Search Documents

By Eduardo Nunez, Asim Tuzun, Dan Graffi, Glenn MacPherson

"In preparation for the milling of a new nickel and copper mine ore, Nickel Rim South, Xstrata’s Strathcona Mill is undertaking numerous process improvement projects. Within the grinding circuit, several projects are under development and an automated grinding control strategy, consistent with the operating objectives, was identified as a key requirement. The grinding strategy is to maximize the throughput (quantitative objective) while maintaining the cyclone overflow within specifications (qualitative objective).This paper describes the implementation of a robust grinding control strategy using the existing control system. The implemented controls maintain the cyclone overflow density at the desired target, while continually optimising the rod mill feed rate to allow maximum throughput. This approach has the added benefit of improving the stability of the rougher flotation circuit down stream of the grinding and improving energy efficiency of the rod and primary ball mills. This paper discusses the comparison of the before and after the implementation of results.INTRODUCTIONThe grinding process is a size reduction operation used in the mining industry to liberate the valuable minerals from the gangue. Grinding is one of the most important and expensive processes in a concentrator (Xi-song, 2007; Pomerleau 2000; Najim 1995), often accounting for around half of the total operating costs in base metal concentrators (Wills, 1990), which has led to a focus on development and implementation of control and optimisation strategies. The grinding process prepares the ore for the subsequent concentration step, which for sulphide base metal operations, is predominantly flotation. The performance of the concentration (flotation) is very much determined by the feed characteristics of the slurry coming from grinding. The valuable minerals recovery process in flotation is very much influenced by the grinding process and the liberation of the desired minerals from the gangue minerals (McIvor, 1991).The true objective of grinding is to obtain a proper liberation of the minerals as defined by a particle size distribution referenced typically by d80 (80% passing size of product). Besides achieving the desired mineral d80 size, it is clearly desirable to produce as narrow a size distribution as possible to squeeze the maximum amount of the mineral value into the highest recovery region (McIvor, 1991). This is an important criterion for the mill in economically optimizing the grade and recovery for the concentrate product. It is important not to over or under grind, while keeping the specific comminution energy as low as possible (Nunez, 2005) to achieve the target liberation. In other words, maintain an optimal throughput depending on the ore conditions to the capacity of the grinding mills, while providing the flotation process with a constant and narrow size distribution, at a cut size selected to meet the metallurgical requirements (Bascur, 1991)."

Jan 1, 2009

By P. J. van der Walt

Some 30 years ago exposure to dense-medium separation in South Africa, culminated in the adaptation of the process for the treatment of -0.5 mm fines. The first commercial plant at Greenside Colliery apparently operated for some 18 years. Three further plants followed, including one treating tin ore. It is gratifying to learn, therefore, that there is renewed interest. The objective of making the process easier to operate (?more practical??) is commendable but the cumbersome technical approach could be counter productive. Perhaps a brief outline of the original thinking might be helpful when analysing the problem.

Jan 1, 2003

By A. L. Mular, R. P. Edwards

"The operation of flotation circuits is often regarded as a combination of art and science. Expert systems offer a method by which the art may be captured and supervisory control of flotation circuits fully realized. Operating knowledge, the art, can be consistently employed to enhance regulatory control through the judicious application of an expert system. Using an expert system, a supervisory control routine was developed, and successfully implemented, in the copper flotation circuit at Brenda Mines Ltd.The expert system ran in conjunction with regulatory PI controllers on a personal computer. The expert system received assays via an on-stream analyzer and adjusted regulatory loop setpoints as required in real-time. From its commissioning in November 1989, to the end of the mine's operation in June, 1990, the ES was enthusiastically embraced by the operators and attained operating levels superior to those achievable manually.INTRODUCTIONExpert system (ES) software springs from research into artificial intelligence and is currently making significant inroads into business and industry. Proponents of ES's make many attractive claims; they are a means of capturing the knowledge of experts and they can be programmed by non-programmers. To date, most uses of this software in the process industry are in off-line applications, meaning that the applications are not tied directly to operating (on-line) environments. Moreover, in on-line environments, they are typically employed as advisors and only suggest changes. Human operators are required to close-the-loop to the process. Yet, ES's should be applicable to operating environments and, if the claims of the proponents are valid, should also be better than existing tools. As an intelligent controller an ES must use the knowledge of experienced operators, apply it directly to a process and do this without the intervention of human operators. On-line applications have been successfully employed in the closed loop control of SAG circuits (Herbst et al., 1989) and flotation circuits (Hales, 1989). Harris and Kosick (1988) detail an implementation for flotation control at the Polaris Mine."

Jan 1, 1991

By Wilbert T. Malenka

A modified factorial experiment was used to determine the effect of operating factors in hydraulic mining of anthracite. Seven basic factors at various levels were considered. The significant factors were found to be pressure-volume, pattern, and jet traverse speed. Mining data were programed for computer, and a prediction equation was determined from printout information based on the hydraulic "jumbo" operating parameters and characteristics of anthracite, The source of error is discussed. The prediction equation is general in nature and might be useful in delineating performance characteristics in the design of equipment and/or more effective utilization in a medium with characteristics similar to those of anthracite.

Jan 1, 1968

By K. L. Whitehead

An examination of 60 mines, 11 illumination hardware manufacturers, and Q mobile face-equipment manufacturers was conducted to determine the state of the art of mine-illumination hardware, define lighting system installation and maintenance problems, and assess personnel acceptance of lighting. Longwall and mobile face-machine illumination were studied. Major problems on room and pillar installations include damage of exposed components, electrical failures, and reduced lamp life, with extreme variability in the degree of these problems. Most longwall systems had low or moderate maintenance requirements, cable damage being the most significant problem. Most mobile face-equipment operators liked their machines' lighting systems, but many complained of glare and other problems. Longwall lighting was unanimously accepted by face personnel, and most complaints were minor. Based on the survey, general installation and maintenance guidelines have been established, addressing hardware design aspects, approaches proved effective to minimize problems, and improper practices noted which are detrimental to effective lighting.

Jan 1, 1981

EARLY in 1911 the Public Service Board of New South Wales suggested the advisability of inaugurating a School of Mines at Broken Hill, arid made inquiries to determine how such an institution should be conducted. He, the author, believed the Board, as a result of the inquiries, was in favour of the project being worked in conjunction with the Technical College, and hoped to be ready to receive students at the commencement of 1912. That the inauguration has not yet taken place is probably due to the vast amount of consideration and preparation that a new departure of the sort would require. At the present time New South Wales or, to speak more broadly under the same denunciation, Australia is not at all suitably catering for the technical training of young men to provide the increasing demand for officers to work the valuable mines within its territory...

Jan 1, 1912

By C. J. Badenhorst

Oxides of sulphur are corrosive and are produced when sulphur-containing fuels are burned. Sulphur dioxide (SO2) is a colourless gas with a characteristic, irritating, pungent odour. Exposure routes to the human body are mainly through inhalation and skin and/or eye contact. Symptoms of exposure to SO2 may include irritation of the eyes, nose, and throat; rhinorrhea (discharge of thin nasal mucous); choking; cough; and reflex bronchoconstriction. To protect employees against the ill health effects of SO2 exposure, they are often required to make use of respiratory protection whenever entering areas were the SO2 levels exceed the statutory limits. The use of respiratory protective equipment should always be a last resort and should be considered only after other control measures have failed to reduce occupational exposure levels to below the occupational exposure limit or whilst other control measures are being investigated or implemented. Whenever the use of respiratory protection equipment is considered, it should always be used as part of a comprehensive respiratory protection plan. It is also extremely important that all potentially exposed persons are adequately and comprehensively informed and trained.

Jan 1, 2007

By Eric R. Bauer

The U.S. Bureau of Mines, in cooperation with a southwestern Pennsylvania coal mining company, BethEnergy Inc., Mine No. 60, Eighty-Four, PA, recently assessed the feasibility of using pre driven recovery rooms (open entry recovery) when longwall mining to increase the productivity of the coal extraction process. Two recovery entries, one 200 ft long and another 600 ft long, were supplementally supported with bolts, channels, and wire mesh, and either fly ash-cement piers or fiber cribs, then mined into by the longwall face. The recovery entries showed little deterioration as the supports provided adequate resistance to the front abutment loading. Compared with conventional recovery methods, the fullface recovery room allowed for panel extraction to be completed nearly 17 days faster and to reduce face equipment move time by 1-1/2 days. The potential productivity increase accompanying recovery rooms is greater than the cost of supporting a fullface recovery room. The fullface recovery room provided over 18 additional production days and the opportunity to mine nearly 68,400 st of coal per year per panel mined.

Jan 1, 1989

Upgrading of a Flow Sheet Selection PC Algorithm for Refractory Concentrates Treatment

Sep 13, 2010

By R. S. Warfield

Several reconnaissance-type surface and drill core samples of Arctic Northwestern Alaska coals were taken during the summer field seasons of 1964 and 1966 for coking studies. Surface samples were taken from the Kokolik River and the Cape Beaufort areas; core samples were obtained from the Kukpowruk River and the Cape Beaufort areas. Only one Kokolik River surface sample possessed coking properties. This sample, representing an 11.6-ft coal seam, made coke approaching metallurgical quality when a 30-pct portion of selected blending coals was added. Four Kukpowruk River core samples, each representing the same 19-to 20-ft coal seam, were all of about the same coking quality. No differences of coke quality attributable to depth of permanently frozen overburden were found, but the data confirm previously reported information that the 19- to 20-ft coal bed is a potentially satisfactory base coking coal. In the Cape Beaufort area, a core sample with appreciable coking properties was taken at depth from a coalbed determined noncoking in a surface sample.

Jan 1, 1969

The amount of liquid retained in a porous bed is determined by weighing a column containing the bed.The column is attached to the free end of a cantilevered beam, and changes in weight are determined by calibrated strain gauges (which form a resistance bridge) attached near the fixed cnd of the beam. By coupling the output from the strain gauges to an amplifier and a recorder, a continuous record of changes in the drainage characteristics of the bed may be obtained.

Jan 1, 1968

By K. J. Oliver, A. G. Meyers, S. P. Hunt

Deformation Rate Analysis (DRA) and porosimetry have been used to demonstrate the “stress memory” effect in rock and to estimate the vertical in-situ stress in samples of fine-coarse grained sandstone and carbonaceous mudstone. The results of this study indicate that the stresses predicted using both methods are similar to those determined from depth and density of the overburden rocks. The results confirmed that DRA was still applicable even when the core had been sampled 18 months prior to testing. Additionally, the DRA results were modelled using the software PFC2D. A uniaxial test was modelled using the same rock parameters as those observed for the actual core samples. This numerical technique can be used as an aid for DRA results analysis, and can also be used to predict the minimum stress level at which the DRA technique is applicable. The results confirm that any rock mechanics laboratory having standard test equipment could apply the DRA method combined with standard UCS testwork to determine the in-situ stress. Mit der Analyse der Deformationsrate (DRA) und der Anwendung der Porosimetrie wird der Spannungsgedaechtnisseffekts (Stress Memory Effect) im Fels demonstriert, und es werden Abschaetzungen fuer die vertikale in-situ Spannung einer Probe aus mittelgrobem Sandstein und carbonierten Lehmstein getroffen. Die Ergebnisse dieser Untersuchung zeigen, dass die mit Hilfe dieser beiden Methoden ermittelten Spannungen sind vergleichbar. Die Ergebnisse bestaetigen, dass DRA noch anwendbar ist, wenn die Proben schon 18 Monate vor Untersuchungsbeginn gesammelt worden sind. Darueber hinaus wurden die DRA Ergebnisse mit Hilfe des Sofwarepakets PFC modelliert. Ein einaxialer Test wurde mit genau die gleichen Felsparametern, die fuer die eigentliche Probe gelten, modelliert. Diese numerische Methode kann sowohl als eine Unterstuetzung fuer DRA Ergebnisanalyse als auch zur Ermittlung der minimalen Spannung, bei dem die DRA Methode noch anwendbar ist, herangezogen werden. Die Ergebnisse bestaetigen, dass jedes Felsmechaniklabor, das mit den ueblichen Testgeraeten ausgestattet ist, die DRA Methode in Kombination mit dem Standard UCS Testarbeit zur Bestimmung der in-situ Spannungen anwenden kann. L'Analyse du Taux de la difformité (DRA) et les porosimetry ont été utilisés démontrer le " effet de la mémoire " du stress dans roc et estimer le stress dans - situ vertical dans échantillons de grès du grained fin grossier et mudstone carbonifère. Les résultats de cette étude indiquent que les insistances ont prédit utiliser les deux methods est semblable à ceux déterminés de profondeur et densité du surchargez des rocs. Les résultats ont confirmé ce DRA était encore même applicable quand le coeur avait été goûté 18 mois avant tester. En outre, les résultats DRA étaient des modelled qui utilisent le logiciel PFC2D. Une épreuve de l'uniaxial était modelled qui utilise les mêmes paramètres du roc comme ceux observé pour les réels échantillons du coeur. Cette technique numérique peut être utilisée comme une aide pour DRA résulte analyse, et peut aussi être utilisé pour prédire le niveau du stress minimum à que la technique DRA est applicable. Les résultats confirment que tout laboratoire des mécaniques du roc qui a le matériel de l'épreuve standard pourrait appliquer la méthode DRA combinée avec testwork UCS standard pour déterminer le stress dans - situ.

Jan 1, 2003

By Konstantinos Modis

According to recently established theoretical analysis and under certain conditions, a critical sampling density can be determined for an earth-related space-distributed natural variable. Sampling above this critical limit adds little to the mapping results. The objective of this paper is the application of the above theory to the Sesklo clay quarry in Greece, where Heracles General Cement Company had conducted a sampling campaign to estimate its reserves. The structural analysis of Al2O3 values generated a variogram model, from which the critical sampling density was identified. This critical number was by far lower than the existing sampling density. Clay reserves were then estimated using geostatistics and inverse distance squares in different data schemes with variable densities. The results of the comparisons between the various models revealed that, when the sampling density was greater than its critical value, geostatistics and deterministic interpolation gave similar estimations, which is also in agreement to the theory. The optimal sampling grid finally proposed here, will result to significant cost savings in the next drilling program which is now in plan by the company.

Oct 1, 2009

By Terry Keough

Contents for discussion ?Current liner technology ?Innovation of magnetic products ?Development of magnetic wear liners ?Installation and change out method ?Uses and capabilities ?Internal wear liners ?Summary Vulcanized rubber ?Many of you are familiar with using vulcanized rubber to provide wear protection on mining equipment. For years, this was the standard for most mining equipment, and mines spent a lot of money fabricating and lining steel equipment.

May 1, 2010

For the past four years, the Department of Mining Engineering at the University of Kentucky has conducted a validation study of the CFD Fluent code, by comparing its results against mining-related benchmark experimental data provided by NIOSH?s Pittsburgh Research Laboratory. This particular study is dedicated to the effect of machine-mounted dust scrubbers on the performance of face ventilation systems using extended-cut mining with a blowing curtain.

Jan 1, 2009

By Willem Le Roux

1.1 Section 47(1) of the Mine Health and Safety Act, 29 of 1996 (?the MHSA?) establishes a Mine Health and Safety Inspectorate which is administered by the Chief Inspector of Mines. The Mine Health and Safety Inspectorate is part of the Department of Mineral Resources. The Chief Inspector is appointed by the Minister of Mineral Resources (see section 48(1) of the MHSA). 1.2 The Chief Inspector must, amongst other things, ensure that the provisions of the MHSA are complied with and enforced, and that all the duties imposed upon the Chief Inspector and the other Inspectors of Mines in terms of the MHSA and any other law are performed. The Chief Inspector of Mines must appoint Principal Inspectors of Mines and Inspectors of Mines to assist him/her to discharge his/her duties (see section 49(1)(a) and (c) of the MHSA).

Jan 1, 2011

By Xu Lin Sheng

During the mining course, when the roof above coal seams is constituted by thick and hard sandstone (conglomerate), sudden roof movements often take place with great force and de¬struction which is the biggest danger to the safety and production. Such sever movements of the roof in mining directly relate to the rock mechanical properties which are the main fac¬tors that influences the regularity of hard roof movement and its destruction form. A significient work and important technical way for applying rock mechanics into mining en¬gineering is studying the rock mechanics of the hard roof and altering some of the rock me¬chanic parameters which induce the improvement of the rock properties in order to efficiently control the movement of the hard roof.

Jan 1, 1989

By R. Schulz, K. King

Concentrating Line 6 just went down again. The control room operator checks the graphic display. Only one piece of equipment shows an alarm. Clicking on the ball mill icon, he discovers the culprit was the low flow lube switch. The flow looks okay now, but it is the third time this week the switch has stopped the line. Maintenance is called, the switch replaced and the line is up running again. Sending the right person to the right spot immediately can save hundreds of hours of downtime every year. This paper discusses the principles behind implementing smart First-Out Fault Detection to dramatically reduce equipment downtime in new, or existing control system architectures. Methodologies are presented to maximize the system benefits, while minimizing development costs. Case histories are presented for a number of successful implementations in mineral processing plants.

Jan 1, 2001

By G Akdogan, R V. R Handfield-Jones

The application of microwave energy as a substitute for conventional heating has drawn interest from many researchers in extractive metallurgy. Microwaves have a heating effect just as many other forms of radiant energy. Microwaves are able to penetrate the substance at which they are directed and in being absorbed heat the material from the inside. As a result of heat generated in the interior of a particle, microwaves can affect the rupture of a particle (in this case a host ore) and break down the matrix of the particle (host ore) and expose the recoverable mineral to the leaching reagent. Two series of leaching experiments were carried out at temperatures above 90????C using a conventional heater (hot plate) and a modified 850 W, 2.45 Ghz microwave oven. One series of tests was carried out at ambient temperature. A pyritic/arsenopyritic gold concentrate was leached with 3.3 kg/t to 6.8 kg/t NaCN for two hours. The extraction of gold at 6.8 kg/t NaCN was higher in microwave assisted leaching (59 per cent) than the extraction obtained in leaching at conventional heating (39 per cent) and ambient temperature (28 per cent). Extraction of gold was dependent on the size fraction used and was 48 per cent for û75 ¦m, 43 per cent for û90+75 ¦m and 37 per cent for û150 + 90 ¦m size ranges.

Jan 1, 2000

By M. L. Goble

"Inco Metals Ltd. (Manitoba Division) operates a mining, milling, smelting and refining complex, 500 miles north of Winnipeg in central Manitoba. The Thompson Mill is presently operating at 12,000 S.T.P.D. on ore from both underground and open pit mines. The ore is treated in two separate milling and flotation circuits utilizing a common crushing system which is located inside the main mill building. The milling facility employs approximately 43 operating employees, 30 maintenance employees and 20 staff in supervisory or process development roles.In recent years an increasing awareness of the potential hazards of contaminants in the work place has made it mandatory that all employers maintain careful and accurate records of the work environment to which each employee has been exposed during his working career.The importance of this record keeping and general observation of the work place cannot be over emphasized. Proper monitoring of the work place provides an accurate and complete record of the contaminants and physical agents to which an employee is exposed during his work career. This can aid in studies which might be conducted in the future and can also be used as a basis for instituting improvements to the workplace."

Jan 1, 1980