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By A. C. Ross

"The paper will deal with non-destructive testing in general, and its advantages to those responsible for the maintenance of wire rope. An outline of the main features of the M.D. 6 Defectograph will be given, and the method of operation and results obtained will be described.The instrument will accommodate ropes at 7 /16-to 2 %-inch diameter at reasonable speeds, and is capable of detecting the most minute defects in even the largest-diameter wire ropes."

Jan 1, 1969

By L. P. Connolly, M. J. Fraser

"Hydraulic transport of solids has long been an important technique in mining and beneficiation. More recently, slurry pipelines have proved to be economic for longdistance overland transport of many commoditieis, including iron ore concentrates and coal. Now, the Marconaflo system brings the many advantages of hydraulic transport to bulk storage, loading, transportation and unloading of ships and other carrying equipment, thus providing important new means for delivering mineral commodities to market. In this paper, the authors describe the Marconaflo system and the potential economies which can be realized when applying it for loading, transporting, storing, reclaiming and blending a variety of mineral commodities, using several commercial installations as examples."

Jan 1, 1972

By P. Czaja

The paper presents a patented and copyright protected concept of constructing a shaft lining that goes through rock masses having strong rheological properties and being susceptible to leaching. In the case of salt layers, especially at significant depths (over 900 m) the relative convergence of the heading contour may amount to 40 ?/year. That results in the fact that any other method of securing the shaft lining, e.g. by making it flexible, will not be sufficient to ensure the stability of the shaft reinforcement geometry. In the new shaft lining concept the excessive rock creep into the outbreak inside the shaft diameter will be removed by local and controlled leaching of the shaft cheeks by means of fresh water directed through a porous medium at the contact layer behind the watertight tubing lining. The paper presents the structure of such a lining and an outline of the construction technology. In order to implement such a lining, a typical tubing will be applied. Separate design and manufacturing will be required for the technological rings used to control the leaching process behind the lining.

Aug 1, 2013

By Jeremy G. Berg, James B. Mulligan

"There is a very small fraction of wireless experts in the world with experience in underground installations and an even smaller fraction that have experience specific to building mine shafts. This is why in 2009, Redpath created its own system to meet the demands specific to shaft construction. Today, after a dozen shaft installations and several design iterations, Redpath has the expertise and experience required to implement a proper wireless system in any shaft configuration.This document will explain multiple proven wireless communication designs optimized for shaft construction and suitable for permanent use. This includes line of sight installations up to 1200m, short range mesh networks, and the latest patent pending Integrated Leaky Feeder Mesh Network. Additionally, this document will explore the lessons that Redpath learned in its effort to interconnect the people and tools needed to build a mine shaft.INTRODUCTIONAfter a decade of research, several design iterations and a dozen application examples, Redpath has resolved two wireless network architectures to best serve mine shaft construction projects.The long range line-of-sight (LOS) wireless network is the most cost effective and easiest to install, but requires an unobstructed line of sight between the working area and the shaft collar. As such, long range LOS is best suited for ventilation shafts or during the first phase of shaft sinking, before the shaft is equipped.Alternatively, a mesh network uses radios installed at pre-determined intervals in the shaft and on each conveyance. A wireless mesh uses antennas to bridge intervals between shaft radios, whereas Redpath’s integrated leaky feeder mesh network (patent pending) bridges these intervals with radiating cable, commonly referred to as a “leaky feeder” cable. Both of these mesh configurations can provide continuous reception for hoist conveyances travelling in shafts without line-of-sight, making them ideal for shaft equipping and even permanent installations in both mine shafts and lateral drifts.BACKGROUNDHoist operators receive operating commands using what are commonly referred to as “bell signals.” These instructions are delivered in a series of coded pulses on a spring returned pull cord or push button that is typically hardwired back to the hoist operator’s control room from one of many locations in the mine shaft. During the construction phase of a traditional mine shaft, a worker riding inside the sinking bucket would have to reach out to a pull cord installed on the shaft wall to send a stop command to the hoist operator. Today, Redpath’s modern shaft sinking projects use fully enclosed personnel carriers to protect the workers riding inside, specifically preventing workers from reaching out into the shaft while the hoist is in motion. The enforcement of this safety feature on all shaft projects in 2008 forced the engineering group at Redpath to find a suitable wireless solution for hoist communication to facilitate shaft construction.THE IDEAL COMMUNICATION SYSTEM FOR MINE SHAFT CONSTRUCTIONIdeally, the shaft communication system should not transform the tools to which the miners have grown accustomed. It should support the push-to-talk functionality of traditional VHF handsets and the standard belling system that has been used for decades. Additionally, it should be able to support a vendor independent framework upon which new devices and features can be added. The following paragraphs summarize some of the important requirements Redpath has identified.Support for voice transmission: Low latency is critical to prevent jitter during voice transmissions. The system must be compatible with commercially available mobile handsets and support several simultaneous conversations with the ability to broadcast a voice message to all users on a select channel using a “push-to- talk” microphone and loudspeaker.Transmission of PLC data: Low latency is required to"

Jan 1, 2019

By Roger Lacroix

Fuel cell application to mining has been indicated to be potentially beneficial to underground mine worker health and to energy efficiency. In order to define the economic advantages of using hydrogen fuel cell vehicles, a detailed study of operating and capital costs associated with underground loaders and power supply infrastructure has been carried out. The results show that for a typical medium-size mine, operating costs and infrastructure costs are less for the fuel cell option versus diesel. The reverse occurs for capital costs owing to the currently higher cost of fuels cells versus diesel engines. This disparity is expected to decrease given the decline in price associated with fuel cell technology advances. Related market issues for fuel cell manufacturers are also presented. Despite the difference in cost, the resources and mine infrastructure required to operate loaders, and base design of the mine loader, is similar for diesel and fuel call versions.

May 1, 2007

By Jirí Faltus

The paper deals with studying the impact of structural properties and anodizing of surface on the corrosion properties of extruded rods from commercial aluminium alloys: AA6082, AA6262, AA6012, AA2007 and new lead-free aluminium alloys AA6023, AA2015 and AA2111B. Samples were exposed to the corrosive atmosphere NSS, AASS in the chamber by EN ISO 9227. Surface of samples were either in the original state or anodizing by selected mode. The depth of corrosion attack and the form of corrosion attack are evaluated depending on the type of alloy, the metallurgical condition and surface treatment of the samples.

Jan 1, 2015

By Osvaldo A. Bascur

Industrial complexes rely on measurements of flow rates, qualities, and concentrations for monitoring and optimizing their operation. Corporations use the data from the various sensors and measurements to make business decisions, which affect the profitability of the operation. However, gross errors, due to a variety of reasons like faulty sensors, bad instrument calibration, or incorrect process models may corrupt the actionable information supplied to operations, quality managers, and maintenance personnel. The solution is to use the sophisticated new tools to model the process, sift through the available data to locate the gross errors, and use statistical data reconciliation to validate the sensors and instruments. In this way the data are unified to give the most accurate plant information for use by the monitoring and decision making processes. Most mining and metallurgical plants use predictive maintenance policies based on statistical analysis and special techniques, like vibration analysis, and oil and lube analysis for critical equipment. Process control strategies are installed in several metallurgical sites. All of these depend on reliable and accurate data. The data unification methods validate the individual measurements by using the concept of balances and statistical techniques where each instrument is no longer independent of the other measurements in the facility. This paper refers to the data unification and analysis methods required for profitable plant operations. Continuous improvement and monitoring of the measurement system at the plant and analysis of the reconciled data provide the best information for the decision-making process. On-line gross error detection and elimination methods are required to ensure efficient evaluation of process performance and process optimization. An open discussion of the new methods for gross error detection and data unification will be presented.

May 1, 2001

By K. E. Waters, N. Brodusch, R. Gauvin, C. Teng, H. Demers

Rare earth elements play an increasingly important role in renewable energy devices and high-end electronics. In this project, the composition and morphology of REEs-bearing minerals are characterized with a field-emission scanning electron microscope at high spatial resolution and high counts rate using an X-ray silicon drift detector system. High spatial resolution imaging and energy dispersive X-ray microanalysis were applied at low and high magnification to obtain the composition of each phase in the minerals. From the standardless quantitative analysis results, the amount of REEs in each phase was measured and the relationships between those phases were identified.

Jan 1, 2014

By Gary M. Bone

The autonomous control of vehicles interacting forcibly with their environment, such as dozers and tractors, is an unsolved and challenging problem. Forces and motions are inherently coupled between the tool and the means of vehicle propulsion. Furthermore, they are often operated within uncertain and unstructured environments, such as those encountered in underground mining. There is a growing industrial interest in the development of robotic vehicles to improve productivity, efficiency and safety in mining and construction. This paper focuses on the modeling and control of autonomous robotic dozing for a material removal operation. A dozing process model has been developed based on observations of both a fullscale dozer and a scaled-down version. The model characterizes the dynamic interactions between the blade position, material accumulation on the blade, material distribution in the environment, and the motions of the dozer. The dozing control objective is to remove the loose material as rapidly as possible by driving forwards at full power while automatically raising/lowering the blade in response to sensor measurements. Two different controllers were developed to meet this objective. The first controller is based on a set of heuristic rules, and the second is an optimal controller based on the dynamic model. An instrumented scaled-down robotic dozer and dozing environment, designed to emulate the full-scale operation, are used to implement the controllers and compare their performances over multiple dozing passes. Experimental results are presented showing that the model-based controller increased the material removal rate by 33% compared to the rule-based controller. Lastly, technologies for full-scale implementation are discussed, followed by proposed future work and conclusions.

Aug 1, 2013

By Stavros A. Argyropoulos, Radhakrishna Valiveti, Bernard Closset

"The use of microprocessors in metallurgy is currently increasing at a very fast rate. A large number of companies are offering systems ""off the shelf"" which are aimed at the data acquisition and process control market. There are two main drawbacks to these systems: first, they are usually quite expensive, and second, they are not completely compatible with the target metallurgical application. An alternative is to develop a microcomputer-based system "" in lab "".A dedicated microcomputer system has proved to be very useful in many metallurgical research applications(1,2)). However, in this system the analog input signals had to be transferred over long distances , and significant noise was introduced despite the use of shielded cables. In order to overcome this problem a network of low pass-filter s was designed and built. The usage of the abovementioned system brought the need to digitize the analog signals in-situ and transfer the digital signals, which are much less susceptible to noise over very long distances. This distinctly different design philosophy has become a reality with the evolution of microprocessor technology over the last few years. This design philosophy is utilized in this development."

Jan 1, 1984

By Chen Bang, Xia Xiao’ou, Zhang Feng

"Ores with compressive strength lower than 150 MPa are usually easy to be crushed by conventional jaw crushers and cone crushers. However, for hard ores with compressive strength exceeding 150 MPa and 200 MPa and even up to 250 MPa, such as andesite, hard basalt and olivine, it is difficult to reach satisfactory crushing size and yield or difficult to meet service life and stability use requirements of quick-wear parts by using conventional crushers. As continued increase in ore mining depth and constant generation of new type materials, equipment demand for crushing hard ores becomes increasing high. A new type inertia vibrating crusher is designed. It is powered by a high-speed rotating vibration exciter and can obtain required crushing force by adjusting eccentric mass, eccentricity and rotating speed so as to crush various ores with high hardness. This paper introduces the design process of its structure and working principle, discusses the design calculation methods of vibration excitation system, vibration damping and energy storage system and other key mechanism and provides technical references for this type of vibrating crusher.DESIGN PHILOSOPHYThe conventional jaw crusher mainly acquires extrusion force from crank motion to realize crushing. The motor drives the eccentric shaft via the transmission device to bring the moving jaw to swing relative to the stationary jaw. When the moving jaw moves close to the stationary jaw, ores between them are crushed by extrusion; when the moving jaw moves away from the stationary jaw, crushed ores are discharged from the discharge gate at the lower end between the moving jaw and the stationary jaw.The conventional spring cone crusher and the hydraulic cone crusher mainly acquire extrusion force from cranking motion to realize crushing. The motor drives the eccentric sleeve via the transmission device, the moving cone shaft generates an eccentric distance to make cranking motion under the action of the eccentric sleeve. When the moving cone moves close to the stationary cone, ores between them are crushed by extrusion. When the moving cone moves away from the stationary jaw, crushed ores are discharged from the discharge gate at the lower end between the moving cone and the stationary cone under the action of dead weight."

Jan 1, 2016

"Sink-float analysis is often used to obtain yield-ash and density partition curves in the coal industry. These provide a valuable tool for evaluating the performance of a separation process. However, for dense minerals, obtaining complete grade-recovery and density partition curves is more difficult due to the lack of heavy liquids available with the required densities. This paper examines a potential solution to this problem which is to perform batch fractionation of mineral samples in a laboratory-scale REFLUX™ Classifier using high viscosity fluidising liquids. The REFLUX™ Classifier is a gravity separation unit consisting of a system of parallel inclined channels positioned above a vertical fluidised bed. Operated in semi-batch mode, a charge of particles is fluidised from below and particles up to a certain density are elutriated from the top of the system. The fluidisation rate is then increased incrementally to fractionate the sample at progressively increasing densities. Previous work by Hunter et al. (2014) and Iveson et al. (2015) has shown that this method provides excellent agreement with yield-ash and partition curves for coal, especially when glycerol solutions are used as the fluidising liquid. This approach has now been extended to obtain the grade-recovery and density partition curves of high density mineral samples. This method has the potential to provide the minerals industry with an effective tool to evaluate the performance of unit operations separating at cut points higher than the available heavy liquids.INTRODUCTIONMeasuring efficiency and effectiveness is of key importance in the continuous improvement of mineral processing plants. For density based separation, one way the performance of a process can be evaluated is the measurement of density-based partition curves. Currently, this is done in the coal industry using the sink-float method, where heavy liquids are used to fractionate particles into discrete density intervals. However, with high density minerals such as iron ore, liquids of sufficient density are rare, and in most cases also pose serious health and safety concerns to laboratory operators. Most commercial laboratories do not perform sink-float separations above a density of about 4400 kg/m3, the maximum density of Clerici solution without operating at excessive temperatures (Koroznikova, Klutke, McKnight & Hall, 2007; Rosenblum, 1974)."

Jan 1, 2016

By P. C. M. Knops, K. Rijnsburger, R. M. Santos

To overcome the challenges of mineral CO2 sequestration, this work utilizes a unique proprietary Gravity Pressure Vessel (GPV) reactor technology, and focuses on reaction products of high economic value. The GPV provides intense process conditions through hydrostatic pressurization and heat exchange integration that harvests exothermic reaction energy. Here, laboratory-scale tests of the envisioned process was performed in tubular and continuously stirred tank reactor (CSTR) autoclave reactors. The mineral used was Olivine (~Mg1.6Fe2+0.4(SiO4) + ppm Ni/Cr), although asbestos, steel slags and oil shale residues are also under investigation. The effect of several process parameters on reaction extent and product properties was tested: CO2 pressure, temperature, residence time, additives (buffers, lixiviants, chelators, oxidizers), solids loading, and mixing rate. The products (carbonates, amorphous silica and Chromite) were physically separated (based on size, density and magnetic properties), characterized (for chemistry, mineralogy and morphology) and tested in intended applications (e.g. as pozzolanic carbon-negative building material). Economically, it is found that product value is the main driver for mineral carbonation, rather than, or in addition to, the sequestered CO2. The approach of using a GPV and focusing on valuable reaction products could thus make CO2 mineralization a feasible and sustainable hydrometallurgical process.

Jan 1, 2015

By J. Palarski

Hard coal, mined in Silesia Region as well as in the eastern part of Poland, is a key national resource. In Polish underground coal industry, modern mining technologies have been successfully tested and used in the last 50 years. More than 98% of the coal produced underground is extracted by longwall mining method. Current underground coal mining expands into increasing depths. The use of conventional coal extraction methods ? room and pillar and longwall with caving - is becoming increasingly difficult. The coal mining is modifying existing methods and is testing innovative technologies. Backfill is an important component of modern underground mining operations. In Polish underground mines, backfill is recognized as an integral component for extraction of coal from greater depths in a densely populated environment. The modifying and innovative methods require the use of backfill or grouting of caving to provide structural support in underground excavations and to ensure that the mining operations are safe. Depending on the geological structure, mining conditions and environmental requirements there are several variations of longwall methods used in underground coal mining in Poland, in particular: longwall with caving, longwall with backfill, longwall with grouting of caving area. This paper will discuss the different components of an effective longwall production and filling process of caving area. The paper will give a overview of the current application of backfill technology, focusing on Polish coal mining operations. This paper will also briefly describe how backfill contributes to an innovative method ? underground coal gasification. The paper discusses specific requirements for fill materials and the technology of backfilling for underground coal gasification (UCG) operations and problems of implementation and correlation of backfill parameters with other processes that occur during thermal processing of coal.

Aug 1, 2013

By A. Khan

The purpose of this paper is to demonstrate the value of identifying and optimizing throughput constraints by utilizing a Constraint Model. This will be achieved by first understanding the overall concept of Operational Excellence, Continuous Improvement and Theory of Constraints as practiced within Vale Canada Limited. Next, the value of utilizing a Constraint Model is demonstrated by primarily identifying constraints. The applications in utilizing Constraint Models will be demonstrated, including the primary benefit of identifying constraints. The remainder of the paper will focus on how to properly setup a Constraint Model using discrete simulation (regardless of simulation software). Benefits of understanding the severity of constraints and movement of the bottleneck will be recognized. The paper will conclude with the summary of real applications within Vale Canada Limited.

Aug 1, 2013

By P. Radziszewski

Industrial practice in mineral processing shows that an important problem in understanding and monitoring in-mill parameters is due to the lack of fundamental knowledge and appropriate sensors. With the development and growing use of DEM charge motion simulators for mill optimisation and design, it is possible to describe the fundamentals of grinding mill behaviour, in improving the understanding of internal grinding mill dynamics and in developing solutions to industrial practice. The main challenge to bringing this DEM technology to the mill operator however was the need for substantial computing power and time. However, what about a simplified DEM charge motion model running in real-time? What about the use of sensor technologies to correct any possible drift in simulator prediction? Could such a technological system be used to predict mill performance and eventually be used for mill control and optimisation? Some of these questions are answered with the development of an "on-line" DEM charge motion simulator package (SAGTools?) along with that of a number of sensor technologies (liner wear, acoustic, instrumented ball) that can contribute to simulator precision. With the objective of bringing this modelling and sensor technology into the concentrator control room to assist operators, this paper aims to describe the main elements of this emerging and developing technology and discuss how it can lead to online mill performance prediction and eventual control.

Jan 1, 2007

By Ralph J. Holmes

"An accurate knowledge of the chemical, mineralogical and physical characteristics of ores and mineral products that are mined, processed and sold commercially is crucial to resource definition, effective resource utilisation, plant design, process control, metallurgical accounting and finally quality control to ensure that contract specifications are met and equitable payment is received for product sales. However, the responsibility for sampling is often entrusted to personnel who do not fully appreciate the significance and importance of collecting fully representative samples for analysis, and they seem satisfied as long as some material is collected and returned to the laboratory for analysis. Furthermore, sample stations incorporated into the design of new plants are often the first casualties when cost cutting exercises commence. There is really little point in accurately analysing samples if they are not representative in the first place, because the resultant analyses can be seriously biased and the effort taken to carefully analyse such samples is largely a waste of time and resources.Ultimately, a poor knowledge of the characteristics of ores and mineral products limits the ability of mining companies to optimise the life of ore resources and plant performance, and failure to meet final product specifications can have disastrous consequences, including price penalties and more seriously loss of sales contracts and significant revenue losses due to poor sampling practices at the point of sale. Consequently, it is critical that sampling is given the attention it deserves as the first important step in the quality measurement chain. The golden rule for correct sampling is that all parts of the ore, concentrate, slurry or other material being sampled must have an equal opportunity of being collected and becoming part of the final sample for analysis."

Jan 1, 2016

An optimized long-term mine planning determines the best order of material extraction, so that the Net Present Value (NPV) becomes maximum. In the case of oil sands surface mining, one of the key constraints in NPV maximization is the volume of tailings slurry that will be generated downstream. Specifications of tailings slurry are also important from environmental perspective. Moreover, most of the material that will be used for the reclamation of tailings ponds in later periods is generated in extraction and processing of oil sands. In this paper, an integrated optimization framework is proposed to maximize the NPV of the produced oil sands, with respect to tailings capacity constraints and reclamation material requirements. A mixed integer linear programming (MILP) model is developed to find the optimal solution for long-term mine planning problem. The proposed model is coded in Matlab and has been run using CPLEX for verification. The results for real-case oil sands dataset show that the optimal production schedule meets material requirements for reclamation, tailings volume is within tailings capacity range in all periods and the production schedule follows the predetermined horizontal direction.

Aug 1, 2013

By Henrik Saxén, Mikko Helle

The operation of hot stoves used for preheating the blast in the ironmaking blast furnace has a strong effect on the consumption of reductants, economic performance of and CO2 emissions from the steelmaking site. Generally, it is recommended to maintain as high blast temperature as possible, because this minimizes the rate of reductants in the blast furnace. The blast temperature is affected in a complex way by the time periods of heating and cooling of the stoves, and by the amount of gas combusted in the stoves. Furthermore, as the hot stoves show degraded performance with age, it is a non-trivial task to select optimal operation parameters for the stoves. The paper addresses this computationally by applying a one-dimensional heat-transfer model of the hot stoves for optimization of the performance of the system. The complexity and strong coupling of the decision variables is demonstrated by numerical examples, where the blast temperature is maximized under different constraints.

Jan 1, 2015

By Xianglin Yang, Hong Zhong, Jingjing Xiao, Guangyi Liu

"The selective adsorption of a flotation collector to a mineral plays a crucial role in enhancing the hydrophobicity of targeted mineral particles for attaching air bubbles in pulp. The recent progress of the structure-reactivity relationship of flotation collectors, the characterization methods for mineral surfaces with adsorbed collectors and their commercial application are reviewed in this paper. Particular emphasis is placed on the density functional theory (DFT) for understanding the reactivity of new collectors, the surface analysis techniques including time-of-flight secondary ion mass spectrometry (ToF-SIMS), in situ scanning electrochemical microscopy (SECM) and atomic force microscope (AFM) to characterize mineral/collector interface, and the flotation technologies for optimizing recovery of valuable minerals. Especially, the recently developing collectors such as Gemini, alkoxyalkylthiourea, dithiourea, amide-hydroxamate and oximido-thiol surfactants, and their specificity to given minerals are evaluated. Based on this crucial review, it is evident that the structural modification approaches for minerophilic or hydrophobic groups, and combined surface analysis approach for further understanding the adsorption mechanism of collectors on mineral surfaces will lay a solid foundation for the future development of flotation collectors. INTRODUCTIONIn mineral processing, flotation is the main process for separation and recovery of valuable minerals from the ores contained them (Fuerstenau et al., 2007). One of the key requirements in flotation process is to increase selectively the surface hydrophobicity of the targeted minerals by collector adsorption so that these mineral particles can preferably attach to air bubbles in a slurry or pulp (Fuerstenau et al., 2007). Flotation collector is a kind of functional surfactant, which is composed of polar and non-polar groups (Somasundaran, & Wang, 2006). Non-polar portion, commonly being linear, branch or ring hydrocarbon group, is termed hydrophobic group. The polar portion, exhibiting strong affinity to mineral surfaces, is known as minerophilic group (Nagaraj, 1988). According to mineral types including saline, oxide and sulfide minerals, flotation collector divides into sulfide and oxide mineral collectors. For efficient recovery of valuable minerals from the refractory complex ores, insights into the adsorption mechanism, hydrophobic model and subsequent flotation approach of flotation collectors have been regarded as an indispensable issue in mineral processing."

Jan 1, 2016