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By Aijuan Zhang, Liang Zhao, Yutao Wang, Yu Bao

In the green backfilling mining of underground coal mines, gangue in a coal seam is used to replace and fill goafs. However, the gas drainage time changes in the amount of gangue output and order in the extraction sequence of stope blocks, thereby changing the production output. A multi-objective integer programming model was proposed to solve this based on an improved non-dominated sorting genetic algorithm. The results show a feasible gangue filling rate can be found and the extraction sequence for a long-term planning time is optimized. It increases the planned annual output by 26% and reduces equipment idle time.

May 23, 2022

By Paul Javor

Optimization of a process is achieved by selecting, 'from all the known options, the most beneficial method of obtaining a product. It is rare that the optimum process is arrived at by conventional methods, because of the great amount of time required for developing and comparing all the options. On the other hand, it is now possible, by means of an optimization program based on special mathematical formulas involving an algorithm and implemented by a computer, to plot the optimum process realizing considerable savings and in a reasonably short time. The flow sheet arrived at in accordance with the optimization program described in this paper investigates and develops all the possible options and, with the aid of the computer, makes it possible to select the most economical ore beneficiation process. The options in an ore beneficiation process are all the possible trajectories that can be traced through the particle sizes to which the ore is reducible in the extraction of its valuable minerals. Although an ore can have a wide range of composition and several valuable minerals that can be extracted, this paper is concerned with the special case in which only one mineral is extracted from the ore and in which the maximum allowable percentage of impurities in the end product is defined.

Jan 1, 1971

By Wan Entong, Xie Junlin, Jiann YangHwang, Yang Chengwei, Chen Junfu, Zhang Jianjun, Cao Tongyou, He Feng, Peng Zhugang, Fang De

During the solidification process of peritectic steel (PS), the peritectic reaction often causes volume contraction which associated with surface longitudinal cracks, and using mould flux with low heat flux density help for alleviating surface longitudinal cracks. New peritectic steel mold flux with Co2O3 doping reduced the heat flux density, and the optimal content was found to be 2.0 wt %. Furthermore, basicity and Na2O addition were designed, and the minimum heat flux density required basicity of 1.4 and 10.0 wt %. Na2O content. As a result, the optimal peritectic composition was CaO(35.67wt% ), SiO2(25.48 wt %)，Al2O3(3.7 wt %)， MgO(2.53 wt %)，Na2O(10 wt %)，CaF2(14 wt %)，Co2O3(2 wt %).

Jan 1, 2015

By Bingjie Huo

"China is a major coal producer and consumer. It is necessary to mine the steeply pitching coal seams due to development of the coal industry to meet the increasing needs for coal. Flexible shield supports mining is a safe and efficient mining method for steeply pitching coal seam that was first applied in HuaiNan mining area in the 1970s. The coal seams are steeply pitching in DaAnShan Colliery, so mining is mainly done by the flexible shield supports method. The roadway lay-out and extraction technology are researched in order to improve the safety, yield and work efficiency in the flexible shield supports working face. Optimization of the flexible shield supports mining method is discussed. The main optimization aspects are as follows: (1) the angle of working face and mining track roadways are increased from 23° to 28°, and (2) the technology and parameters of coal breaking are optimized. Applicable conditions, as well as advantages and disadvantages are also discussed. Finally, a comparison is made of the two different flexible shield supports mining methods, namely ""bench blasting . technology"" and ""piecewise blasting technology"".INTRODUCTIONChina is the largest producer and consumer of coal in the world and relies heavily on coal for energy production. At present, Chinese production is about 42% of the worldwide production, and coal has accounted for 76% of primary energy production. Coal plays a dominant role in the structure of energy production and consumption, which is fuel and an important industrial raw material but it is non-renewable. In recent years, the high inclined seams (35°< angle of coal seam < 45°) and steeply pitching coal seams (angle of coal seam >45°) have drawn increasing attention in the mining sector along with the growth of coal mining. There are two reasons. First, there are abundant reserves of high inclined and steeply pitching coal seams in China, which account for 15- 20% of total reserves (Xie, Dong-hai, 2007). Highly inclined and the steeply pitching coal seams are mined in more than 50% of the western mining provinces such as Sichuan, ChongQing, YunNan, GuiZhou, XinJiang, GanSu, NingXia, etc. As the mining of mineral resources continues west in the 21st century, the study of coal mining in high inclined seams and steeply pitching coal seams will be of great importance. Secondly, better quality coal has become scarcer in the eastern mining areas after years of exploitation, so steeply pitching seam mmmg is growing more prevalent. In short, carrying out research on steeply pitching seam mining technology plays an important role in sustaining the development of the Chinese coal industry."

Jan 1, 2010

By A. Ghadyani

This investigation was undertaken to assess the possibility of ash and sulfur removal by microbial action of high sulfur-content coal. Thiobacillus ferrooxidans and Thiobacillus thiooxidans have been used for biodesulfurization of coal. Feed samples were provided from Tabas coal mine located in Yazd province, Iran. The sample contained 28.80% ash and 2.30% sulfur. Flotation tests were implemented to optimize the effective parameters in these cells which were constant during bio-flotation tests. According to the results, obtained from various tests using Taguchi orthogonal array design (L27), the values of optimized parameters were pH at 7, 1000 g/t gas oil as a collector, 10% solid content, 15 min conditioning time, 100 g/t MIBC as a frother and 800 rev/min rotor speed. Bio-flotation tests are carried out by means of laboratory double discharge cell and mesophilic bacteria as depressant reagent using above mentioned optimized parameters. The bio-flotation experiments were conducted based on a Taguchi orthogonal array design (L9) with four variables (bacteria type, bacteria count, rotor speed of mixer and bio-conditioning time). The collected data was analyzed by using DX7.0, Minitab14.0 and WinRobust1.02 softwares for evaluation the effect of each parameter on the optimization criteria. Considering the highest combustible recovery and the lowest ash and sulfur content, the value of optimized bacteria type, bacteria count, rotor speed of mixer and bio-conditioning time were Thiobacillus ferrooxidans, 5×107 cells/g(coal), 100 rev/min and 20 min respectively. Under this condition, ash and sulfur content and combustible recovery were predicted 12.39%, 2.08% and 82.03% respectively.

Sep 1, 2012

By C G. Robinson, B. K. Loveday, J. C. Paynter

"A method of optimizing the design of a processing plant has been developed which minimizes capital and operating costs for average stripping ratios and ore characteristics. Models were developed to describe the operating characteristics and costs involved in various operations such as up-grading, leaching and solid-liquid separation.The options available in up-grading policy and the relation between the cut-off grade and the costs incurred subsequently in the treatment of the ore formed the basis of the optimization. To arrive at an optimum plant configuration and a set of operating parameters, the interrelation between grinding size, leaching temperature, leaching time, and various plant recycle options was investigated."

Jan 1, 2014

By Ali Dehghani Ahmad Abady

In Sarcheshmeh Copper Complex, a molybdenite floatation concentrate was produced by selective removal of copper impurities with 7 stages of cleaner floatation banks, that contains around 1% copper and 54.5% molybdenum. Mineralogical studies, physical and chemical characterizations showed that the sample contained 91% molybdenite (MoS2), 2.6% chalcopyrite (CuFeS2), 0.2%Covellite (CuS), 1.6% pyrite (FeS2) and 4.6% other nonmetallic impurities. In the present study, the removal of the copper sulfide was investigated by ferric chloride leaching for achieving a molybdenite concentrate with copper content less than 0.3%. Therefore, the application of response surface methodology (RSM) for modeling and optimization of the influence of three control parameters including ferric chloride (FeCl3) dosage, reaction temperature and reaction time, each varying in five levels, were considered, and the mathematical model for prediction of %Cu removal from molybdenite concentrate was derived. This study showed that RSM could effectively be applied for the modeling of ferric chloride leaching, and finding an economical optimum condition to achieve maximum de-coppering efficiency while consuming minimum leaching reagents. The optimum dissolution conditions to maximize Cu extraction were 200 kg/t for ferric chloride dosage, 120 min for reaction time and 80 °C for reaction temperature with a prediction of 83.20% Cu dissolution. Keywords: molybdenite concentrate, ferric chloride, leaching, response surface methodology (RSM)

Sep 1, 2012

By Giannini M

Of the optimization techniques proposed in determining the optimum open pit limits, dynamic programming and graph theory have proved most successful. However, publications on these two methods lack a certain amount of rigour and clarity in exposition. Certain ideas in the methods have been clarified and additional features introduced in order to make them more sensitive to practical applications. A case study in the form of an application of these ideas on data from a producing mine is presented and discussed.

Jan 1, 1986

By Xia Hong-ying, Peng Jin-hui, Zheng Zhao-qiang, Zhang Li-bo

"Preparation of activated carbon from the walnut shell by microwave assisted steam activation was studied. Influences of the three parameters, activation temperature, activation duration and steam flow rate on the adsorption capacity and yield of walnut shell activated carbon(WSAC) were investigated,optimization process was obtained by the Response Surface Methodology (RSM). The optimum preparation conditions were as follows: activation temperature of 980°C, activation duration of 41 min and steam flow rate of 1.66 ml/min. The optimum conditions resulted in an activation carbon with an iodine number of 1025 mg/g and a yield of 52.17%, while the BET surface area, total pore volume and average pore diameter of WSAC were 1328m2/g, 0.72ml/g and 2.2nm respectively. The study supported the potentiality of comprehensive utilization ofWalnut shell and the benefits of the microwave heating.IntroductionActivated carbons are one of the most important adsorbent materials in modern society because of its abundantly developed pore structure, strong adsorption ability, high surface area and thermo stability. They have extensive application in many industries fields which include gas purification [1], catalyst supports [2] and other pollutants [3]. However, in recent years, the industrial production of activated carbon is facing the problem of raw material scarcity and high cost, which limit to be widely used. Therefore, the selection of an appropriate precursor plays an important role and it has become hot sport to seek cheap raw material to lower preparation cost. As a kind of reproducible resource, the waste from agriculture and forestry is a high-grade raw material for preparing activated carbon due to is high carbon content, such as palm shell [4], rice hull [5], and coconut shell [6]. At present Walnut shell is widely accepted to be a renewable source of biomass. According to statistics, there is more than 1000,000 tonnes of walnut shells are produced in China annually [7]. As a good precursor for activated carbon production, Walnut shell is a major agricultural waste, to make better use of the cheap and abundant agricultural waste, it is proposed for activated carbon production."

Jan 1, 2014

By Peter Cameron, Tom BoBo

Comminution, being the energy intensive part of a mining operation receives much scrutiny by cost controllers, CEO’s, investors and others as the mining industry goes “back to basics” to reverse the decline in productivity which occurred during the mining super cycle.

Jan 1, 2019

By C. Rodriguez, T. BoBo

Comminution, being the energy intensive part of a mining operation receives much scrutiny by cost controllers, CEO’s, investors and others as the mining industry goes “back to basics” to reverse the decline in productivity which occurred during the mining super cycle. Blasting is the first and lowest cost per ton stage in the comminution value chain. The basic principle that effective blast design can optimize fragmentation from the Run of Mine (ROM) ore muck pile to improve productivity through digging, loading and crushing to grinding and increase mine site profits has been well documented. Benefits of controlling fragmentation in the blast include reduced wear on equipment, faster loading, increased truck loads while detecting oversize rocks at the muck pile can reduce the frequency of a blocked primary crusher. A second basic principle is a measure of particle size distribution (PSD) at each unit operation in the comminution cycle allows engineers to manage blast design to produce fragmentation in the ROM ore most suitable to optimize downstream unit processes to improve mine site productivity and profits. Split-Online® systems have measured PSD of rocks on conveyors from the primary crusher to the SAG mill for over 20 years. Split-Engineering partnered with various mining companies to develop Split-ShovelCam® to automatically measure fragmentation from shovels and excavators working the ROM muck pile. This paper takes the reader “Back to Basics” by discussing the use of real time fragmentation analysis at the muck pile as an important parameter to optimize energy factors required for each blast. Case studies are given. INTRODUCTION The basics of mining are: • Explore for and find economic resources of valuable minerals • Mine rocks containing valuable minerals using blasting • Crush and grind rocks to liberate valuable minerals (comminution) • Recover valuable minerals for sale Comminution is an energy intensive process which accounts for a major proportion of mine site costs. Effective blasting can improve comminution and deliver significant reductions to mine site unit costs, (CEEC, 2016). Engineers, scientists, builders and even philosophers have long promoted the phrase “measure to manage”; the premise being “you can’t improve what you don’t measure”. Blast Engineers measure fragmentation in ROM ore for feedback to manage energy input in the design of blast patterns to optimize the ROM product size for downstream operations, whether they be for ROM Leach or feed into the primary crusher.

Jan 1, 2019

By Javier Castaneda, Luis Zozaya, Noel Huarachi, María Rocha

The objective of the project was to implement and calibrate drill and blast models supported by Geotechnical and Geological models as well as the mine and operation characteristics. The models would then be migrated to HxGN Blast to ensure a productive process that is simplified, digitized and optimized.

Feb 1, 2020

By Matt Brandon

This case study demonstrates how integrating drone and GPS surveying with 3D modeling software creates more effective blast designs that address specific geotechnical challenges while improving safety and blast performance. In this case study an 80ft (25m) highwall experienced recurring slip plane failures exacerbated by a previously mined 40ft (12m) bench that removed back support, creating an unstable triangular rock mass. Previous blasting along this wall displaced the upper 40ft (12m) of material, opening geological discontinuities and causing progressive slope failures that compromised crew safety and blast effectiveness. High-resolution drone photogrammetry, GPS surveying, and laser measurements were employed to precisely map slip planes, bedding planes, and fault structures within the bench geometry. These geological features were imported into 3D design software to develop a shot pattern that strategically utilizes natural rock discontinuities rather than working against them. GPS-guided hole placement ensured accurate field implementation, while marking geological features on the surface of the bench provided visual references for the blast crew. The final blast design positioned the last row of holes to break preferentially along an existing slip plane while avoiding intersecting the next slip plane behind the blast. Explosive loading and timing sequences were adjusted based on the hole location relative to the 3D geological model to optimize fragmentation while maintaining wall stability. The optimized design improved highwall stability significantly, by reducing the slip plane failure mechanism that had previously compromised operations. Measurable improvements included enhanced highwall stability, reduced back-break, improved blast performance, and reduced safety risks for equipment operators and blast crews. Two subsequent shots using identical methodology were able to remove the rest of this problem area, confirming the repeatability and effectiveness of this integrated approach. This methodology demonstrates practical integration of surveying technologies with geological understanding to solve complex blasting challenges. Accurate 3D modeling of geological features enables blast designers to work with natural rock structures rather than against them, resulting in safer, more effective blasting practices. This case study shows the value of understanding the precise locations of geological features for optimizing blast design and provides a replicable process for addressing geotechnical challenges in blasting operations.

Jan 26, 2026

By Jose Pineda, Abraham Lindo

The Panama Metro System’s Network expansion involves excavating a launching shaft for a tunnel boring machine (TBM) to traverse beneath the Panama Canal. The blasting needed for this shaft construction poses significant challenges due to the presence of concrete walls encircling the excavation. These walls must remain intact throughout construction and the tunnel's future operation. This case study is focused on devising and implementing safe blasting techniques crucial for the shaft's construction, ensuring the preservation of surrounding concrete walls and project equipment. As the interest was potential damage to the concrete walls, an appropriate vibration threshold for this project was also required as an alternative to the traditional U.S. Bureau of Mining RI-8507 limit (USBM RI8507). Blast modeling software was employed to conduct a series of blasting simulations. Parameters like hole diameter, spacing, depth, explosive type, and initiation methods were varied to evaluate their potential effects on wall stability and damage risk. The simulations revealed that smaller diameter holes and reduced spacing between blast holes would effectively mitigate the risk of wall instability. Additionally, utilizing electronic delay detonators and carefully planning the blast hole detonation sequence proved critical in minimizing potential damage. Executing these blasts in the field presented unique challenges, including strict charge per delay thresholds and logistical constraints. Consequently, continuous adjustments to blasting parameters were made and comparative result analysis. Beyond providing a safe blasting strategy for the TBM launching shaft, this study offers invaluable insights into adapting blasting designs to align with environmental and structural safety standards. These findings hold great potential to shape guidelines for analogous sensitive construction projects. They underscore the importance of leveraging prior research as a reference point, engaging with project designers and local authorities, and continually conducting testing and adjustments to ensure project success.

Jan 21, 2025

By A. V. Abshilawa, D. G. Talakhadze, R. I. Sturua

"Processing of the tailings accumulated over the lifetime of Madneuli Copper Concentrator is an opportunity to extract additional salable copper and gold products. This paper presents a pre-concentration process for the valuable components (copper and gold) of the accumulated tailings. The developed process makes it possible to obtain a copper pyrite concentrate with a yield of 14.05%, copper grade of 1.36%, and recovery of 83.22% containing 3.78 g/ton of gold at a recovery of 84.31%. The bulk concentrate is produced by a combined process bringing together selective flotation to produce salable copper concentrate and hydrometallurgical processing of the selective flotation tailings to recover gold. KEYWORDS: FLOTATION, ALBION PROCESS, LEACHING, COPPER CONCENTRATE, SELECTION Madneuli Copper Concentrator, Georgia, was put into operation in 1975. Over its lifetime, 40 mn tons of tailings have been accumulated at the tailings storage facility (TSF). Sampling of the TSF has indicated that the average copper and gold grade is 0.23% and 0.56-0.65 g/ton, respectively. Accordingly, the TSF can be classified as a technogenic reserve. This paper discusses pre-concentration of valuable components using flotation, followed by processing of the bulk concentrate in the Albion process. Mineralogical analysis of the accumulated tailings showed that the main ore mineral is pyrite (11.71%). Copper minerals are mainly represented by chalcopyrite (0.7%). The main nonmetallic mineral is quartz (67.3%); sericite, chlorites, etc. also occur. Pyrite is present both as liberated grains and intergrowth. The absolute majority of copper minerals are found as intergrowth with pyrite, less often with quartz. Ore minerals are slightly oxidized. Chemical analysis results are shown in Table 1. Particle size distribution shows that the size class -0.2 mm - 0.045 mm has the highest grade of 0.85 to 0.97 g/ton of gold. Size class +1.25 mm has the lowest grade. Based on the chemical and mineralogical studies and particle size distribution, an optimized process was developed for pre-concentration of the valuable components prior to hydrometallurgical processing. Several gravitation, direct selective, bulk, and bulk selective flotation processes were trialed. (1,2)"

Jan 1, 2018

By Stephen Pogorski, Colin R. Phillips, Atika Khan

An optimized counting scheme for a mixture of radon daughters and thoron daughters typical of Ontario mines, developed in a previous study, was experimentally examined under mine conditions. The counting scheme requires a 10 minute sample and 5 1/2 hours counting instead of a 60 minute sample and more than 40 hours counting as required by a previous method. Taking into account the uncertainties associated with concentrations, flowrate and radioactive decay, the precision of the counting scheme was analyzed and found to be on average better than the 40 hour method.

Jan 1, 1981

By T. Fraszczak, U. A. Peuker, T. Mütze, O. Ortlepp

Dolomite is a calcium carbonate sedimentary rock that can be found all over the world. In its calcined form it is employed for water treatment or as an additive in iron production. Calcined dolomite is produced at the Wünschendorfer Dolomitwerk GmbH in shaft furnaces (kilns). Because of an expansion of the mined deposit, significantly higher extraction costs were expected. Therefore, the existing upgrading processes for the kiln stone fraction had to be adapted and improved. This paper presents a process optimisation which allows for an increase of the yield of calcined dolomite by 10 % due to a redesign of the crusher circuit and by an additional 5 % due to a comprehensive characterisation of the kiln stone fraction itself. Here the interdependency between the pressure drop in the furnace during calcination and the size distribution of furnace stones was used to increase the amount of fine size fractions in the furnace feed without deterioration of the calcination process. Keywords: Dolomite, crushing circuits, kiln stone production, flowability, calcination

Jan 1, 2020

By Eric C. Gerst

"In this current era of soft commodity and coal prices the mining industry is turning towards optimizingall levels of production to reduce operating costs. Part of this trend includes the automation of miningmachines. As the first tier of the mining process blast hole drill automation offers benefits through the entire value stream from drill bench to material processing."

Jan 1, 2017

By Jian Wang, Kun Li, Hao Wu, Juan Nan

In this paper, in order to solve the problems of low accuracy and slow speed of fire flame recognition, an extreme learning machine (ELM) method based on improved Harris hawks optimization (IHHO) is proposed for fire flame recognition. A novel Harris hawks optimization (HHO) is used to solve the problem of parameter selection of ELM. In order to solve the problem that the original HHO is prone to fall into local optimum, firstly circle mapping is used to initialize the population to solve the problem of uneven distribution and small range of the initial population. Then the formula of escaping energy of HHO is modified to make the population have a large range in the middle and late iterations while gradually decreasing in the whole iteration process. Thus, the exploitation stage in HHO is improved to make the search range smaller near the optimal solution to accelerate the convergence process. Finally, at the end of each iteration, a certain number of individuals are selected to perform Gaussian and Cauchy hybrid mutation to prevent the IHHO from falling into local optimization. Through three groups of experiments, the effectiveness of the proposed IHHO and IHHO-ELM is verified. In experiment 1, the convergence performance of IHHO is significantly better than that of the other remaining algorithms in the test results of six benchmark functions. In experiments 2 and 3 of real fire flame recognition case, IHHO-ELM outperforms other remaining algorithms on the whole and has significant advantages in some indexes.

Jan 17, 2023

By Rene Grabowski

Optimization of workflows and intelligent stock management; Slab stacking improvement by automated transport orders; and System automatically registers any slab movements even in manual operation. Case story: Steel producer ArcelorMittal Eisenhüttenstadt GmbH in Germany uses Primetals Technologie’s new stock yard logistics system in its finishing department. An exact image of its slab storage at any times is given by the warehouse logistics system to the company. It not only enhances the composition of the stacks of slabs, but also automates recording of manual restacking operations. Therefore the solution improves workflows and simplifies stock control. Cycle times have also been reduced due to the fact that the slabs can be charged to reheating furnaces ahead of the rolling mill due to less restacking operations within the slab storage. The expandable, modular system is based on the Siemens Simatic IT and Primetals Technologies’ IT4METALS Logistics product platform. It provides a large number of organizational and commercial features in the form of sophisticated graphics and tabular evaluations. For example, it can show how many crane movements have been made per shift for any category of slab, so that the time and cost for each operation can be calculated accurately.

Aug 16, 2017