will maximize data utilization decreasing the frequently criticized high estimation errors. The cokriging formulation will also provide more accurate estimates for under sampled variables using better-sampled ones. This is a common case with coal with regard to the non-cored reconnaissance drill holes for which only very few variables were recorded. A case study illustrates the improvements that may be obtained by taking advantage of the intervariable correlations.

Jan 1, 1986

By A. T. Visser

The expansion of surface mining has led to the development of very large off-highway trucks capable of hauling payloads in excess of 290 t (320 st). Mine haul roads have historically been designed empirically, relying heavily on local experience; the trend in increasing truck size will thus render the current pavement systems inadequate. Because truck haulage costs can account for 10% to 50% of the total costs incurred by a surface mine, not only would the maintenance costs of existing roads of inadequate design increase, but vehicle operating and maintenance costs would increase prohibitively. Thus, there is a need for improved design technologies encompassing the construction and management techniques of mine haul roads appropriate for the wheel loads of vehicles now in use. This paper presents the different components of a mine haul road design and management system and demonstrates the value of its application through case studies. The system has been applied at several South African surface mines, and distinct benefits have been derived. The improved structural design of a new road resulted in a 29% saving in construction costs and provided better service, while the optimal selection and management of wearing course materials provided better functionality at lower total transportation operating costs.

Jan 1, 2000

Early experiences suggested autogenous mills were difficult to operate and consumed substantially more energy than conventional rod/ball mill circuits. As our understanding has increased and the technology has matured this perception has changed to the point where most new comminution circuits are ag/sag based. In addition many operators have replaced existing conventional circuits with this technology. The JKMRC has been studying ag/sag mills for over 20 years. During this time it has amassed what is probably the single largest and most detailed data base of pilot and full scale mill operations in the world. This has been used to help develop and refine its cur- rent commercially available mathematical model of ag/sag mills. A decade of its application has greatly helped simplify both design and operation of ag/sag milling circuits as well as helping to promote the effective use of recycle crushing, secondary crushing and closed-circuit operation. This paper describes the development of ag and sag milling in terms of our understanding and the evolution of the technology. In addition the application of mathematical modelling and simulation in designing and operating efficient circuits is described with the aid of practical examples.

Jan 1, 1998

By M. Tarshan, M. C. Williams, T. P. Meloy

A methodology is presented for the spreadsheet solution of separation processing networks. With the methodology developed, a spreadsheet grid is used to represent networks both with and without recycle loops. In this manner, network solutions are numerically approximated by spreadsheet grid solutions. The methodology was used to explore the ramifications of networks developed by the Chinese for tungsten and molybdenum processing Nonlinear stage-transfer functions for two-component sharp separations can be used.

Jan 1, 1996

By David D. Gallagher

Customer demand for greater efficiency and reduced operational costs on modern overland conveyors has focused attention on the conveyor belt's rolling resistance properties. Studies have indicated as much as 60% of the power losses on a long horizontal conveyor can be attributed to the indentation of the pulley cover rubber as it passes over idlers. This paper will compare tan delta values of different compounds with large scale rolling resistance test data from the University of Hannover. Results will then be compared to actual power consumption data gathered on several long overland conveyors using identical belt construction except with different pulley cover compounds. Concluding comments will be made indicating substantial operating cost differences based on the rolling resistance of the cover compound.

Jan 1, 2000

By B. S. Treiber, R. A. Lohnes, S. M. Levorson

As part of a research program to develop a coal-handleability index that would predict the ease with which a coal would flow through a handling system, an apparatus was developed to directly measure the unconfined Yield strength and bulk density of consolidated-coal samples. The new test apparatus provides a fast and simple method for determining the strength and compressibility parameters that are associated with the handling characteristics of crushed coal. Comparative tests were conducted using a low-stress triaxial-test apparatus. To check the accuracy of the new method, four coals with a variety of moisture contents and gradations were tested using the new method. These tests indicate that the new test device yields valid results. Further, the speed and ease of operation of the new device makes it suitable for quality control and quality assurance in plants.

Jan 1, 1996

By Thomas W. Camm

A WINDOWS-based object-oriented expert system for prefeasibility evaluation of hard rock mines is being developed at the Western Field Operations Center (WFOC) of the Bureau of Mines. Designed for use with the Bureau's Cost Estimating System (CES), this expert system assists an evaluator in choosing an underground mining method, and the related design parameters. The system provides the engineering and design guidelines necessary for an evaluator to perform a prefeasibility type cost estimate.

Jan 1, 1992

By R. C. Ford

The advent of solvent extraction-electrowinning (SX-EW) technology for recovery of copper from low grade oxide ores has extended the operational lives of many historic mines in the western United States, and made many other orebodies economically viable worldwide. Many of these operations are mature and face closure within the next decade, depending on market conditions. Closure of a large copper heap leach operation has not been undertaken, and differs in some important chemical respects from closure of gold leach pads. Challenges for closure include prediction of solution chemistry and draindown characteristics, determining the benefit of cover placement in semi-arid climates and evaluation of solution management strategies once the economics of copper recovery are no longer favorable. This paper discusses issues pertinent to copper heap closure in semi-arid and arid climates, and strategies for their management.

Jan 1, 2000

By Lynn B. Hales, Randy A. Ynchausti

Introduction There continues to be a large economic opportunity associated with improving process performance through advanced process control systems within the minerals industry. The basis for this opportunity lies in the inherently low efficiencies of many of the unit operations found in mineral processing plants as well as the continual variation that is present in the ores being processed. The ageless target of such control systems is improved recoveries and concentrate grades, higher processing rates and lower unit costs. Many plants are enjoying the benefits of modem, well functioning process control systems but few if any have achieved plant-wide optimization in an economical sense. As new process modeling and control technologies, such as neural networks, continue to evolve and develop, the potential for plant- wide optimization is becoming a closer reality. Neural network technology appears to have a significant potential in the general field of process control and control of mineral processing operations. Neural networks are an emerging technology that have been evolving out of the study of biological systems since the early 1940's. The first software simulation of neural computing networks was reported in 1956 by Nathanial Rochester of IBM Research during the first conference on artificial intelligence which was sponsored by the Rockefeller Foundation. Neural Networks Neural networks can be considered to be a class of computer program that perform their problem solving functions based on a rudimentary model of the human brain and how it solves problems. Traditional computer programs and even computers themselves solve problems or process data sequentially and in a deterministic manner. The human brain, on the other hand, processes data and solves problems in a massively parallel fashion. We think of computers normally in terms of having a single processing unit, sometimes a co-processor to assist in certain activities such as mathematical functions or communications, bytes of memory, processing speed and program/data storage size.

Jan 1, 1992

By M. H. Weinecke, B. P. Faulkner

This paper discusses the process for making lightweight aggregate, the waste materials that make good lightweight aggregate, the chemistry of making lightweight aggregate and the commercial prospects for making lightweight aggregate from wastes. Svedala Industries has been making lightweight aggregate (LWA) from waste materials for the last 10 years. Many claylike materials, such as coal fired boiler ash and washings from a granite quarry, can be used alone or with additional waste materials to produce commercially salable LWA.

Jan 1, 2003

By B. M. Davis, J. Wilkins

The method of conditional simulation is easily implemented on the personal computer when the LU decomposition algorithm of Davis (1987) is employed. This algorithm is fairly compact, yet can generate moderate-sized simulations in a few minutes on a 80286 or 80386-based personal computer. The application of conditional simulation presented here is to generate possible ore inventories from a limited amount of exploration sampling. The simulations can then he examined to decide if the potential inventories are sufficiently attractive to proceed with further exploration. An example showing one application of this approach is presented.

Jan 1, 1992