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By J. A. Herbst, K. N. Han, P. B. Queneau, S. W. Asihene

As hydrometallurgy matures as a technology, more of its existing process knowledge will continue to be summarized in the form of detailed mathematical models. This development is happening at a time when major improvements in computer hardware have reduced the cost of computing. The opportunity then exists, through the solution of these process models, to design, control, and optimize hydrometallurgical plants on the basis of the physics and chemistry of its processes and less on empiricism. In this paper, a review of the current capabilities of sensors and phenomenological models for selected hydrometallurgical processes is presented. Future trends, in terms of the control and optimization of hydrometallurgical plants, are then explored. The possibility of simultaneously optimizing plant design and associated process control system performance is discussed.

Jan 1, 1993

By Frank Littlewood

Research over a period of ten years resulted in the development of an efficient automatic ore feed regulator for mill grinding circuits. The facilities that a large mining company gave the inventor made it possible to develop the control apparatus under actual mill operating conditions. The Littlewood Regulator automatically determines the optimum power input at which a mill should operate, and controls the rate of ore feed to maintain this optimum power for any predetermined operating conditions. It is to be noted that the optimum power varies with many factors such as ball, rod, and mill liner wear, therefore the regulator is designed to automaticall keep itself properly calibrated. To efficiently control the rate of ore feed of a mill grinding circuit the regulator analyzes and interprets all power changes of the mill motor. The critical electrical measurements for this type of control are made possible by a patented device that has the ability to detect and integrate minute changes in power. In ball mill operation the small but significant changes in power serve to select the rate of ore feed in accordance with the rate at which ore accumulation takes place within the mill, and in rod mill operation they serve to select the rate of ore feed in accordance with the degree of rod spread.

Jan 1, 1970

By W. D. Monaghan, A. J. Kwitowski, A. L. Brautigam

Teleoperation is a technology that can provide significant health and safety improvements in mining operations by locating machine operators hundreds of meters away from the face area. The US Bureau of Mines recently developed a teleoperation system for continuous mining and haulage equipment. This system features near real-time closed-loop control. A prototype system was developed and demonstrated. This system could be used in thin-seam applications down to 36 in (914 mm). Provided are details of the teleoperation system, the results of testing and the expected applications of this technology.

Jan 1, 1996

By F. L. Jackson

When using perlite as an insulation, it is important to determine the requirements for different applications as this influences the processing of the perlite. In cryogenic application, perlite properties of low density and fine particle size are desirable, while loose fill insulation applications require similar properties and water repellency. However, in perlite insulating concrete applications, a coarser particle, of higher density, is required to provide improved compression strength. The essential properties of perlite including particle size, density, and surface treatment are discussed in relation to the various insulation applications. Also, typical mineral processing and manufacturing techniques are reviewed.

Jan 1, 1987

By K. Tokutake

Kobe Steel, Ltd. improved the quality of iron ore pellets for blast furnace burdens when it enlarged its blast furnaces. However. there still remained room to increase reducibility at high temperatures for better blast furnace operation. In particular, it was still necessary to lessen the reduction retardation above 1200?C. In the last few years, by employing iron ore and additives of optimum size structure, large pore pellets with a high porosity have been obtained. By using this method. Kobe Steel. Ltd. has accomplished the technology to produce pellets with remarkably high reducibility.

Jan 1, 1989

By G. M. Ellis

This paper deals with some aspects of concrete construction in remote locations and/or cold climates. The writer's experience covers 25 years in construction in western and Central Canada. I will bring forth some pertinent observations and cost facts learned from this experience. Let us start by saying that there is nothing more important than preplanning the entire project. By this I mean the production of the engineering design, working drawings, soliciting of prices and ordering of all equipment and contractors work, the delivery of all equipment and all onsite work. All of this should be placed on a master schedule, preferably a C.P.M. We have been using C.P M. Scheduling for all of our work for 5 years and have found it in-valuable. This preliminary schedule will show initial items of work and target dates. After main equipment orders are placed and deliveries confirmed, the construction schedule can be revised to include manpower and construction equipment requirements. From this information the size of camp is determined. This, of course, must be ordered several months ahead. The manpower schedule can be broken into trades to tell us the number of men of each trade required at any time. This is important in helping to determine where the men must come from and whether or not any incentive is needed to get them. The schedule will also point out if it is impossible to get the project closed in before winter becomes too severe unless overtime is worked or the project is started in early spring. In most parts of Canada cold weather starts in October and lasts through April. A common term of reference has been to wait for the frost to come out of the ground before starting work in the spring. In some areas this can be as late as June. The construct-

Jan 1, 1971

By John G. Watson, Judith C. Chow, Richard T. Egami, Daniel L. Freeman

A methodology for apportioning ambient PM-10 (particulate matter) concentrations to sources is described and applied to PM-10 concentrations in the vicinity of a large gold mining operation. With this methodology, samples representative of particulate sources such as desert overburden, diesel equipment, milling operations, road surfaces, and others are collected and analyzed to derive chemical source profiles. Ambient 6-hour PM-10 samples collected downwind from the mine are analyzed and used with the Chemical Mass Balance model to apportion ambient PM-10 among the various sources. In an example application, primary contributing source types are found to be desert overburden and diesel equipment. Relative contributions vary according to time of day, with diesel equipment frequently being the dominant contributor during nighttime periods.

Jan 1, 1991

By S. Komar Kawatra, Henry J. Walqui, Timothy C. Eisele

Population balance models were used to model the grinding action of industrial scale coal pulverizers. Experimental work was conducted with two different coal samples to determine the values of the appearance and selection function. These functions were determined for vertical mills by using s 6-inch by 10-inch laboratory roll mill to represent the action of a vertical mill. Two very important operating variables were identified for vertical mills: feed rate and roll spacing. Factorially designed experiments were used to analyze .and quantify the effect of these two variables. The models were then adapted to represent changes in operating conditions by incorporating the effect of the feed rate and roll spacing effects. This resulted in a simulation model able to respond to changes in operating conditions, by providing corrected predicted values for the product size distribution.

Jan 1, 2002

By F. W. DeVries

The preoccupation with cyanide as an environmental issue has been described as virtually an obsession for state and federal agencies enacting regulations for environmental protection. This seems likely to continue in legislative planning, as well. This is despite the fact that the only significant group of cyanide-related incidents has been the bird-mortality occurrences, predominantly in arid areas, and these have been greatly reduced by a concerted effort by operators. What follows is a brief list of areas for which the industry may need either additional information or plans for defensive strategies over the next two to five years.

Jan 1, 1991

By Osamu Shoji, Mamoru Kato

In order to continue improving the quality of telecommunication services to meet the expectations of the people and to increase reliability in the case of emergency such as disasters, Nippon Telegraph and Telephone Public Corporation (NTT) is now constructing cable tunnels which connect main urban telephone offices. However, almost all the large cities in Japan are built in river deltas, so that their chief underground features are low strength fluvial deposit and a high ground water level. In this saturated soft ground, the ground surface at an installation site has occasionally subsided through deep excavations for cable tunneling construction. As these settlements have sometimes caused accidents, especially in densely populated large cities, NTT has made much effort to avoid such accidents. These accidents have occured mainly in flexible sheeting due to its inward movement. Therefore, after the investigation into forecast method of sheeting deflection with accuracy, NTT has reserched a system which forecasts ground surface settlements. This paper describes an outline of the ground settlement forecast system and practical example on the site.

Jan 1, 1979

By Daniel Saramak, Agnieszka Saramak

A big issue in crushing and grinding operations in raw materials handling is high energy consumption and low breakage effectiveness. According to the Legendre [7], only 10% of energy input is directly consumed on the feed material breakage, while the remaining portion is dissipated in the form of heat and noise [8]. In the industry of limestone powder production, the grinding operations constitute integral part of technological circuits, and the energy consumption in operations of industrial comminution consume as high as 2% of world energy [14]. High-pressure grinding is the technology with proved energy benefits both in ore processing circuits and in limestone grinding. The promising results concerned mostly the achieved energy savings and good results of material breakage were achieved and demonstrated in numerous investigations [1,3,12]. However, it appears that a proper selection of operational parameters of the press devise, determination the feed material characteristics and adjustment of process course san be of a key-significance in improving an effectiveness the HPGR operation. Operational parameters of devices and process course should be verified towards the characteristics of the feed material, which mainly applies to the particle size and shape of the feed material and its moisture, and also mineralization in case of ores [2,4,9]. There are various investigations concerning an impact of the operational pressing force on comminution results which mostly refer to the determination of energy consumption and crushing ratio [5,6,10,13]. Investigations on the moisture content are less common, however their results suggest that, in general, the HPGR feed with higher moisture shows the tendency to higher comminution intensity, while the energy consumption increases together with increasing of feed material moisture. Investigations on olivine sand feed [11] showed that crushing ratio decreases for higher moisture, especially when the material is crushed at higher pressing force. HPGR devices, however, shouldn’t be regarded as a unique and perfect solution for comminution of each type of material. But they indeed may bring technological and economic benefits, comparing to conventional crushing and grinding machines, resulting in more favourable breakage of material particles and lower consumption of energy per unit mass of processed feed material.

Feb 1, 2025

By Tracy T. Morris

The current state of the mining community has made it imperative for operations to reduce costs and increase productivity in order to remain competitive. This has been done in Colorado with the installation of an Outokumpu flash flotation machine for the production of a gold/silver/lead concentrate.

Jan 1, 1987

By Koehler Stout, Leroy Friel

INTRODUCTION Hydraulic sand fills have been extensively used in the United States in deep metal mines since 1940, and hydraulic fills have been placed in coal mines in Europe for many years. Numerous surface hydraulic fills exist in Appalachia for the disposal of coal mine waste and throughout the United States for the disposal of other mining, manufacturing, city, and paper company wastes. Hydraulic fills, as they are now deposited in stopes in mines, are often deposited at near minimum density and hence provide very little support to stope walls and pillars. If the support strength of fills could be increased, perhaps ground conditions in deep mines could be improved making them safer and more efficient. Surface fills deposited at higher densities could be covered with top soil upon which grass could be planted. The purpose of this paper is to describe procedures where the support strength of hydraulic fills can be considerably increased, and the focus of the paper is on applications to deep mines. In deep mines the objective of increased fill strength is to reduce heavy ground problems, improve destressing techniques, reduce or eliminate rock burst incidences, provide better working conditions, provide wall support so that more or all ore pillars can be removed, and improve mine safety, efficiency, and reduce surface environmental problems. The authors have shown that it is possible to improve fill strength used in deep mines. This paper reports the slurry filling procedure, fill testing techniques, and some recommendations for application in deep mines. Some of the reasons for low strength hydraulic fills are:

Jan 1, 1979

By John Rushton

Surface mining, from ore extraction to processing, requires many types of equipment to obtain the final product. Mine equipment often includes shovels, drills and haul trucks. Ore processing equipment, including plants, mills and concentrators, are also part of surface mining operations. Surface mining operations emphasize production. Production is where the bills are paid and fortunes are made. However, there must be support to keep the equipment operational. To most production people, equipment maintenance is a necessary evil. Maintenance is not glamorous work. It is often neglected when praise is being passed around. It is easy to recognize higher production, greater capacities, faster cycle times or more loads hauled. But who cares if an engine is replaced in 12 hours instead of 48? The answer is, everyone should - from the hourly miner to the mine manager. Surface mining equipment needs constant maintenance work. It must be lubricated, components replaced, electrical problems repaired and other problems addressed. Repair work for any surface equipment takes time away from production. It costs money. Maintenance costs cannot be avoided. However, they can be minimized. Minewide communication should include operations cooperating with maintenance. Traditionally, operations resist surrendering equipment to maintenance if it can continue to produce. The rationale is, every load that can be hauled today is money in the bank. If the unit is taken down, the money is lost. This thinking is prevalent in many surface mining areas, including the mill. "Not on my shift," the operator thinks. "Let the next crew worry about it. The problem with this thinking is in probability and statistics. The longer equipment goes without maintenance work, the higher the probability of equipment failure. When the failure does occur, it is certain to cause the equipment to remain down longer than if the maintenance department had been allowed to take it down. Many mining operations have closed early in their lives because of poor maintenance practices. This has become the industry standard because substandard levels of performance are acceptable. Management believes it gets five to six hours of work from maintenance people during an eight-hour shift. Actually, the industry average is less than two hours of work per shift. Real productivity levels of less than one hour are not unusual. There are few exceptions. However, a daily work schedule (DWS) will increase productivity at many properties by 50% to 100%. A 200% improvement is not unusual. The DWS will work. Maintenance people are among the most intelligent and motivated people on the property. They deserve the chance to be productive. [ ] In preparing a DWS, management needs to understand two productivity principles - the productivity spread and the real maintenance workday.

Jan 1, 1997

By R. S. Mateer

Linear programming on desktop computers is commonly used to optimize coal blending proportions. The objective function is usually the cost of the blend. The constraints consist of materials and heat balances as expressed as linear functions of the blend. This is illustrated in Example 1. Inclusion of a sulfur compliance constraint in more complex because the maximum permitted sulfur percentage is not a pre-specified constant. Rather, it is a function of the calorific power of the blend itself. The current limit of 1.2 pounds of sulfur dioxide per million Btu may be expressed as: [Sulfur Max%= 0.6 . Hl10,OOO with H in Btu/lb.] A proper constraint equation may be formed by defining for each coal a function that is the difference between the actual sulfur percentage and the maximum sulfur percentage. This may be regarded us an excess sulfur percentage. For Coal A of Example 1. this would be: [ Sulfur Excess%=0.5-0.6 13,000/10,000=-0.28] This value would be used as the coefficient of the weight proportions of this coal in the blend. The complete constraint equation would then be the sum of such terms for each coal set less than or equal to zero. This is illustrated in Example II. [ ]

Jan 1, 1995

By A. L. Mular

Steady-state material balances calculated from data measured at various locations around process units are useful for many purposes, such as metallurgical accounting, on-line control, and the development of mathematical models. Often it is possible to calculate material balances by several independent procedures when excess measurement information, i.e., redundant data, is available. Clearly, if the data were collected without measurement errors, a theoretical condition never found in practice, all material balances calculated from redundant data would be in agreement. The real situation is that error exists in practical measurements, so that the results of material balances determined from available optional procedures differ. Consequently, best fit computational procedures to improve the material balances by taking measurement errors into account have been formulated. Such procedures can be used also to judge whether measurements are grossly in error due to either faulty observations or defective data sensing devices. A variety of mathematical techniques are available which serve to adjust raw data. The adjusted data permit mass balancing that does not depend on the computational method. To illustrate the need for an adjustment procedure, Table 1 shows a raw data set acquired around the Brenda Mines Ltd. No. 4 grinding circuit shown schematically in Fig. 1. At least seven optional ways to calculate a circulating load ratio may be employed. These are shown in Table 2 where, depending upon the calculation [ ]

Jan 1, 1979

By Stanislaw Wasilewski, Zdzislaw Krzystanek, Boleslaw Firganek

The experimental system for mine venti1ation control in Staszic colliery has two - level structure. In the lower - measuring 1evel the existing computer - based early fire detection system has been used completed with a number of additional sensors needed for ventilation parameters monitoring. The higher 1evel is a secondary computer equipped with a suitab1e dedicated software performing data processing according to the control a1gorithm. Direct control of air flow in a selected mine district is performed by means of a remotely controlled automatic regulator. Apart from functional tests of the system and its elements some research work has been carrying out in the colliery based on observations of transient effects caused by changes in air flow distribution.

Jan 1, 1989

By Charles D. Litton

This report describes a smoke particle detector which utilizes a novel three electrode configuration and 5.0 [] source of Americium 241. The detector operates on the principle of diffusional charging by a region of unipolar molecular ions. The detector is sensitive to particle concentrations in the range of 10 to 5 20 ug/m3. The detector is intended for use primarily as an early warning fire detector but has the potential for other applications of particulate monitoring. In particular, this report adresses the potential use of the detector for monitoring diesel particulate matter (DPM). To assess the viability of this application, particle size data obtained from in-mine sampling of both DPM and dust were used to derive detector sensitivity functions for DPM and dust as a function of their mass concentrations only. These sensitivity functions are dependent upon the average diameters and size distributions of the DPM and dust. Using the derived sensitivity function for DPM, experiments were conducted in a ventilated tunnel where the true DPM mass concentrations, measured using a Tapered Element Oscillating Microbalance (TEOM) were compared to the mass concentrations calculated using the detector sensitivity function. The agreement between the two measurements was good, indicating that with additional experiments, coupled with in-mine evaluation of the detector, refinement of the device for use as a continuous monitor for DPM appears feasible.

Jan 1, 1989

By Jerome C. Neyer

Within most of Canada and the northern third of the United States, the soils overlying bedrock are of glacial origin. Tunnelling in glacial soils presents numerous challenges to the contractor, including abrupt changes in soil type, boulders and glacial erratics, water bearing fine sands and silts, toxic or explosive gases, and glacial till. This paper examines the available techniques for geotechnical exploration in glacial soils; the relationship between subsurface conditions predicted by various techniques and conditions actually encountered during tunnel construction; and potential improvements in the planning and implementation of geotechnical explorations. Case histories of geotechnical exploration and tunnel construction in glacial soils are also reviewed.

Jan 1, 1985

By S. S. Nadgauda, A. J. Hathaway

Typically, as long as the coal quality is within the specified range, electric utilities have used delivered cost of fuel per million Btu as the primary criteria for qualified coals when making coal-procurement decisions. Such an approach may not fully address the total cost of using different quality coals at a given plant. A practical and easy-to-build model is described for estimating plant-specific utilization costs for coals of different qualities. Examples are included to illustrate the modeling results for plants operated by two utilities. While the model has certain limitations, it does represent an improved method for evaluating coal bids, and, consequently, reducing generation costs.

Jan 1, 1990