Search Documents

By Brian Flintoff

"When I was first asked to prepare this paper and presentation in late June, I thought it might be fun to ""step back and paint the bigger picture."" Having attempted to do this, fun is not the first descriptor that now comes to mind, and speaking dyslexically, I've had 'nuf.'Unlike Nostradamus, or even Orwell, I've discovered that I'm ""clairvoyantly challenged"" and not even the psychic hot-line was of much help, at least with respect to process control! I am somewhat comfortable speculating on evolutionary change, but the radical developments that will arise from revolutionary changes are well beyond my mortal capabilities. Even with evolutionary change, I'm reminded of the lessons of time series analysis which show the prediction error to grow exponentially as the horizon moves into the future. As Macluhan is reported to have said: ""Predicting the future based on the past is a little like driving your car while looking in the rearview mirror!""Having honestly presented my qualifications, allow me to try to look at process control and to offer some conjecture on where we're probably headed. In the end, it is said that: ""The plant of the future will have only two employees, a man and a dog. The dog will be there to keep the man from touching the equipment.1""IntroductionA little less than a decade ago Andy Mular and I co-edited a monograph entitled ""A Practical Guide to Process Control in the Minerals Industry."" The work was commissioned by the senior management of a consortium of Canadian mining companies, since it was widely perceived that control was an area of great economic potential, but one that had not been effectively tapped. The concern was that if the industry could not soon deliver on the ""potential"", the term may well have appeared in the epitaph of what was, to these men, a very attractive investment opportunity. I think it is fair to say that over the past few years process control has clearly established itself as an essential technology in plant operation and optimization. That isn't to say that we get it all-right, all-the-time, but, the circumstances are much different than they were. In the eyes of many, process control has attained the distinction of being considered a mature technology, even though there are still countless avenues for exploration."

Jan 1, 1998

By J. Chelsey Dawson

In presenting a thesis on this subject it is advisable to explain a few of the reasons for its seeming incompleteness. World progress has brought us to a position where approximations are not only to be condoned, but regarded as absolute essentials. Production in anticipation of demand is always accompanied by mistakes on the part of the producers. Only through trial and sometimes erring hypotheses may there be evolved the true course and theory upon which the steady triumphant march of world-wide industry depends. The average person likes to have everything placed ?before him in a clear and convincing manner. It is the impossibility of doing this which, in many cases, arises to confound the writer on shales. All that one can do is to present, as lucidly as possible, the known hypotheses' and theories on the subject and leave the reader to study and work out the truth for himself. Many theories have been advanced on the origin of oil-shales ; some may be correct in certain instances and not in others; however, the writer will attempt no decision as to which are and which are not correct, but .will merely point out the relative merits of each. The figures given for reserves of oil and shale in different countries are only approximations and give but a rough idea of the true conditions.

Jan 1, 1925

By W. L. Thayer, K. A. Jonasson, R. D. Coleman, J. D. Hazlett, C. E. Capes

"Loss of coal fines in reject slurries limits the yield of coal cleaning operations. Difficulties in handling fines also limit the extent of physical cleaning in treating coals with finely-disseminated impurities. Selective oil agglomeration allows even extreme fines to be processed and offers some novel approaches for coal cleaning and utilization.The oil agglomeration process for the recovery and beneficiation of fine and ultrafine coal has now been commercialized by the Chemical Engineering Section/Chemistry Division of the National Research Council (NRC). This paper describes these activities to apply oil agglomeration and related fine coal technologies on an industrial scale. Pilot plant and large scale results are described, as well as aspects of agglomerate utilization in both wet and dry form."

Jan 1, 1988

By J. G. Strasser

"There has been considerable output over the last three decades from the social sciences concerning man and his working environment. In the mining industry at large, however, authoritarian, hierarchical control systems remain the norm, and it can be argued that something less than optimum effectiveness in terms of both productivity and worker satisfaction has resulted.Recently (/975), Campbell Chibougamau Mines Ltd. devised a most interesting organization and incentive system that links the underground production of a standard ton of mined output at controlled grade to an incentive payment scheme. A parallel scheme in the mill complex is based on maximizing recovery of copper and gold from available feed. A key part of both minsystems is the formation of groups who have considerable autonomy, particularly when compared to the still prevalent traditional mining industry relationships between the worker and supervisory levels.This paper traces the development of Campbell Chibougamau's system . Attention is drawn to qualitative and quantitative measures of the success of the method through the commentary of those miners involved in the scheme, and by reference to the favourable records on productivity, absenteeism, safety, turnover and grievance activity.IntroductionPyramidal or hierarchical management control systems, coupled to piece-work incentive schemes, predominate throughout Canada's underground mining industry. Although specific details of such systems vary from site to site, they , are generally understood and accepted as fact by the majority of the work force.Normally, a front-line supervisor (shift boss) directs a number of workmen and assigns them to tasks and working locations commensurate with their abilities, knowledge, training and skills. This front -line supervisor may direct or supervise from as few as 12 to as many as 75 or more workmen. He issues orders according to his assigned production objectives and ensures that these directions are fulfilled in accordance with standard mine practice . Several shift bosses are usually directed by a mine foreman or mine captain. The mine captains report to a general foreman or directly to the mine superintendent or his assistant, depending on the size and scope of the operation."

Jan 1, 1981

By Camilo I. Morales

At present, many open pit mines are designed to operate and feed a processing plant with ore characteristics that were defined in the design of the mining business, which are not necessarily the same as those found during the operation. This is the case of Spence Mine, whose design was conceived considering the extraction of primary iron sulphides, however, with the extraction of such minerals, it was necessary to mine and process minerals with secondary enrichment. Then it is necessary to work with a greater selectivity degree in the operation, however the capacities of the mine and operational resources were not designed for this. Thus, the changes in the general conditions of the operation should be considered as a series of geometallurgical restrictions to achieve production schedules. The above facts impacts directly in the short-term planning, whose task is to achieve the goals proposed in productive long-term planning because the company does not have the tools necessary to plan with the degree of selectivity required, so it should be done by hand, discretizating and scheduling the production polygons. Naturally, this manual process in the short term planning deviate sharply from the areas in operation, opening new fronts and benches that result in a significant increase in costs and a loss of the value of the mineral resource to miss the exploitation sequence. The research presented in this paper is related to the development of a mathematical programming model to support the short-term planning, so as to integrate the challenge of selective mining with geometallurgy restrictions, to provide the planner a guide to construction of the polygon of exploitation, guiding the fines production to achieve the goals of the proposed production plan.

Oct 1, 2009

By P. P. Rosario, D. M. Maijer

The primary crusher is a key component in the comminution process applied in open pit mines. A collaborative research project between the University of British Columbia and Highland Valley Copper (HVC) was conducted aiming at understanding gyratory crusher liner wear in the overall context of the crushing process. This paper presents an analysis methodology applied to data collected using a laser-based tool for assessing wear in gyratory crushers. Data from the wear measurements was correlated with crusher production information such as current draw and throughput. As a result of the knowledge developed during this work, an innovative way to evaluate crusher liner profiles was created and new mantle profiles were designed. This led to a reformulation of HVC’s standard liner management policy with a resulting estimated annual savings of 13% in total crusher liner cost and a 15% reduction in liner replacement downtime.

Jan 1, 2006

Mine Evaluation Engineering , Operational and Social evaluation. Focus is on what opportunities are available. Social ??History ??Past Management Practices ??Community / Available labor force Mining Method / Equipment ??Competent rock ?little support required, no backfill ??Shallow mining ?ramp mining, no shafts or hoisting ??Large scale mining potential ??Simple rock breaking and crushing on surfaceMill Process ??Straightforward gold liberation process Create a Plan / Create a Team Following the feasibility 44-101. Key people were hired and a full operational Business Plan was developed. Focus is on how to get the job done. ??Scoping Study / Pre-Feasibility / Feasibility ??Operational Business Plan ??Hire key people ??Purchase key equipment

May 1, 2006

By Johnna Muinonen

"The Thompson Mill processes ores from the Thompson and Birchtree Mines. While the Thompson ore has very little magnesium containing gangue, the Birchtree orebody consists of veins of massive sulphide in a rock matrix that contains a high proportion of magnesium silicate minerals. A significant fraction of the magnesium is floatable, which lead to MgO levels varying from 3-11 wt% in the Birchtree concentrate. The magnesium in the concentrate causes a higher operating temperature in the smelter, reducing furnace life.Birchtree ore represented 20-30% of the mill ore receipts prior to October 2003. Since then the fraction of Birchtree ore has increased to 50%. A reduction of the MgO in concentrate to less than 3% in the total mill concentrate was required to allow safe and economic smelter operation.In October of 2002 a miniplant was set up to simulate the Birchtree plant circuit. Several flow sheet modifications were tested that led to a proposal for a circuit having increased cleaning capacity for the scavenger concentrate and a recleaner on this concentrate. Addition of CMC in rougher cleaner feed was also found to be required. The solution was confirmed through pilot plant testing in the mill in December of 2002. A full-scale installation was designed, engineered, and installed between February and September of 2003 with commissioning in September and October of 2003. Target metallurgy was achieved one week after start-up on slurry to coincide with the Birchtree Mine tonnage increase. This paper highlights the development, design and commissioning stages of the project.The new MgO rejection circuit has successfully allowed the processing of Birchtree ores producing concentrate consistently below 3% MgO. In addition, the new circuit increased overall nickel recovery in the mill.INTRODUCTIONThe Thompson Nickel Belt located approximately 700km north of Winnipeg was discovered in the early 1950’s. Inco first produced nickel from the area in 1960. Over the years the mill has processed several ores from different ore bodies in the area. Currently the Thompson Mill processes two significantly different ores from two mines, Thompson and Birchtree. The Thompson ore is a massive sulphide orebody hosted in schist, containing feldspars, quartz and biotite. Thompson Ore is characterized by high nickel recoveries and clean, low MgO containing concentrates (<2.5% MgO). The Birchtree ore is ultramafic and contains a high percentage of Mg-silicates such as serpentine, chlorite, biotite, amphiboles and talc. Some of these Mg-silicates report to the nickel concentrate and prior to commissioning of the MgO rejection circuit the Birchtree nickel concentrate typically contained 5-8% MgO"

Jan 1, 2006

By G. Zhu

The straight Y-shaped silica nanorods have been synthesized on Si wafer by thermal chemical evaporation of mixed powders of silica and graphite at 1300_ and condensation on Si substrate without assistance of any catalyst. The synthesized samples were characterized by means of scanning electron microscopy, transmission electron microscopy. The results suggested that the straight Y-shaped silica nanorods have uniform diameter about 50-200nm and neat smooth surface. The growth of such silica nanorods may be a result of the fluctuation of external conditions and internal structure faults causing a change in the growth direction of silica nanorods developed.

May 1, 2008

By J. P. Sancho, L. F. Verdeja, J. I. Verdeja

"This paper analyzes the present state of the different processes competing to keep their market shares within the future iron and steel business sector.The continuous transformations in the steel making process are also studied here. These transformations have happened especially during the two last decades obviously favouring steel price, properties, quality and environmental compatibility in the new millennium. IntroductionIn the early 1980s, world steel production reached a historic figure; specifically in 1982, the amount was 645 Mt (Verdeja et al., 1993). This might have been one of the reasons why the United States, Japan and the European Community drew up a declaration of principles after which the leading industries and sectors in the following century’s development would be: advanced materials, also known by the very diffuse term of new materials; information technologies; and biotechnology (Eager, 1998).On the threshold of the 21st century, it can be inferred that information technologies (computers and telecommunications) have progressed spectacularly. Nevertheless, there have been downsides too; technology develops so quickly that after a few months the products are obsolete. Environmental problems may also appear in a few years due to storing so many useless devices. At the same time, the achievements of biotechnology did not meet the optimistic forecasts made in the early 1980s.On the other hand, it is also curious that some solutions for the environmental problems generated by star technologies of the new millennium, such as computers and biotechnology, are closely linked to the iron and steel industry. For example, blast furnaces in Germany and Japan are prepared for burning residua by introducing polymer materials from computers and other electronic prepared devices through their tuyeres, while cement tube furnaces can destroy any organic residua from different origins."

Jan 1, 2002

By Frederic M. Langevin

?? Introduction ?? LaRonde ?? History of Seismicity and Rockbursting ?? November 27th 2002 Rockburst ?? April 1st 2006 Rockburst ?? December 11th 2006 & January 11th 2007 Rockbursts ?? Seismic Risk Management Plan ?? Conclusions ?? Located in Northwestern Quebec (Can.) ?? In operation since 1988 ?? Reserves at Shafts #1 and #2 depleted ?? Production now comes entirely from Penna Shaft ?? Deepest single-lift shaft in the western hemisphere (2240 metres) ?? 7300+ tonnes per day ?? 2007 Reserves (proven & probable): ?? By-products: Ag, Cu, Zn ?? Sinking #4 Shaft (LaRonde II winze)

Feb 1, 2008

By C. A. Rowland Jr

"I. INTRODUCTIONFred C. Bond's ""Third Theory of Comminution"" (1) was published in 1952. The mathematical statement of the Third Theory is the well-known Bond Formula:where W - Kw H per short tonWl - Work IndexP - Product size in microns which 80% passesF .. Product size in microns which 80% passesWork Index, as defined by Fred Bond, "" ... is the comminution parameter which expresses the resistance of the material to crushing and grinding. Numerically, the Work Index is the KwHrs per short ton required to reduce the material from theoretically infinite feed size to 80% passing 100 microns."" (2)Work indices for grinding can be obtained tram Bond grindability tests and can be calculated from plant grinding mill operating data when power consumed per ton of ore ground, the feed size analysis and the product size analysis are known.Work indices obtained tram Bond grindability tests, having been obtained from standard and controlled laboratory procedures, are reproducible and for the sample tested are accurate. The degree of accuracy relative to plant mill operation depends upon how representative the sample is of the total mill feed.The results of the Bond closed circuit rod and ball mill grindability tests (3) are given in grams of product sized material produced per revolution of the test mill. In developing a method to evaluate plant operating data and results from his grindability test, Fred Bond developed the ""Third Theory of Comminution."" In the process formulae were developed for converting grams per revolutionobtained from grindability tests to work index.The standard feed sizes for the Bond grindability tests are:Rod Mill Test ore crushed to minus 1ll inchBall Mill Test ore crushed to minus 6 mesh (Tyler)The formulae for converting grams per revolution to work index incorporate the 80% passing sizes for the feed to and the product produced in the specific test. Therefore, accurate work indices can be obtained from Bond grindability tests when the feed size is finer than standard. To obtain accurate test results, the ratio of reduction should be greater than 6 to 1."

Jan 1, 1972

By Steven Townend

Mining-related activities have been known to create a challenging operating environment for mining companies located in close proximity to communities. Issues such as noise, vibrations from mining operations, land use and emissions are often a concern for community residents. In order to develop good community relationships it is necessary to take a proactive approach. This paper documents this approach and also deals with the social implications for Vale associated with mining activities in the heart of the community of Copper Cliff, Ontario, Canada.

May 1, 2011

By Brigitte J. Dejou

The Red Dog sediment-hosted zinc-lead deposit is located in the Brooks Range thrust belt in northwest Alaska, approximately 1000 km northwest of Anchorage. The mine constitutes the primary deposit in a 400 square kilometre district, which hosts several other mineral occurrences. All the known mineralisation is hosted by the Mississippian Ikalukrok Member, deep basinal shale of the Kuna Formation, part of a Devonian to Cretaceous sedimentary sequence. The rocks underwent intense deformation during the Brookian Orogeny in Middle Cretaceous time. Several thrust faults juxtapose the stratigraphy. The Red Dog mine is composed of four deposits which together contain 105 Mt in resources and reserves for a total resource exceeding 18 Mt of Zn metal. The mine is an open pit with 25 foot high benches. The biggest challenge is not the Arctic conditions, but metal extraction, due to the fine grained nature of the mineralisation and the variability of the ore. The mine produces Zn and Pb-Ag concentrates that are shipped to smelters around the world from the Red Dog port facilities during the short summer period. Ore mineralogy is generally simple and consists of sphalerite, pyrite, galena and marcasite. The deposits are generally overlain by decametre thick exhalative barite horizons and exhibit strong silicification, which locally obliterates the original textures. Although described as a world class Sedex-type deposit, a large portion of the mineralisation exhibits sub-surface replacement textures. Moreover, unlike most other Sedex deposits, the reconstruction of the basin is made difficult by the structural complexity of the district. To assist exploration in the district, several assumptions are made regarding the deposit settings relative to metal source, growth faults or crustal extension.

May 1, 2006

By Jiwen Zhang

Abstract Due to the blocking nature at the crusher station, straightforward application of queuing theory cannot give realistic results on the performance of a shovel-truck-crusher system. A new queuing network-based model has been developed in which, the crusher station is formulated into an open queuing network and the whole shovel-truck-crusher system into a closed queuing network with the crusher station as a special server. To fully account for the influence of blocking, Monte Carlo simulation is first used to obtain the performance parameters of the open queuing network for the crusher station. The closed queuing network for the entire system is solved by applying the Extended Summation Method (ESUM), in which the crusher server is described by the simulation results. The model has been applied to the Yuanbaoshan open-pit coal mine to analyze its shovel-truck-crusher system and to improve its efficiency. Results indicate that the blocking at the crusher is an important factor affecting the crusher output and in turn the efficiency of the whole system, and prove that the model can realistically describe the behavior of such systems.

Oct 1, 2009

By Jiwen Zhang

Due to the blocking nature at the crusher station, straightforward application of queuing theory cannot give realistic results on the performance of a shovel-truck-crusher system. A new queuing network-based model has been developed in which, the crusher station is formulated into an open queuing network and the whole shovel-truck-crusher system into a closed queuing network with the crusher station as a special server. To fully account for the influence of blocking, Monte Carlo simulation is first used to obtain the performance parameters of the open queuing network for the crusher station. The closed queuing network for the entire system is solved by applying the Extended Summation Method (ESUM), in which the crusher server is described by the simulation results. The model has been applied to the Yuanbaoshan open-pit coal mine to analyze its shovel-truck-crusher system and to improve its efficiency. Results indicate that the blocking at the crusher is an important factor affecting the crusher output and in turn the efficiency of the whole system, and prove that the model can realistically describe the behavior of such systems.

Oct 1, 2009

?General Facts:Barrick?sFirst Mine in Peru Production started in November 1998 ?The Facilities:Open Pit, Primary and Secondary Crusher Valley Fill Heap Leach PadMerrill Crowe PlantRefinery Environmental Facts: High Rainfall - Average Annual Precipitation of 1,200 mm (47 inches) Rainfall Events: Common 20mm daily events High Altitude Site - Elevations range from 3900 to 4250m. Steep topography - Terrain ranges from 3:1 slopes up to cliffs. Water Issues: Sediment Control - Open Pit PAG Encapsulation - Waste Dump Stormwater control - Leach Pad Erosion Control Techniques ? Offsite impacts mitigation Social Issues: 11 communities surrounding the property Town of Huaraz

May 1, 2003

By Jessica Egan, Daniel Hodouin, Claude Bazin

"The recovery of gold by leaching is influenced by the size of the gold carrier particles and the chemical environment. Using the relationships between the leaching rate, infinite recovery and particle size for a given set of chemical conditions, it is possible to simulate gold recovery for various feed size distributions. However the use of these particle size relationships is only valid if the leaching of gold from a given size class is independent of the production history of this size class. For instance, to use these relationships it is necessary to verify that gold recovery from the leaching of the 200-270 mesh size class remains the same if the size fraction is taken from a coarse or finely ground ore sample. Several laboratory tests were carried out to answer that question. Results of the tests show that within the large error margin associated to gold content measurements, the history of the production of a size class does not affect the gold leaching from that size class. Emphasis of the discussion is put on the difficulty associated with the processing of data containing significant measurement errors as it is the case for gold assays of leaching tests.INTRODUCTIONMore than 75% of the gold produced in the world is extracted by cyanide leaching of gold ores. The ore is ground to expose the gold carriers and the ground material is reacted in an oxygenated cyanide solution that dissolves gold, leaving solids gangue minerals that are disposed to tailings ponds or returned in underground mines as paste fill. The gold contained in the solution is recovered by either the carbon in pulp process or by cementation onto zinc powder, before being melted and casted into a brick (Marsden and House, 2006)."

Jan 1, 2009

By Dominic Fragomeni, Tony DiFeo, Martyn P. Hay

"As part of an investigation into flotation modelling of industrial scale operations, Falconbridge Ltd organised a “blind” test of the SUPASIM flotation model developed by Eurus Mineral Consultants (EMC). Two sets of rougher rate data, a flowsheet and the number and size of cells in the rougher bank were supplied from a plant that had been previously surveyed in November 2003. The name of the plant, cleaner circuit details and circuit mass balance were, at the time, unknown to EMC. With only these data, flotation performance was simulated and the cleaner circuit sizedFalconbridge then compared predicted and actual float performance and mass balance and found that final concentrate recovery and mass and circuit cell volume matched closely. Simulated recoveries relative to actual were +0.4% Cu, +0.1% Ni and -0.7% Co. However, prediction of metal distribution in the internal streams making up the various circulating loads showed some sizeable errors. On this initial success, the trial was extended and additional float test data for rougher feed, cleaner feed and cleaner scavenger feed was generated on site in April 2005. Further simulations significantly improved prediction accuracy for metal distribution in the internal streams. The average difference between predicted and actual recovery for all streams was reduced from 10.5% to 0.4%. This updated simulation was then used to ascertain the impact on final recovery, grade and plant circulating loads of increasing feed tonnage from 114 to 150t/hr. A number of scenarios were simulated in order to understand the contribution that (a) the fast and slow floating fractions and (b) regrinding of cleaner tailings are making to overall plant recovery.Simulation was then used to determine how much the flotation kinetics of both rougher feed and cleaner scavenger feed have to increase in order to deliver a 1.5% improvement in overall plant recovery. These improved kinetic values provide a target for laboratory testwork and operating conditions can be varied to determine how best to achieve these new values of fraction and rate."

Jan 1, 2006

By Don Langlois, Udo Weber

"The effect of grinding media performance on milling and operational behaviour was demonstrated under different selected milling conditions of calcium carbonate. A variety of grinding media material and bead sizes, along with 2 different stirrer tip speeds, were used in the grinding process to generate a particle size reduction of the calcium carbonate (CaCO3). To determine the optimum milling parameters the collected test data was used to calculate and evaluate specific energy as well as stress intensity under different milling conditions.INTRODUCTIONAs a result of increasing energy costs and raw material prices it is important to look at the efficiency of the manufacturing process. Wet grinding and ultrafine wet grinding in stirred media mills are now a possible cost-effective production step for the processing of industrial minerals and precious metals. The generation of smaller particle sizes (down to micrometer scale) can be advantageous for further production steps – i.e. better liberation of precious metals or improved industrial mineral qualities.In the following, the wet grinding process is investigated under different milling conditions of calcium carbonate. Different grinding media materials varying in specific weight, bead size and stirrer tip speeds are used to determine optimal energy consumption for the milling process.DESCRIPTION OF TEST CONDITIONS AND PARAMETERSMill ParametersTests were performed in a Drais Laboratory Perl Mill PML H/V with an installed electrical motor power of 3 kW. The mill chamber is silicon carbide where as the stirrer and discs are made of yttria stabilised zirconia. The mill working volume is 0.9 l. A screen cartridge with a screen size of 0.2 mm is used to separate the beads and slurry at the outlet of the mill. All tests were performed with a grinding media filling grade of 80% (Mill working volume). The stirrer tip speed was set at 6 m/s and 10 m/s."

Jan 1, 2009