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By J. L. Brinkman

"One of the most common emissions from detonating explosives are nitrogen oxides (NOx), which are potentially deadly if inhaled. Lab studies estimate emission quantities, though great variation is shown based on site-specific conditions, and lab tests may not fully represent field results. Field VALUES (have not been measured due to the vast area affected. OSMRE recently promised to release a ruling regarding surface mine NOx production. Once the ruling is implemented, it may eventually be necessary to monitor site-specific NOx production from blasting. A small unmanned aerial vehicle system (sUAS) is able to carry a NOx gas monitor, rapidly travel to the blast location, and to follow resulting clouds of dust and emission gasses. This project will perform laboratory tests to expand on current estimations, determine an optimal method for collecting data, and evaluate the ability for this unique application of sUAS to assist in health risk assessment for mine employees and nearby communities. Additionally, large initial NOx concentrations do not necessarily correlate to unsafe conditions, and this project will be ground breaking in observance of surface blasting emission dispersion. The project is still in early phases at the time of submission for this paper (Nov 1, 2017). Therefore, this paper focuses primarily on summarizing background research related to the project and a description of the project plan. INTRODUCTION Nitrogen oxide gases (NOx) are common emission by products of surface mine blasting. These gases can potentially cause risk to human health and safety, both for mine workers and communities near the blast site. However, these emission quantities are largely unmeasured and no attempts have been made to relate these VALUES (to human health risk. The primary objectives of this project are to determine actual quantities of emission gases produced during surface blasting, to evaluate immediate and long-term risks to nearby people, communities, and ecosystems, to develop a system for mine employees to easily monitor emission and risk levels, and then provide guidelines for mitigating health risks based on a location’s emission results. BACKGROUND Current research regarding health risk produced by surface mine blasting NOx emissions is extremely lacking. Estimations have been made based on laboratory research, though these same test results show wide ranges of possible gas quantities produced based on site-specific conditions. Even if these estimations are accurate, no method has been created to relate gas quantity produced to human exposure concentrations. To further understand this field, background research was studied pertaining to blasting emission gas formation, laboratory and field measurements, harmful effects of blasting emission gases, and relevant government regulations. Background on Blasting Emission Gases"

Jan 1, 2018

By André Oliveira

The present paper describes state-of-the-art Pulverized Coal Injection technology with focus to Dynamic Distribution guaranteeing highest accuracy on equal distribution and being thus one of the key factors enabling constantly highest injection rates. As an alternative to the construction of a new plant, existing plants may be modernized and upgraded to latest technology. Two recent examples are presented. As a conclusion, two case studies of return on investment are showing that the PCI technology, both for new facilities as well as for upgrades, is very profitable and mandatory for high blast furnace operation effectiveness.

Aug 17, 2017

By Mustafa Kumral, Mehmet Balci

Strategic mine planning focuses on cutoff grade selection, capacity planning and block sequencing. Despite significant knowledge accumulated, potential value can be added to mineral sourcing by addressing various aspects. A case study on a metallic deposit with a lognormal grade distribution examines if grade/metal distribution influences cutoff grade selection. Six data sets with different shape and scale factors, but the same ore tonnage and metal quantity, are analyzed. Results indicate deposits with lower shape and scale factors are more sensitive to metal price and discount rate changes. The study also investigates the effect of economies of scale (EoS) on project value, focusing on the ratio of variable cost to total cost (capacity factor). Two regression analyses are conducted for optimal capacity planning and cutoff grade selection. The first shows capacity planning is highly sensitive to the EoS of mining and mineral-processing costs, with grade variability and metal distribution being negligible. In the second analysis, grade variability and EoS of mineral processing costs are vital for cutoff grade selection.

Sep 1, 2024

By H Turrer, M Badawi, R Belissont, Y Foucaud, E Kleiderer, L Southavy, J Mesquita, Y Basselin

The Mont Reed iron ore deposit, owned by ArcelorMittal, is situated approximately 140 km southwest of the Mont-Wright mine in the southern region of the Labrador Trough, Canada. Acquired by Québec Cartier Mining (QCM) in the 1960s, the Mont Reed mining property has remained unexploited due to the complex nature of the ore in the area. However, during the last years ArcelorMittal’s R&D team has been dedicated to developing a process to beneficiate the Mont Reed ore and produce high-quality pellet feed suitable for direct reduction furnaces. Extensive research revealed that achieving a good liberation degree of particles required grinding the material below 75 μm (P80 of 53 μm). To find the most effective technology for this task, a detailed comparison between ball mill and vertical stirred mill grinding was conducted. Both grinding technologies underwent detailed testing in bench-scale experiments. The ground products were comprehensively characterised, including size distribution analysis and chemical analysis per size fraction. Additionally, liberation analysis was performed using an automated scanning electron microscope (SEM). To determine the grinding specific energy, a method previously developed at Samarco (Brazil) for fine grinding of iron ores was employed. Furthermore, magnetic separation and flotation tests were conducted on the ground products. After a thorough evaluation of all the results, it was observed that both ball mill and vertical stirred mill grinding produced samples with similar physical characteristics. However, the vertical mill demonstrated higher efficiency in grinding the material. To conclude the study, an economic evaluation was conducted for both options considering various factors. Overall, ArcelorMittal’s R&D team’s dedicated efforts have brought them closer to unlocking the potential of the Mont Reed ore deposit and paving the way for its future utilisation to the production of high-quality pellet feed.

Sep 18, 2023

By Antônio César de Araújo Freitas

As empresas de mineração têm desafios logísticos em sua operação no dia a dia, visto o crescente volume de minério movimentado nas Usinas e Portos e pressão crescente por resultados operacionais que se traduzem na busca contínua por níveis superiores de produtividade. A tecnologia de automação dos processos produtivos e de máquinas evoluiu muito na última década, entretanto o processo da logística nos pátios de matéria prima e produtos apresenta baixo nível de automação e é baseado em informações verbais e observações visuais a respeito do nível de estoques e disposição dos materiais nas pilhas e áreas dos pátios de manuseio. Em um processo tão complexo, pequenas decisões da operação no dia a dia, que podem variar de acordo com o operador, supervisor ou turno de operação, podem influenciar a produtividade diretamente, afetando indicadores como horas paradas e deslocamento de máquinas por tonelada expedida, afetando dessa forma custos significativos na operação de uma usina ou porto. Este trabalho tem por objetivo então descrever as técnicas utilizadas para modelar os desafios de logística nos pátios de minério, descrevendo sistemas de otimização utilizados com apresentação de resultados em projetos como o de Carajás, planta da VALE que é atualmente a maior mina de minério de ferro do mundo, abordando a redução de deslocamento de máquinas, diminuição da exposição ao risco de colisão e redução de paradas.

Jul 30, 2018

By Adelson Goncalves

No processo de extração mineral, a perfuração de rocha é uma atividade essencial. Por isso, a redução de custo com materiais de desgaste é sempre um desafio para todos no campo da mineração. A partir desse desafio, o grupo de melhoria contínua Perfuração desenvolveu um projeto que visa redução de custo com buchas guia de hastes para perfuratrizes de grande porte. A metodologia aplicada para elaboração do projeto foi o PDCA, onde foi desenvolvido um novo modelo de bucha que evita o descarte precoce da peça, otimizando a vida útil e consequentemente reduzindo o custo com materiais de desgaste de perfuração.

Aug 17, 2017

By Ricardo dos Santos Oliveira

Devido ao grande aumento da concentração de gases do efeito estufa, a criação de uma energia limpa tem sido um desafio para a ciência e as indústrias. Após identificar possíveis soluções para este problema uma alternativa seria a utilização de biomassa vegetal com capacidade térmica como fonte energética redutora no processo de redução do minério de ferro em altos-fornos. Este trabalho teve como objetivo utilizar capim elefante (Pennisetum purpureum) e carvão mineral na injeção de finos pulverizados pelas ventaneiras de altos-fornos nas siderúrgicas a fim de reduzir custos da produção de ferro gusa e reduzir a dependência de combustíveis fósseis no processo. O capim elefante é uma fonte renovável e de rápido crescimento que através da fotossíntese captura o CO2 da atmosfera, reduzindo a poluição causada pelos altos-fornos. Para simular a injeção dos materiais estudados foi construído na Escola de Minas - UFOP um modelo de partículas de combustão para analisar as amostras. Outras técnicas são utilizadas para caracterização como combustão, calorimetria, análise de gás, análise química imediata e elementar. Assim, em teoria, esta pesquisa mostra que o capim elefante misturado com carvão mineral através de sua injeção em altos-fornos mostrou-se viável em termos metalúrgicos e ambientais.

Aug 17, 2017

By Matthias Wörndl

A indústria siderúrgica demanda um acabamento superficial de excelente qualidade em placas (slabs), antes de seu processamento em laminadores. O limite da temperatura de fresagem de 300°C exigia um esfriamento com posterior reaquecimento, gerando elevadas perdas energéticas. A empresa austríaca Maschinenfabrik Liezen com ampla experiência na fabricação de fresadoras de grande porte até 300°C desenvolveu e fabricou uma revolucionaria fresadora de alta capacidade (600.000 ton/ano), para operar de forma contínua em 800°C; nesse desenvolvimento de hardware e software foram também incorporadas várias otimizações operacionais e ambientais, sendo o destaque a fresagem modulada/inteligente, com precedente relevamento topográfico e termográfico para a localização dos defeitos superficiais, para a posterior fresagem com profundidade variável para a minimização de material retirado e simultânea eliminação dos defeitos localizados.

Aug 17, 2017

By Gergö Rimaszéki

Due the fast growing of pig iron and steel in the last years associate with some mineral resources changes (Hematite?Itabirite), has been checking the sinter feed degradation. The typical sinter feed (0.15;-6.3 mm) has become limited and the rapid growing production resulted in more and more fine ore (< 150 µm) availability in the market. The sinter plant operators are facing several new challenges since the mixing and granulation- and the sintering behavior of the fines containing mixtures often differs from the traditional sinter feed´s behavior. The utilization of fines in the sinter plants might increase the process water consumption required for the mixing and granulation process or even the solid fuel consumption, which effects the operational cost of the plant significantly. The current study presents an overview about Outotec´s laboratory facilities and competence regarding the mixing and granulation of fines in different equipments. The usage of high intensity mixers (HIM) – vertical and horizontal as well – showed to be the most effective, based in cold agglomeration tests in small scale, in case of fine ore handling. Permeability and particle size distribution curves are used to evaluate and demonstrate the efficiency of the different equipments. Outotec´s ”Know-How” with the different type of mixer and the modern laboratory facilities provide an excellent opportunities to optimize the mixing and granulation procedure and utilize up to 100 % pellet feed

Aug 17, 2017

By Márcio Aurélio dos Santos

A Automação Industrial utiliza de forma intensiva os mesmos equipamentos e softwares de TI como servidores, historiadores, switches, firewall, dentre outros. No entanto, são poucas as áreas de automação que aplicam de forma eficaz todos os controles e cuidados que esses ativos requerem. Neste cenário, a garantia de altos níveis de disponibilidade dos sistemas de automação inicia-se pelo ambiente físico no qual tais sistemas estão instalados. É comum a improvisação de ambientes inadequados dentro das áreas industriais ou a instalação em subestações elétricas que não foram construídas com o rigor necessário para receber os ativos de TI Industrial utilizados nos sistemas automação. A solução para manter elevados os índices de disponibilidade destes ativos é, sem dúvida, instalá-los em Data Centers, comumente utilizados nas áreas de TI, o que é facilmente justificável pelo fato de que a indisponibilidade dos ativos de automação representa um impacto maior aos resultados das indústrias ao se comparar com a indisponibilidade dos ativos de “TI Corporativa”. Assim, este trabalho conceitua um ambiente de Data Center, discute as particularidades relacionadas à Automação Industrial (projetos de cabeamento estruturado e as interligações entre os níveis 1 e 2 de Automação) e apresenta as estratégias que a Samarco Mineração está adotando com relação ao tema.

Jul 30, 2018

By H. W. Kasaini, E. Bourricaudy, T. Larochelle

Rare Element Resources Inc., a U.S. based company, has developed a three-stage process for producing a +98% mixed REO powder from hard rock feedstock (-48 mesh, 2.9-4.8% REO) consisting of bastnaesite and ancylite minerals. Firstly, the whole ore is digested in chloride media at low temperature in counter-current flow mode. Secondly, the rare earths (REEs) are selectively precipitated as oxalates directly from an impure pregnant leach solution (PLS). Finally, significant amounts of free acid and water are recovered from the REE-depleted filtrate and subsequently recycled within the process. Excess heat from the oxalate calcination process is captured and reused in the plant. Due to the low leach temperature (45 ºC) and moderate acid dosage (240-297 kg/t, HCl), rare earth oxides (REOs) are preferentially leached out of fine solids leaving most of the base metals (Ba, Fe, and Al ) in the residue. Selective recovery of REEs from the PLS is achieved by mixing dilute oxalic acid (33% H2C2O4) and PLS at elevated temperature (85-95 ºC). The REEs plus thorium are precipitated as oxalates (REE2 (C2O4).xH2O) while the base metals are left behind in the barren filtrate. Multiple batch and pilot test results have confirmed that 50-80% of the oxalic acid can be recovered from the REE-depleted PLS through low-temperature crystallization (10-15 ºC). Typical leach efficiencies of critical rare earths at 45 ºC range from 85-99% (average 93%) while oxalate precipitation at high temperature increases the crystal size of RE oxalates (>450 microns, d80) thereby improving filtration. The economic benefits of this process include elimination of flotation and magnetic separation Capex and driving hydrometallurgical Opex down to $6- 7/kg, REO produced. As part of a comprehensive risk mitigation strategy, Rare Element Resources Inc has operated multiple pilot plants at SGS in Lakefield, Ontario, Canada to optimize counter-current leaching (CCL), REE oxalate precipitation (OXP), and thorium removal circuits. This paper presents pilot testing data from CCL and REE OXP circuits.

Jan 1, 2016

By Wagner da Silva Lima

Um Sistema Piloto de alimentação de biomassa foi instalado em paralelo ao sistema de alimentação de coque em uma caldeira leito fluidizado circulante movida a coque de petróleo na Unidade Fabril da Votorantim Metais em Niquelandia, GO. Quatro experimentos foram realizados utilizando os alimentadores de coque (limitados a capacidade de mistura da pá-carregadeira) e o sistema piloto instalado que tem capacidade de 30 m3/h de cavaco de eucalipto. A substituição energética chegou a 19%, bem acima dos 10% determinados pelo fabricante utilizando o sistema atual de alimentação de combustível na caldeira. O potencial de redução de custo do vapor varia de 4 a 7%.

Aug 17, 2017

By L. Cheng, Y. Liu, Z. Shen, H. Shang, Y. Li

The pre-concentration process of magnetic coarse particles can discharge waste rock or liberated gangue before milling, which is an effective means to reduce cost and increase the efficiency of the concentrator, but the weakly magnetic ore doesn’t have the effective separation method of coarse particle such as hematite, limonite, ilmenite and so on, Because the composite iron minerals contain both strong and weak magnetic elements, the pre-concentration process cannot be applied, or the existing pre-concentration process has problems of complicated configuration and high operation cost. By researching a new type of external magnetic separation technology, the pre-concentration process of composite iron ore was realised by single equipment, which can have a good recovery rate with simple arrangement. In this paper, the separation principle and structure characteristics of the external magnetic separator were researched, and the magnetic circuit characteristics of the external magnet were analysed. The laboratory tests of vanadium titanium magnetite were conducted, and the test results proved that the external magnetic separator can be applied for the pre-concentration process. The industrial application shows that a product of TFe 24.76% with 90.08% recovery, TiO2 10.10% with 91.78% recovery can be achieved from the feed of TFe 20.67%, TiO2 8.33%. Keywords: Coarse particle pre-concentration, composite iron ore, external magnet, magnetic separator

Jan 1, 2020

By Everton Azola de Mattos

A Retomadora de Minério 342-RE-001 da Anglo American é um equipamento fundamental para a homogeneização do minério, porém este equipamento apresentava problemas de performance operacional desde início da operação da Planta Industrial de Barro Alto. Em agosto de 2015, as equipes de Engenharia e Manutenção realizaram um levantamento de todas as intervenções feitas no equipamento desde o início da operação em 2012, classificando estas intervenções em seis grupos, utilizando as ferramentas da metodologia Lean Six Sigma. Desta forma, foi possível realizar o Retrofit da roda de caçambas, manutenção geral nos rastelos, trucks e na lógica de automação que eram os sistemas que mais impactavam na estabilidade e disponibilidade física do equipamento.

Aug 17, 2017

By Charles H. Fulton

ONE of the events of note in mineral industry education circles during the year was the summer school for engineering teachers, devoted to mining and metallurgical engineering, which was conducted by the Society for the Promotion of Engineering Education in co¬operation with the University of Wisconsin. It was in charge of Prof. Harry P. Hammond, director of the summer school, and Prof. Richard S. McCaffery of the University of Wisconsin. It was attended by 63 people, and practically every educational institution offering mineral industry courses had representatives present. The session was successful and those in attendance spoke highly of the pro¬gram and results obtained. The Mineral Industry Education Division cooperated with the S.P.E.E. in this project. Prof. Hammond will discuss the purpose and results of this session at the February meeting.

Jan 1, 1934

By Jesús Cruces

La fragmentación de rocas es unos de los procesos más importantes dentro del proceso productivo global Mina- Concentradora -en tanto genera rentabilidad y mayor tonelaje tratado durante la etapa de trituración y molienda. En esta perspectiva, el presente texto señala no solo el incremento de la producción en la Concentradora (toneladas/hora que tratan las trituradoras y molinos), sino también de las palas, mejorando el volumen cargado. Para ello, se optimiza el llenado de las tolvas de los volquetes y los vagones con material homogéneo y menor espacio intersticial desperdiciado.

Sep 12, 2011

By Richard D. Grove

The on-stream analysis of phosphorus and silica has not been possible by XRF techniques and only recently has some success been indicated with quantitative XRD for P. Yet there has been a recognized need for an on-stream analysis of P and acid insoluble to permit the automatic control of phosphate rock flotation plants which produce some 30-40 million tons of concentrate each year in the southeastern U.S. IMC Fertilizer, Inc., the largest U.S. phosphate rock producer, embarked on a program to develop such an on-stream analysis capability several years ago. Following many months of lab and prototype development, the first commercial installations started in December 1986 and now have completed some 400,000 analyses with surprising accuracy, precision and reliability. The use of these devices in the improved control of the phosphate flotation plant is currently receiving some very serious attention at IMC.

Jan 1, 1989

By Carlos Alexandre Azevedo

Aços microligados ao nióbio possuem grande aplicação na indústria automotiva, muitas vezes como itens de segurança. Estes aços possuem certa tendência à geração de trincas transversais de superfície em placas produzidas via lingotamento contínuo, principalmente se as variáveis de processo durante a solidificação não forem adequadas. Experimentalmente, verificou-se que a ocorrência de trincas estava associada à composição química e às variáveis de processo. Com base nestas observações, avaliações da literatura e simulações com software Thermocalc ®, foram propostas alterações de composição química e ajuste na curva de oscilação, sendo este último considerado fator principal para a obtenção de placas isentas de trincas.

Aug 17, 2017

By L Mikhael Gurieff, D Baas

The Phu Kham Copper-Gold Operation (Phu Kham Operation) is located in the Lao People's Democratic Republic and is owned and operated by the Lao-registered company, Phu Bia Mining Limited (PBM). Australian-headquartered copper and gold producer, PanAust Limited holds a 90 per cent interest in PBM; the Government of Laos owns the remaining 10 per cent. The Phu Kham Operation was commissioned in 2008 with an initial concentrator nameplate throughput of 12 million tonnes per annum (Mt/a). Subsequent improvement projects, including the Phu Kham Upgrade Project (PKU), completed in 2012, and the Phu Kham Increased Recovery Project (IRP), completed in 2013, increased the design throughput to 18 Mt/yr. In 2016, the actual mill throughput exceeded 19 Mt/a, this throughput is budgeted to be maintained until the end of 2020.The concentrator flotation circuit upgrade, completed during the IRP, called for a non-selective bulk sulphide concentrate to be generated from the rougher circuit. This in turn caused the mechanical flotation cells in the cleaner circuit, particularly those in the second cleaner bank, to become volumetrically overload. The overload reduced the cleaner circuit performance to approximately 92 per cent copper recovery at a 23 per cent copper concentrate grade, below the expected 95 per cent recovery. This bottleneck restricted copper units entering the plant to approximately 14.5 tonnes per hour (t/h) due to uncontrolled recirculating load build-up in the mechanical cleaning circuit.Maintaining the operating methodologies would have led to a copper production shortfall beyond 2016, to address this shortfall the Phu Kham Operation looked to optimise the Jameson Cell and mechanical cleaner circuit performance. The work included fundamental application of flotation practice and modelling, mineralogical analysis, bubble size analysis, plant surveys and test work. The results were used to develop and implement an innovative automated control system strategy incorporating flotation theory and operating strategies. The automation has the ability to quickly adapt to disturbances in the circuit and maintain optimised performance with little or no intervention by flotation operators.Upon completion, cleaner recovery increased to 95 per cent at a final concentrate grade of 23 per cent copper, and copper units entering the plant increased to 17.5 t/h.CITATION:Baas, D and Mikhael Gurieff, L, 2018. Developing flotation circuit control and automation for the Phu Kham Copper-Gold Operation concentrator, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 37–58 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

By L. Sandbak

The TRJV Mine is located approximately 43 miles northeast of Winnemucca, along the east flank of the Osgood Mountains in the Potosi Mining District, Humboldt County, Northwest Nevada (see Figure 1). The Turquoise Ridge Mine is an underground mine, and is a 25% joint venture partner with Newmont Mining. The TRJV mine utilizes the underhand cut-and-fill mining method due to the relatively low rock quality in the ore zones and the relatively shallow dipping 25-45 degree ore body geometries. This paper defines a rehabilitation risk rating system (RRRS) for prioritizing rehabilitation of drifts damaged in the mining processes including long term development drifts providing access to the mining areas. The ultimate use is as a mine planning tool for the organized scheduling of rehab in a timely manner. A few case studies of the most needy rehab areas identified by the RRRS mapping system is presented, and the type of rehab completed design for these areas. Suggestions on improving the rehab risk mapping system include the use of support history and rock mass strength rating factors.

Feb 23, 2014