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By Daniel Mapa Clemente

Processing of tin slags in reduction furnaces was studied in order to optimize tin recovery and reduce recirculation rates of slags containing thorium and uranium oxides. A theoretical approach considering a mass balance of the process was developed and adjusted by experimental results in order to predict the final slag composition. A metallic phase (FeSnSi) was discovered trapped in the slag due to high apparent viscosity, raising the FeO and SnO2 contents of the slag sample. This FeSnSi alloy is rich in tin and its recovery would help to reduce the slags recirculation. High contents of ZrO2 were found in the slag, restricting it from reaching complete fluid phase. Through an analysis of the slag in the CaO-FeOx-SiO2 and ZrO2-CaO-SiO2 phase systems it can be concluded that final slags should be modeled aiming fluid phase at working conditions and additions should be planned in order to control ZrO2 levels.

Oct 30, 2017

By Fernando Velazquez Guzman

Titanium is an alloying element used to refine grain size in steel and improve its physical and mechanical properties. In some stainless steels it is used to increase the resistance to corrosion by the precipitation of titanium carbides or carbonitrides. Its alloying performance is highly variable and depends largely on the stage of the secondary metallurgy process when it is added. Furthermore, the addition method (wire injection or direct addition) has a remarkable influence in secondary refining. This paper describes the tests performed in vacuum degasser (VD), with a highly compacted and encapsulated Ferrotitanium wire (FeTi HC). The yield of titanium in steel increased from 52% to 89%. Moreover, the consumption of the highly compacted Ferrotitanium was optimized.

Oct 30, 2017

By Guoqing Li, Hao Wang, Nailian Hu, Victor Tenorio, Jie Hou

This paper presents an algorithm for optimizing the scheduling of trackless equipment in underground mines. With the shortest working interval and maximum productivity as goals, a genetic algorithm (GA) is used to solve the problem, and obtain the optimal working sequence with the most suitable equipment configuration possible. The input for the proposed method is the number of units and capacity of trackless equipment, the production process, ore amount in stopes, and the distance between stopes. The algorithmis verified using four setups of 5 stopes with 5 cycles, 5 stopes with 15 cycles, 10 stopes with 10 cycles, and 10 stopes with 30 cycles. The solution time of the algorithmis no more than 20 min, which is acceptable for practical applications. The results show that the setup of 10 stopes with 30 cycles is closer to the actual production of the mines, and the optimization model can effectively improve the operation efficiency. In this scenario, the robustness of the optimization is tested by simulating equipment failure events. Under the condition of 8% failure rate, the operation time is extended over 3.21–14.56% than expected, which represents strong robustness. The algorithm can quickly provide a feasible and effective solution for the production scheduling decision of trackless equipment in underground mines.

Aug 12, 2020

The relative abundance of coal in India compared to other fossil fuels makes it a natural choice as the primary source of fuel, be it for steel making, power generation or for other uses. The wide variations in nature and type of Indian coals formed during lower Gondawana period and categorized as difficult-to-wash due to its typical mineral matter association with the organic matrix call for suitable beneficiation techniques as the preferred option for quality upgradation. The good quality coking coals of the upper seams are fast depleting leaving behind the inferior quality lower seam coal. The lower seam coals presently being mined are mostly low volatile coking coal (LVC). They constitute about 50% of the total coking coal reserves in India. The beneficiation of Low Volatile Coking coals pose a major challenge and detailed R & D studies was taken up to study the beneficiation characteristics of these coals. The studies revealed that the liberation characteristics at coarser sizes are very poor and the coal is to be ground to finer sizes for liberation. The most important factor that determines coal cleaning efficiency is liberation of organic matter from mineral matter. To achieve liberation grinding is necessary as a result range amount of ultra fines (-0.063 mm) coal is generated. Presence of these large amount of ultrafine in the coal fines, often impose severe technical constraints affecting not only its floatability but also in the downstream treatment of the products like dewatering and cake formation particularly when it is beneficiating through froth flotation. In the present paper optimization of ultra fines (-0.063 mm) has been tried for a LVC coal of Jharia coal field for the better liberation and beneficiation of the above coal fines. It is observed that by optimized, combination of size and number of balls generation of fines can be controlled with liberation. Keywords: coking coal, liberation, floatability, dewatering

Sep 1, 2012

By Juan Pablo Guevara, Victor Munoz, Rob Bush, Gonzalo Marias

Cerro Negro Mine, property of Goldcorp Inc., is in the process of developing four separate underground access ramps for the exploitation of high grade, narrow vein gold deposits with vertical to sub-vertical dips. The Mariana Central, Mariana Norte, and San Marcos accesses are primarily in the development stages, while the Eureka access began production stope blasting in April of 2013. Mariana Central will also begin production in May or June of 2014.

Jan 1, 2015

By Dan S. Nilsson

When an open pit mine is deepened, more and more waste rock must normally be removed. Techniques for optimization of open pit design are well-established within the mining industry. The recommended method is to choose the open pit alternative with the highest net present capital value of open pit and future underground mining. When the open pit is mined out, the operation must be closed, or, if it is profitable, mining must start underground. When planning an underground operation we experience the same type of optimization problem that occurs when determining the optimal depth for open pit mining. When mining underground the ore body is often divided into a number of areas, blocks or slices, each containing a transportation system with trains, trucks, conveyors, etc. When all the ore within such a part of the deposit is extracted, the operation must be closed, or, if it is profitable, a new transportation must be developed. The question that now arises is: how large a pan of a deposit shall be included in the first development and how much shall be left for future consideration?

Jan 1, 1981

By S. Gajardo, E. Valdés Guerra

Together with Sociedad Punta del Cobre S.A. (Pucobre) and Orica, we are carrying out a study of alternatives for methodology of excavation in Slot Up Raises from actually built with Blind Hole (BH) to drilling and blasting (DB) methodology. The study is part of the permanent search for innovation, the use of technology and the reduction of mine operation costs. This application aims to optimize the Sub Level Stoping method, which has historically been exploited at Pucobre. Using a new variant of the method “Open Stoping”, through the initial development of ascending blind raises using a pilot drilling of a bore hole, with the objective of eliminating the upper level in order to excavate the free face opening. This industrial test aims to replace the mechanized BH Up Raise of 1.5m (4.9 ft.) in diameter and 30m (98.4 ft.) high, with a Up Slot Raise considering two separate blasting events, using different technological enablers, as detailed below: accuracy drilling with relief holes of 254mm (10 in.) diameter, high viscosity bulk emulsion, wireless initiation system and high-strength injectable bulk resin. Considering the importance of the success of this application, a DB diagram was defined to allow the opening of the up raise in two blasting events, separated by intermediate stemming deck located at the same level at a height of 15m (49.2 ft.) from the collar, using high-strength injectable resin. The first blasting event considers the first section from the collar to the first 15m (49.2 ft.), using wired electronic initiation that is detonated on the first day. A second event blasts the section from 16.5 to 30m (54.1 to 98.4 ft.), using a wireless initiation system, as, it has no physical connection, is blasted on the second day after the extraction of the material resulting from the first event. For greater precision, the design of the explosive charge configuration and initiation sequence is made, adjusted to the measurements of trajectory deviations of the actual ground drilling and is also considered for the control of the explosive charge configuration with high viscosity bulk emulsion. This application improves the profitability of the mining business by generating savings through the change of Blind Hole methodology, estimating a savings of more than 75% per Up Slot Raise

Jan 1, 2024

By R. S. Jurani

Sunshine Mining Co.'s Kellogg operation is the primary silver producer in the US. Maintaining a comfortable working environment in this deep underground mine historically has been a complex and costly problem. To improve the ventilation and cooling systems at a time of declining and un-certain silver markets, it was proposed to optimize the performance of existing facilities at minimum cost. This paper discusses a two-year, $400,000 optimization program that resulted in increased total mine airflow, cooler ambient temperatures, reduced compressed air usage, and lower energy consumption by primary fans, air compressors, and refrigeration plants. This saved the company about $650,000 per year.

Jan 1, 1988

By R. S. Jurani

Sunshine Mining Company's Kellogg operation is the primary silver producer in the United States, and maintaining a comfortable working environment in this deep underground mine historically has been a complex and costly problem. To improve the ventilation and cooling systems at a time of declining and uncertain silver market, it was proposed to optimize the performance of existing facilities at minimum cost. This paper discusses a 2-year, $400 000 optimization program that resulted in increased total mine airflow, cooler ambient temperatures, reduced compressed air usage, and lower energy consumption by primary fans, air compressors, and refrigeration plants, thereby saving the company approximately $650 000 per year.

Jan 1, 1987

By X. Wu, M. Karfakis, E. Topuz

The generalized ventilation network problems encompassing both natural and controlled splitting networks, is formulated using a nonlinear nonconvex programming model, which has not yet been solved satisfactorily. This paper presents a methodology which can deal with the problem. The proposed methodology converts the nonlinear problem into a linear problem, by using special ordered sets of variables, and optimizes it by a modified branch and bound technique. The global optimality of the methodology and its applicability to different cases are investigated

Jan 1, 1991

By L. Xu, S Jones, R. Bhaskar, J. McKenzie

The objective of this project was to optimize the ventilation parameters of a continuous miner underboom scrubber. This would result in further control of the amount of airborne dust discharged during mining, reduce the exposure of face personnel for an exhaust brattice ventilation system, and avoid recirculation of contaminants at the face. This research was performed in an underground coal mine in Utah. The tasks performed included preliminary face ventilation evaluation, and optimization of the scrubber system to eliminate recirculation of the scrubber discharge air. Airflow tests were conducted on the currently used dust control system and the modified scrubber system. Tracer gas tests were performed to evaluate face ventilation effectiveness. Confirmatory tests of the scrubber system under actual operating conditions, modifications to the scrubber system and a comparative evaluation of the scrubber system vs. the existing system were performed. This paper presents the results of the airflow pattern tests and the respirable dust levels in the modified scrubber system and the existing system. The optimized face ventilation parameters and the developed operating guidelines may provide the benefits of dust reduction, better lace ventilation and improved visibility.

Jan 1, 1994

By R. Bhaskar

The objective of the project was to optimize the ventilation parameters of a continuous miner underboom scrubber to further control. the amount of airborne dust discharged during mining, to further reduce the exposure of face personnel for an exhaust brattice ventilation system, and avoid recirculation of contaminants at the face. This research was performed in an underground coal mine in Utah. The tasks included preliminary face ventilation evaluation and optimization of the scrubber system to eliminate recirculation of the scrubber discharge air. Airflow tests were conducted on the currently used dust control system and the modified scrubber system. Tracer gas tests were performed to evaluate face ventilation effectiveness. Confirmatory tests of the scrubber system under actual operating conditions, modifications to the scrubber system, and a comparative evaluation of the scrubber system vs. the existing system were performed. This paper presents the results of the airflow pattern tests and the respirable dust levels in the modified scrubber system and the existing system. The optimized face ventilation parameters and the developed operating guidelines may provide the benefits of dust reduction, better face ventilation, and improved visibility.

Jan 1, 1994

By Raymond Philippe

Background ?Hatch Water has worked with most major mining companies in Chile on water supply and optimization projects ?Many(copper) mining projects are located in Northern Chile, which hosts the driest desert on earth Water supply options in Northern Chile ?River ?Availability/Rights ?Well(Brackish) Water ?Availability/Rights ?Municipal Wastewater ?Water rights ?Volume ?(Desalinated) Seawater ?Infinite source ?Cost depends on distance and altitude ?Recycling/Reutilization ?Water losses All these options present water quality issues

May 1, 2009

By Brian Hays, Victor Mwaba

Optimization of water use has become a top priority for virtually every mining operation. The mineral extraction process typically requires vast quantities of water, which can be particularly challenging when a mine is located in an arid location. Most mining permits have very strict limits on water usage, so tight control of water utilization and extensive recycling are critical to regulatory compliance and profitability. Water management is not only dependent for selecting the right flowmeter for different applications.

Apr 1, 2026

By James M. Reichman

Waterjet assist of mechanical cutters has been demonstrated in a variety of laboratory studies as well as on field equipment. As this technique becomes more widely accepted, it will be necessary to develop methods of minimizing the horsepower and water requirements. In machines such as roadheaders, continuous miners, and longwall shearers, the use of waterjet assist can be optimized through the development of phasing valves. Phasing valves will allow only the cutters in contact with the rock to be assisted. Since only 30 - 40% of the cutters are in contact with the rock, the saving power is significant. Flow Industries has developed a phasing system for use on roadheading machines. This system allows the operator extensive control of the angle of assist as well as the quadrant being assisted. This system could be greatly simplified for production machines and adapted for use in continuous miners and longwall machines.

Jan 1, 1985

By Jiang Feng, Zhang Libo, Peng Jinhui, Guo Zhanyong, Ju Shaohua, Lei Ting

The clean utilization of the residue containing chloride, CuCl residue, produced from zinc hydrometallurgy is very important for the recycle of valuable metals. And drying is the main process in recycling. In this study, response surface methodology was used to optimize operating conditions of the drying of CuCl residue in a convection oven and desirability function used as the methodology for the optimization. Optimization factors were air temperature (80–100°C), material thickness (10–25mm) and process time (80–120min) while investigated responses was final moisture content. The optimum conditions were found to be the temperature of 95.48°C with the material thickness of 13.47mm for the process time of 89.48 min. Under optimum conditions, the predicted moisture content of CuCl residue was 4.11% while the experimental date was 4.13%. The experimental value after process optimization was found to agree satisfactory with the predicted value. After drying, XRD was used to analyze the main phases of CuCl residue. The CuCl residue is made up of CuCl,Cu2O, ZnS and other compounds.

Jan 1, 2015

By J. Herhold, S. Plaum

The focus within the economical optimization of projects, which are conducted underground, shifts more and more towards the conduction of construction work underground. Underground operations can be defined in a wide range of various projects, from underground mining tasks to the construction of engineering structures. Within these projects the conduction of construction work cannot only be defined as absolutely necessary, but sometimes also as optimizing for underground processes (e. g. installation of workshops underground to support the mining processes). Even though the conduction of underground construction might cause positive outcomes concerning the productivity, it also tends to be challenging due to local (sub-surface) conditions and influences. To minimize the risk of failure and sudden events within in the conduction of construction work underground, the tool “work preparation” shall be used. Under the given constraints, such as local influences, expected construction work and set time frame, the conduction of the construction work will be planned in advance by consideration of the construction logistics as well as the selection of a fitted construction technique. PROBLEM DEFINITION Economic Challenges - Raw Material Extraction Enterprises in the construction, mining and raw material extraction industries are increasingly under the pressure to perform economically to sustain their position on the global market. Profitability, efficiency and productivity are the basic conditions to be an active participant on the global market as well as a business partner and contractor for mining and construction projects or projects related to the extraction of raw materials. The completion of large-scale as well as common construction projects above ground has been under the pressure to minimize costs and time whilst maximizing the potential outcome, in the meanings of quality and economic gain, for more than a decade now. Whereas the construction industry has to fight the competition on the market with efficient project outcomes, the mining industry has to find ways to perform efficiently to further conduct the extraction of decreasing raw material deposits. The ongoing exploitation of existing raw material deposits to satisfy the constantly increasing raw material demands world-wide, led to the predicament that economically mineable deposits have decreased dramatically. Even tough mineral deposits do still exist on a global level, near-surface deposits decrease rapidly. Therefore, the extraction of raw materials within mining operations will be relocated further away from the surface in greater depths. With the growing distance from the surface to the mineral deposit, the extraction costs will increase many times over. With that in mind, the extraction costs will increase whilst the economic efficiency will decrease. The extraction of certain deposits will no longer be profitable with the common approach. To further extract raw materials efficiently even in greater depth, companies have to change their practice in different ways. That leads to the fact, if the deposits are in the depths, where the extraction processes won´t be economically, other (support) processes have to be in order to guaranty an economical corporate process itself. This precept will divert the focus from the actual mining process to support processes, where potential for optimization still can be found, as shown in figure 1.

Jan 1, 2019

By Andrew L. Mular, Richard R. Klimpel

Optimization strategies of possible interest to mineral processing are reviewed and typical strategies initiated in processing plants to date are discussed. Both On-Line and Off-Line optimization procedures have been employed by industry, assisted either by operators or by digital computers. In every case, dollar benefits have accrued.

Jan 1, 1991

By SUHAINA ISMAIL, NORLIA BAHARUN, SHAIK ABDUL RAHMAN, WAN NUR SYAFIQAH ANUAR, MOHAMMAD REZAEI ARDANI

Refractory gold ore contains sulfide minerals like pyrite, chalcopyrite and sphalerite that are difficult to be directly leached by cyanidation or by lixiviants such as thiourea and halides. In such cases, it is necessary to perform oxidative pretreatment of the ore to oxidize the sulfide matrix, and gold particles can be exposed to the solution during the leaching process [1]. In recent years, hypochlorite and chloride solutions have been introduced as alternative materials for hydrometallurgical methods of gold extraction instead of cyanide solution [2]. A previous study by Hasab et al. [3] reported that the gold dissolution rate in hypochlorite solution was higher than in the cyanidation process, due to the presence of hypochlorous acid (HOCl) as a strong oxidizing agent. In a hypochlorite leaching system, the change in pH can influence the presence of oxidant species in the solution: the hypochlorite ion (OCl−) is stable in pH greater than 7.5, HOCl can be found in pH between 4.0 and 7.5, and aqueous chlorine (Cl2 (aq)) is the predominant oxidant when pH is below 4.0. As HOCl is the most effective oxidizing agent for gold extraction, pH should be maintained in the range of HOCl stability [4].

By SUHAINA ISMAIL, NORLIA BAHARUN, SHAIK ABDUL RAHMAN, WAN NUR SYAFIQAH ANUAR, MOHAMMAD REZAEI ARDANI

Hypochlorite leaching system is a strong oxidizing solution for metal sulfides, which are naturally associated with gold extraction. This study evaluated the hypochlorite leaching of refractory gold ore by using the response surface method–central composite design (RSM-CCD) as a statistical approach in determining the optimum condition of gold extraction from refractory gold ore. The studied parameters for the gold recovery were pH (4 to 6), concentrations of Ca(OCl)2 (0.5 to 1.5 M) and NaCl (2.5 to 3.5 M) in the solution. It was found that the maximum gold extraction of 82.46% (13.85 g/t) was achieved at a pH of 4.0 with NaCl and Ca(OCl)2 concentrations of 2.93 M and 1.08 M, respectively. The statistical analysis also revealed that the amount of gold recovery in chloride solution was significantly depended on pH as the main factor, followed by concentrations of Ca(OCl)2 and NaCl.

Jan 8, 2021