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By J. A. McLennan, J. M. Ortiz

Nickel laterite deposits are typically formed from tropically weathered mafic-to-ultramafic complexes. The resulting nickel concentration is found within soil horizons and is mineable with regular dozer units. At the time of mining, digging elevations are needed at selective mining units (SMUs) or representative dozer regions (RDRs). Moreover, for mine planning, the costs due to dilution and lost ore require mining elevations to be specified. A conditional simulation approach is used to calculate “optimum” RDR mining elevations. Multiple realizations of the ore base surface are simulated. For a single bottom surface realization, dilution and lost ore costs are calculated over the entire vertical extent of each RDR. The optimum mining elevation is the elevation where the lowest summed cost of “accepting dilution” and “wasting ore” occurs. The reported RDR dilution is the cost of mining the volume of waste located below the bottom surface and above the optimum mining elevation. The reported RDR lost ore is the cost of not mining the volume of ore above the bottom surface and below the optimum mining elevation. For all ore bottom surface realizations, optimum RDR mining elevations and their associated dilution and lost ore costs are calculated and compiled to represent production uncertainty.

Jan 1, 2006

By D. Bois, P. Poirier, B. Bussière

Environmental desulphurization is an attractive alternative for the management of acid generating tailings. Bulk sulphide flotation is the most commonly used method to produce desulphurized tailings, as shown from many previous works. This process can reduce the volume of problematic tailings to manage by making a sulphide fraction concentrate. The desulphurized tailings can then be used as construction material for an engineered cover to prevent acid mine drainage. In this paper, the results from different laboratory and pilot scale flotation tests are presented. These results confirm that low sulphide non-acid generating tailings can be produced by froth flotation. It is also demonstrated that sulphide concentrates obtained from desulphurization mixed with the appropriate binders can be used as feed material for paste backfill. From previous work on the evaluation of operating and capital costs of the desulphurization process for different ore types, the use of desulphurization as a tailings management approach was studied for several scenarios. The desulphurization process was then compared with other technologies (underwater disposal, engineered soil cover) currently used to prevent acidic drainage (AD) for a new mining operation. Results show that partial or total desulphurization are technically and economically viable options to manage tailings during mine operation. Mine waste managers should consider desulphurization as an efficient technology.

Jan 1, 2005

By D. Harrington

Seldom, if ever, has any mining hazard presented itself that some method has not been devised to control it to some extent; the degree of success of such control depends largely upon the intensity of desire to prevent suffering, injury, and death. The economic saving to be realized and the more definitely this is realized by all concerned, the more quickly and effectively will the hazards be handled is an important incentive to prevention of accidents. Preventing coal-mine explosions is by no means a complex problem; all that is necessary is sensible, conscientious, sustained effort. The fact that explosions can be prevented has been well-demonstrated by the record of the post few years; the average annual death toll from explosions for the 5 years 1906-1910 was 438, and for the 20 years prior to 1929 it was 265: during the past 4 years an average of only 32 deaths per year resulted from this cause, although the annual production during that time varied but slightly from that of 1906-10. This is a truly remarkable reduction, and if other types of mine accidents had been reduced in the same ratio only about 300 would be killed annually in our mines instead of the nearly '1,300 killed in 1936 and the approximately 2,000 killed annually for many years. Although frequency of occurrence of explosions has not lessened greatly during the last decade, their severity decreased markedly, which would indicate that effective means are being taken to prevent the spread of explosions, even though ignitions and their causes are not being handled nearly as effectively as they might or should be handled. Several large coal-producing States, which in the past have experienced numerous disastrous explosions, have been free from such disasters for continuous periods as long as 8 years in the relatively recent past. The application of rock dust to underground surfaces has been an important factor in preventing widespread explosions; some of the mast dangerous mines have been rock-dusted fairly adequately, and this has been amply repaid in the reduced severity of explosions, as heretofore indicated; however, many have applied rock dust apparently without giving much consideration to the amount required to prevent

Jan 1, 1938

By Tom Shumka

"All mineral processing facilities that use girth gear driven mills need to inspect the gear teeth on a routine basis, whether it be every six months to every three years. The inspection frequency depends on gear tooth condition, and the objective is to ensure the operational integrity of the gear teeth. Conventional methods such as magnetic particle testing, visual inspection or dye penetrant examinations rely heavily on operator interpretation. At best, these techniques can determine whether a defect exists, but are unable to provide information on defect severity. This paper describes the use of combining combined eddy current array (eca) and alternating current field measurement (acfm) to provide a complete survey of all surface breaking indications on the whole gear tooth depth. This method accurately determines the size, length and depth of any cracks found on the surface.INTRODUCTION In order to gain a fundamental understanding of the evolving operational and production behavior of a piece of machinery over a specified time period as part of an effective condition monitoring program, a robust data collection process must be firmly established and adhered to. To be effectively implemented within an organization, a condition monitoring program must have support of not only the maintenance, production and engineering staffs, but also executive management support to ensure successful roll out to realize the maximum productivity of the machinery and subsequent cost-savings. One of the key elements of a mineral processing facility that use gear driven SAG Mills as a primary stage for grinding solution, is the integrity of the critical gear unit that drive the mill. For the maintenance team, condition monitoring on the gear unit is crucial for preventative maintenance. A catastrophic failure in the critical gear unit would require a minimum of ten days to replace the gear set, depending on the damage occurred. This, of course, would only be applicable if the client had a spare critical gear set in inventory. If a gear set had to be ordered, it could take from four months to two years to receive a new gear set. For example, in 2007, there was a global backlog of these types of gears sets resulting in a two year delivery. The maintenance costs associated with a catastrophic failure of this type would easily cost in the millions."

Jan 1, 2012

The lead concentration of flotation feed ore slurries is determined using two ?-ray absorption gauges mounted directly on a 6 in. diameter flotation feed pipeline. One gauge is a conventional "density" gauge using CS137. The other is a "lead-sensitive" gauge, which depends on the preferential absorption. by lead of 225 key y-rays resulting from Compton backscatter of CS137 y-rays.Gauge outputs are combined using an analogue computer the output signal of which is directly proportional to the lead concentration of the pulp. The accuracy of measurement of the pulp lead concentration is ± 3·6 per cent for ore slurries with lead concentrations in the range 0'07-0·16 g/c.c. and pulp densities 1.43-1.60 g/c.c.This paper sets out the development of the technique and details are given of the two experiments (1964, 1966) conducted in the plant at North Broken Hill Limited. The installation of the two-gauge system inthe plant during May 1968 is described. Details are given of the calibration technique used and the results obtained.

Jan 1, 1969

By A. M. Tunstall, N. Djordjevic, H. A. Villalobos

The damage zone behind a typical smooth-wall blast in the open pit was assessed by visually examining diamond drill core to identify blast-induced cracking, mapping core rock quality designations to identify changes in fracture frequency and conducting uphole seismic testing to determine changes in rock mass characteristics. The results from the three techniques show reasonable correlation. They suggest that major damage, in the form of fracturing of intact rock, occurs at least 7 m behind the smooth-wall blast and significant damage, in the form of opening and extension of calcite-filled fractures, at least 12 m from the blast. At greater distances the dominant damage mechanism is the loosening of existent joints within the rock mass. In the trachytes at El Soldado these damage mechanisms correspond to peak particle velocities of 2 000, 900 and 500 mm/s respectively

Jun 19, 1905

By Warren L. J

The effectiveness of shear-flocculation as a method for upgrading simple mixtures of ultrafine (1-11 \lm) scheelite and garnet was evaluated. Statistical methods were used in the design and analysis of the main test program.The stirrer speed, stirring time, and initial weight ratio were all found to have significant effects on both the recovery and grade of the floes produced. The particle sizes also had an effect on the final grade. There were several important interactions between factors which also affected the results. Optimum conditions for shear-flocculation were established, and under these conditions about 80 per cent of the scheelite could be recovered at a grade which depended on the composition of the starting mixture. Starting with mixtures containing 10 and 50 per cent scheelite, the best final grades were between 20 and 50 per cent and between 70 and 90 per cent respectively, the actual value depending on the particular combination of particle sizes.

Jan 1, 1977

Q: It is May 1961 at Bill Wrather's Washington house. Bill, think back to your first job after college. Wrather: Perhaps I ought to go back a little bit further than my first job. I entered the University of Chicago with the idea of studying law. My intention was to take a 4-yr liberal arts course and superimpose a law degree on that. But during my undergraduate work I fell under the influence of R. D. Salsbury. He decided I had some talent as a geologist and influenced me to take a geological course. Nevertheless, I did not give up the idea of law. While in school I took a spell of typhoid fever and almost died. The doctor recommended outdoor exercise, so a geological job seemed logical. W. H. Emmons was a graduate student in the University and he interceded with Dr. Hayes of the USGS. I went on the payroll as assistant packer at $60 a month. I had one of the most glorious summers I ever spent in my life. That fall and the following year I took law courses and became thoroughly convinced that I was cut out for a geologist rather than a lawyer. I finished up my law work in 1908 while waiting for a job with Bill Emmons, who was doing a careful study of Goldfield and Tonopah.

Jan 4, 1964

By P. Rosario

The application of high pressure grinding rolls (HPGR) has been growing in the mining industry for the last 10 to 15 years. The major benefits supporting this trend are better energy efficiency, improved grinding capacity, and higher metal recovery in downstream processes such as heap leaching and flotation. In general there is limited quantitative knowledge on the true benefits of HPGRs relative to SAG mills in comminution, and about which situations one deals with better than the other. This paper will present a structure for comparison of the energy requirements for HPGR versus SAG mill considering complete circuits for comminution of precious and base metals hard ores. The work presented is from the design of four complete circuits based on ore data from two sites.

Jan 1, 2010

By J Cornejo, A Pinochet, C Caviedes

The ore extraction rate and the incorporation of new areas are key operational parameters. In massive deposits mined by caving techniques they both control the cave back geometry, which is mostly responsible for the induced stress state around productive levels. Early detection of deviations from admissible geometries will prevent stability problems related to geomechanical hazards, helping to improve safety and working conditions and reduce the potential for lost reserves.This paper describes a mine planning tool currently in use at the El Teniente mine. This tool involves the control of the cave geometry based on rules that have been defined as a result of different studies and experience collected during the operational history of the mine.This mine planning strategy achieves an extractive mining process with lower risk than conventional planning methods, ensuring ore reserves extraction if followed as planned while reducing unexpected changes in mining sequences.CITATION:Cornejo, J, Pinochet, A and Caviedes, C, 2016. Geometric control for strategic mine planning at El Teniente Mine, in Proceedings Seventh International Conference and Exhibition on Mass Mining (MassMin 2016), pp 191–196 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2016

Economic Sustainable Power for Mineral Processing

Sep 13, 2010

By Nikhil Dhawan, Veeranjaneyulu Rayapudi

This study investigates upgrading of low-grade banded hematite quartzite iron ore (Fe ~31%). Conventional beneficiation was found to be futile. The susceptibility of iron phases to microwave exposure and their selective absorption assists in the liberation of iron values. Microwave exposure of coarse particles at 540 W for 10 min yielded a concentrate with Fe 56.30% and recovery of 50.68%. Conventional carbothermic reduction at 500 °C, 60 min and 9% charcoal yielded a concentrate with Fe 57.6% and iron recovery of 68%. The presence of sufficiently bonded silica leads to an easy formation of a fayalite phase. The microwave reduction design yielded FeG of 57.6%, FeR of 47% and a yield of 24% at an optimal condition of 540 W, 8 min and 6% charcoal. It was found that a small fraction of microwave-irradiated ore-charcoal mixture melted rapidly, and pure ferrite balls were observed within 8 min. An optical micrograph of a ferrite ball reveals the retained austenite and martensite phase.

By M. Leroux, P. Lacombe, S. R. Rao, J. Y. Kim, J. A. Finch, G. Labonté, N. Macminn, M. Ounpuu

"Laboratory investigations on two complex ores, the A1 zone ore from Les Mines Selbaie and the Lyon Lake ore from Mattabi Mines Ltd. (Division of Noranda Minerals), have been carried out to determine some of the main variables in collectorless flotation. In particular, the effect of pulp potential (controlled by gas composition), conditioning time, pH and grinding media have been studied.Chalcopyrite showed the greatest response to collectorless flotation among the four major sulphide minerals present, followed by galena. Flotation of sphalerite was variable from minimal to important depending on the mineralogy and the pre-treatment performed. Appreciable silver recovery was achieved collectorlessly for the Lyon Lake ore while it could not be achieved for the A1 zone ore of Les Mines Selbaie. It appears that the difference between the two ores is related to silver's predominance as tetrahydrite in the Lyon Lake ore while it is as argentite and native silver in the A1 zone ore.The response of the ores to collectorless flotation is strongly dependent on the pulp potential, Ep, and pH. Using different gas compositions and different conditioning times it was found that collectorless flotation occurs when Ep is +195 to +295 mv (vs SHE). The actual on-set potential for collectorless flotation is dependent on the ore. A too high potential or prolonged oxidation leads to a decrease in selectivity. Some other factors were examined, notably the effect of pH and the type of grinding media on the selectivity achieved in the laboratory.Preliminary results from a plant trial at Mattabi Mines Ltd. confirmed that collectorless flotation occurs and that it is preferential for chalcopyrite and to a lesser extent galena. Collectorless flotation was not attempted at Les Mines Selbaie. However, examination of the distribution of collector between the different addition points in the copper circuit suggests that it may be present."

Jan 1, 1990

It is possible to divide industrial minerals into four general categories: 1. fuels, 2. construction materials, 4. agricultural minerals, and 4. industrial minerals. It is proposed to ignore the fuels in the context of this paper and deal in general terms with the others. Mining companies have often considered getting into the industrial mineral business because they can see a resource development with good growth and consistent profits. However, many mining companies being conversant with the metallic side of the industry have spent sleepless nights determining which industrial minerals are most suited for their particular situation. Some have got into the business for the wrong reasons and wished they had never heard of it. Others have successfully adapted to the industrial minerals philosophy and now operate in both metallic and industrial mineral arenas. There is a large difference between firstly, the philosophy and secondly, the functions of being in the industrial minerals business as opposed to metallicÆs. The philosophies can be considered in parallel but it is necessary to clearly have an appreciation of the dominant influences that affect industrial minerals.

Jan 1, 1984

By Jacqueline H. Jansky

The Mine Safety and Health Administration (MSHA), U.S. Department of Labor, did a linear analysis for a new underground coal mine in Grant County, WV, through the interpretation of LANDSAT imagery and high-altitude, color-infrared aerial photography, to identify areas of potentially unstable roof in advance of mining. The Bureau of Mines included this mine in its ongoing study of the correlation between geologic features and linears. Three years after the analysis, after mining had progressed through the plotted linears, a cooperative Bureau-MSHA study evaluated the effectiveness of the linear plot in predicting areas of unstable roof and defined the geology associated with the linears. Adverse roof conditions at this mine include roof falls, potted-out roof, water inflow, and local areas requiring supplemental support. At the time of this study, 34 pct of the mine workings were within 200 ft of a plotted linear. Fifty percent of the adverse roof area in the mine occurred within this area. The primary geologic anomaly associated with the linears is an increased frequency of jointing. The majority of the plotted linears coincide with the prominent joint orientations. Additional features observed in the linear zones include roof rolls and a sandstone channel that cuts into the coal seam.

Jan 1, 1983

By Bruce Vandenberg, Andy Battfay, Don Lake, Steve Conway, Jeff Yorsz

"High-speed motion pictures are an invaluable resource for blasting analysis. Whether processed by the human eye or a computer, this imagery can provide important insight into a blast and its effects.While certainly popular, traditional high-speed film cameras hamper this process. Instant feedback is not available since film requires developing and, relevant in the case of automated analysis, film isnot immediately compatible with a computer. With these facts in mind, a new high-speed video camera system, the SVCSOO, has been developed. The SVC500 combines the capabilities of a high-speed film camera, the convenience of a solid-state digital video camcorder, and the computing power of a ‘486 PC to provide a complete, standalone platform for high-speed image acquisition and analysis. This paper will describe the design, features, and use of the SVCSOO andcompare these with the analogous aspects of film cameras."

Jan 1, 1994

By N. Mulaudzi, S. Archer

"Direct cobalt electrowinning was developed to produce unrefined cobalt metal as an alternative to producing a mixed hydroxide product (MHP), which is the common cobalt intermediate product in African Copperbelt operations. MHP is preferred due to the high cost of producing high-grade cobalt cathode. Direct cobalt electrowinning test work results have shown that the purity of the unrefined cobalt metal produced from a low-grade copper solvent-extraction raffinate stream was ~97% (w/w), which is significantly higher than the MHP purity (up to 45% (w/w) Co). The current study investigates whether direct cobalt electrowinning would increase the profitability of African Copperbelt copper–cobalt oxide operations, when compared with the MHP flowsheet. An order-of-magnitude economic evaluation was conducted using dynamic differential discounted cash flow models on a “bare-bones” basis, using a 10% discount rate. Three variables were evaluated, namely; reagent utilisation extents, precipitation extents and filter-press wash efficiency. Multivariable risk analysis was also conducted using the Monte Carlo simulation technique to understand the impact of key project drivers. The financial study results indicated that a direct cobalt electrowinning flowsheet could potentially result in a higher mean net present value (NPV) compared with the MHP flowsheet. Cobalt recovery was found to have the most significant impact on the NPV. In addition to increased profitability of African Copperbelt operations, direct cobalt electrowinning has the potential to reduce the environmental footprint of operations as well as addressing the Democratic Republic of Congo government’s drive towards export of higher value metal products instead of low-grade intermediates."

Jan 1, 2015

By D. W. Levinson, L. E. Tanner

DURING the course of an investigation of the zirconium-iron-tin system the zirconium-iron system was reexamined up to 55 pct* Fe. The alloys pre- visible melting3 and X-ray diffraction studies were made of samples of the alloys. The ferromagnetic properties of ZrFe2were determined by Professor P. W. Selwood* using a modified Faraday balance.4 The zirconium-rich portion of the phase diagram is presented in Fig. 1 and compared with the work of Hayes et al.1 The maximum solubility of iron in ß is somewhat decreased while the eutectic temperature is raised. There seemed to be no change in the eutectic composition of 16 pct Fe. Since the base material was so low in iron content, it was possible to establish the maximum solubility in a between 0.017 and 0.025 pct Fe at the eutectoid temperature. The observation of fine ZrFe, particles in the micro structure of a specimen of 0.012 pct Fe alloy quenched from 700°C indicated that the solubility drops below this composition at 700° C and lower. Further study was made of the intermediate phase ZrFe2. wallbaum5 identified the compound initially as ZrFe2 with a C 15 (MgCu2) structure, placing it at 55 pct Fe stoichiometrically. Hayes et al.1 believed they found the phase at about 47.2 pct Fe and called it Zr2Fe3 but reverted to ZrFe, in the discussion of their paper.6 Jordan and Duwez7 confirmed Wallbaum's work as well as finding the same single-phase structure to about 62.3 pct Fe or Zr0-61 Fe2-18. In order to establish the ternary phase relations in the zirconium-iron-tin systema the exact position of this phase had to be known. This was accomplished by X-ray diffraction, visible melting, and metallographic techniques. Elliott8 obtained a single-phase ZrFe2 X-ray diffraction pattern from an alloy of about 55 pct Fe. This was confirmed in the present study with an alloy of 54.81 pct Fe. However, extra lines (attributable to a or ß zirconium) were found in diffraction patterns of the 47.42 and 49.83 pct Fe alloys. The melting characteristics of these same alloys were studied by suspending 47.42, 49.83, and 54.81 pct

Jan 1, 1960

By William H. Highlands

Lightning is a natural phenomenon which poses a potential hazard to people, structures, and equipment unless adequate protection is provided. The type of protection required is related to the nature and of the facility. The decision making process involves a number of interrelated factors which should be considered when determining the need for protection.

Jan 1, 1989

Development of Underground Gold Processing Plants Underground gold processing plants have potential advantages over traditional surface installations related to a smaller environmental footprint, reduced capital and mining costs, improved security and increased value of the product delivered to surface. The concept of processing gold ores on the surface is the traditional paradigm. A process of pre-concentration of ore underground is likely to result in a major shift in operating costs. In particular, run of mine ore or a large proportion of it will not need to be transported to the surface. As a result, environmental and financial benefits are likely. Underground plants are likely to be pre-concentration systems where the process product is a high-grade concentrate and tailings for stope backfill. Units will be either static or modular. Concentration methods will be gravity and/or flotation or leach based. This paper discusses the development underground gold plants from early concept, through to the world's first operational unit, a newly commissioned unit and the technical basis of a fully modular system.

Sep 13, 2010