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Background information, formulae and a systematic set of procedures for estimating capital and operating costs for open pit mining equipment are presented in this paper. Firstly, equipment capital costs are required. These can be obtained from either suppliers, contractors or from first principles. The equipment is then divided into cost elements. Typically these are fuel and power requirements, spare parts consumption, wear items such as tyres, teeth and drill bits and finally repair and operating labour requirements. By consideration of the cost and life of each element a base cost can be derived. The base cost is then adjusted to suit specific site conditions such as the proximity to spare parts suppliers, the duty or ground conditions and the management and operator skills specific to the site. Hence, the same item of equipment can be costed to reflect different operations. Included are tables and data for typical plant items. Several examples are also given to illustrate the methodology being presented. The intention is to provide a set of procedures to allow costs to be built up from base level in a systematic and repeatable way. Applications for these costs include feasibility studies, budgetting and data for economic analyses.

Jan 1, 1990

By R. J. Sweigard, C. T. Justice, T. Beckham, E. D. Thompson, T. C. Hopkins

Fine coal refuse is often pumped, as slurry, into surface impoundments as a means of permanent disposal. As the available volume is filled, the height of the embankments are frequently increased. Many times the additional embankment material is placed upon consolidated fine coal refuse. There has been some concern about the long-term effect of consolidation of this material at or above the liquid limit upon its shear strength. A laboratory investigation was performed using three different types of fine coal sluny taken from Central Appalachian coal preparation plants. The refuse was consolidated in 10-foot plexiglass columns under incremental amounts of surcharge loading. The incremental loads were designed to simulate the effect of increasing the height of a refuse embankment on top of the consolidating coal slurry. After the refuse in the columns had consolidated for several months, the columns were cut apart and triaxial tests were performed on both the consolidated material and unconsolidated material for comparison of their shear strength parameters.

Feb 24, 1997

By R. E. Heithecker

In Kansas, almost every oil well drilled into a limestone formation is treated with hydrochloric (muriatic) acid upon completion. This is done to increase the potential capacity of the well and thereby increase its "daily allowable" production (see p. 9 ), to shorten the time required to produce the recoverable oil, and to increase the quantity of oil recovered ultimately from the reservoir. The porosity and. permeability of limestone formations seldom are uniform throughout the proved area, consequently the production capacities of completed wells vary considerably. Acid treatment of wells tends to increase production capacity and to equalize potential capacity. If offset wells already have been treated with acid, new wells usually are treated to protect the property on which they are drilled against drainage. Even though competitive conditions do not exist in a field, it

Jan 1, 1939

By Regina Maria Pinheiro

This work has for objectives to characterize a waste generated in the form of sludge during the treatment of the effluent of a paper making industry and to evaluate the effect of its incorporation in the amount of 10 wt.% on the properties and microstructure of a clayey body used for brick production. For the characterization of the waste the following techniques were used: X-ray diffraction, X-ray fluorescence, differential thermal analysis and termogravimetric analysis. Incorporated bricks were produced in industrial scale before firing at 750°C in a Modified Caieira type furnace. The physical and mechanical properties evaluated were water absorption and compression strength. The microstructure of the fired ceramic was evaluated by optical microscopy. The environmental evaluation was made by solution test and atmospheric emission by monitoring the release of SO2, NOx and particulate material. The results showed that, in agreement with the characteristics of the waste, its recycling into red ceramic can contribute to decrease the consumption of fuel during the firing stage. The properties of the fired ceramic attend the norms. With respect to the environmental aspect, the incorporation of the waste did not impact the environment.

Jan 1, 2009

By Diankun Lu, Ganfeng Tu, Edouard Asselin, Feng Xie

A novel separation process for detoxifying cadmium-containing residues arising from zinc hydrometallurgical processes has been developed. An initial investigation indicated that a high concentration of zinc in the sulfate solution can be effectively separated from cadmium by solvent extraction with P204 (di(2-ethylhexly)phosphoric acid, D2EHPA). The mixture of sulfuric acid and ammonium citrate ((NH4)3C6H5O7) is thus used to extract metals from the residue at room temperature. Copper in the leachate is recovered by solvent extraction (SX) with LIX 973. Cobalt in the raffinate from the copper SX process is recovered by precipitation with a-nitroso-ß-naphthol. The results show that more than 50% of the copper and virtually all the zinc, cadmium and cobalt in the residue can be leached under the experimental conditions used here. Virtually all dissolved copper and cobalt can be recovered in the subsequent solvent extraction and precipitation processes. The presence of (NH4)3C6H5O7 could significantly facilitate the extraction of zinc by D2EHPA in the subsequent separation of zinc and cadmium. More than 97% of the dissolved zinc can be recovered through a two-stage counter current solvent extraction process. After separating copper, cobalt and zinc, cadmium can easily be recovered from the solution either by cementation with zinc powder or by electrowinning, while the purified solution can be recycled back to the leaching process.

Jan 1, 2014

By Samuel M. Shallcross

The principal function of the Bell limestone mine, of the American Lime & Stone Co., at Bellefonte, Pa., is to supply raw material to the company's modern rotary kiln plant at Bellefonte. Because mining costs are naturally higher than many open quarries with more favorably lying strata, it cannot compete, except to a limited extent, in the markets for road material and fluxing stone. In the broad sense, mining does have an advantage over the average open quarry when the end products are designed for and controlled by process and final inspection for the exacting demands of the industrial and chemical markets. Approximately 80 per cent of the output of the Bell mine is sold in the industrial and chemical markets. And as higher standards are set each year for construction and agricultural work, the remainder of the mine output goes to these two classes. Mining produces more fines than open quarries, and these fines are difficult to market; on the other hand, owing to absence of contaminating clay and impure rock, a greater percentage of the output of a mine is marketable. Because of the great production of fines, rotary kilns for lime burning are necessary when the stone must be mined. In 1921 the American Lime & Stone Co. operated 19 quarries and 72 lime shaft kilns spread over an area of 40 miles between Bellefonte and Altoona, Pa. At that time the lime-production capacity of the 72 kilns amounted to approximately 700 tons per day. After 15 years the company operates three rotary kilns and six shaft kilns, with a combined output of approximately 500 tons of lime per day, concentrated in its single Bellefonte plant (Fig. 1). Its only stone-producing plants are now the limestone mine at Bellefonte and a construction-stone open quarry at Union Furnace, near Tyrone, Pennsylvania. Since the middle of 1922, the management of the American Lime R. Stone Co. has been under the direction and ownership of the Warner Company, of Philadelphia. To the Warner Company's experience, gained through successful operation of lime plants in eastern Pennsylvania for many years, and the successful solution of material-handling problems

Jan 1, 1937

By H. E. Criner, M. G. Driessen

THE cyclone thickener has two important applications in wet washing plants: (1) water clarification, and (2) fine coal recovery. The thickener consists of a conical chamber into which the fluid is injected through a tangential nozzle at the periphery of the large end. The solids of the slurry are concentrated and removed from the apex of the cone while the "thinner" portion is discharged from a central tube in a flat head at the large end, fig. 1. The advantages of the cyclone thickener are that large volumes of slurry may be treated with small space requirements and that the underflow concentration may be controlled easily and readily to meet varying feed conditions. Control of Washery Water Solids Concentration: The first requirement, in the process of controlling solids concentration, is that the solids be removed from the body of circulating water at the rate at which they are introduced. If this condition is satisfied the concentration will remain at a fixed value and will not increase to uncontrollable levels. The second requirement is that the solids concentration

Jan 1, 1951

By M. G. Driessen, H. E. Criner

THE cyclone thickener has two important applications in wet washing plants: (1) water clarification, and (2) fine coal recovery. The thickener consists of a conical chamber into which the fluid is injected through a tangential nozzle at the periphery of the large end. The solids of the slurry are concentrated and removed from the apex of the cone while the "thinner" portion is discharged from a central tube in a flat head at the large end, fig. 1. The advantages of the cyclone thickener are that large volumes of slurry may be treated with small space requirements and that the underflow concentration may be controlled easily and readily to meet varying feed conditions. Control of Washery Water Solids Concentration: The first requirement, in the process of controlling solids concentration, is that the solids be removed from the body of circulating water at the rate at which they are introduced. If this condition is satisfied the concentration will remain at a fixed value and will not increase to uncontrollable levels. The second requirement is that the solids concentration

Jan 1, 1951

By T. Tamura

It is known that the CaO-FetO-P2O5slag system has a wide liquid miscibility gap at steelmaking temperatures and this two-liquid slag phase has many advantages such as high activities of both FetO and CaO and high amount of P2O5. The phosphorus distribution ratio between the two-liquid slag and molten steel was confirmed to be higher than that between CaOsat.-FetO-P2O5slag and molten steel. The two-liquid slag may be useful for dephosphorization of molten steel and reduction of slag volume. Furthermore, the phase equilibrium of two-liquid CaO-FetO-P2O5slagsaturated with MgO was measured to determine the applicability of the two-liquid slag to dephosphorization in steelmaking process. Keywords: slag, refractories, solid solution, two-liquid phase, dephosphorization, steelmaking, phase equilibrium.

Jan 1, 2004

ABSTRACTRock stresses can be modified by physicochemical processes.If rock pores allow the ingress of water and oxygen, but are not large enough to permit the exit of larger molecules of weathering products, anomalous rock pressures develop. Rock masses may also be subjected to osmotic pressures developed as water diffuses into pores and joints filled with saline water. Anomalous rock pressures may also develop as gels filling pores undergo syneresis and as salts crystallize from pore solutions.

Jan 1, 1968

By D. Kruse

Top down constructed large diameter (up to 90 m [300 ft]) shaft design and constructability issues present an interesting suite of challenges and opportunities highlighted in this paper. The study covers 2D and 3D finite element models used to: analyze various failure modes, evaluate the shaft liner and internal structures? response to seismic loading, assist in segment design, and assess final structural design tradeoffs. Efforts to achieve economic advantage over conventional heavy civil practices have prompted innovative solutions for ring and segment design, ring build assembly, and annulus backfill grouting. Intended for soft ground conditions, relationships between soil parameters and structure design are also explored.

Jan 1, 2011

By A-A Latscha, C Boyle

Geological modelling has historically been done using sectional interpretation of paper sections or on a computer screen. Boundaries of geological units or grade shells are interpreted by a geologist section by section and the shapes are drawn onto paper to be digitised later or they are directly digitised into a computer. This approach is referred to as explicit modelling. Such methods are time consuming if there are many section lines or boundaries to be interpreted. The number of metres drilled and resource models made is increasing each year and it will be difficult to keep up using explicit modelling methods. Alternatively, it is possible to use information carried in the drill holes, known geological relationships and point estimation methods in two or three dimensions, to create similar geology boundaries, while eliminating or at least greatly reducing the need to manually interpret and digitise detailed sectional interpretations. Such methods are referred to as implicit modelling and are available in a number of software packages. Implicit modelling approaches have been used in iron ore and found to significantly reduce the time needed for modelling while producing results that are comparable or better than standard explicit modelling approaches. A number of case studies have been undertaken of implicit modelling in iron ore deposits. Stratigraphic surfaces of bedded, folded and faulted iron ore deposits have been modelled in various deposits by Leapfrog Geo, GOCAD (with SKUA) and Vulcan Integrated Stratigraphic Modelling. Leapfrog Mining was used to model iron grade shells at particular cut-off grades. The modelled surfaces are of a high standard equivalent to those that could be produced by traditional explicit modelling but the time required by the implicit methods is far less. Implicit geological modelling is an active area of software development and improvements in software are likely.CITATION:Boyle, C and Latscha, A-A, 2013. Implicit geological modelling of iron ore deposits, in Proceedings Iron Ore 2013 , pp 57-66 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 12, 2013

By Daniel Roy

This paper introduces a new, safer bulk emulsion loading system for underground mining operations. The features and benefits of the equipment, along with the use of Dyno Nobel Inc. patented gassed emulsion technology, is summarized in the application of a stope blast with very difficult and complex ground conditions. The paper describes methods used to optimize the amount of energy required to break the ore while protecting the integrity of the surrounding backfilled pillar.

Jan 1, 2003

By J. N. Van der Merwe

The data base of failed pillar cases as used by Salamon and Munro (1967) in their original analysis to determine the strength of coal pillars empirically, has been updated for this study. It is shown that the Vaal Basin and Klip River coal fields exhibit similar behaviour that differs from the failures in other areas, i.e. failure at high safety factors within a short period of time. Those collapse cases have been omitted from the new data base. Failures in the other areas that occurred after 1967 have been added. Using a technique to minimize the area of overlap between the populations of safety factors of failed and intact pillar cases, the new data base was re-analysed in conjunction with the original Salamon-Munro data base of intact pillar cases, from which the cases in the areas of weak coal were likewise eliminated. It was found that a linear formula reduced the overlap area by22%. The new formula predicts higher strength for pillars with a width-to-height ratio greater than approximately 2.0 to 3.0 and a lower strength for smaller pillars. It was also found that in order to obtain the same relative measure of stability as with the Salamon-Munro formula, the strength constant in the new formula should be within a range of 2.8 to 3.5 MPa. For most current South African coal mining conditions, using the new formula for pillar strength will result in leaving smaller pillars without sacrificing stability. The reason for this is that the Salamon-Munro formula under-estimated the strength of larger pillars and over-estimated the strength of smaller pillars. The new formula will thus result in improved reserve utilization without sacrificing stability.

Jan 1, 2003

"The Antamina orebody is a geologically complex, polymetallic skarn located in the Peruvian Andes. A range of copper and copperzinc ores are campaigned separately through the concentrator producing copper and zinc concentrates as well as lead and molybdenum by-products.Ore type classification at Antamina is based on chemical assays; geological or lithological variations are not considered. Consequently, each ore type demonstrates a wide range of concentrator performance.Antamina is currently implementing a system to track ore movements from the shovel face to the concentrator. Relatively sophisticated models of run-of-mine and coarse ore stockpiles ahead of the mill will be used to account for the variable delay between mining and milling.One of the numerous benefits of ore tracking is the ability to directly associate the measured concentrator performance with a physical location in the orebody. Using existing mine planning software, three-dimensional models can be created of such performance measures as metal recovery, concentrate quality, operating cost, and reagent consumption.Such a database of information allows the true value of different ore sources to be determined. The value of an ore source is conventionally measured as metal content (individual or combined ‘equivalent’) with a cut-off grade applied to indicate some base level operating cost. However, the true value of an ore source should include dynamic factors like haulage cost, reagent use, smelter penalties, and even prevailing metal prices. If an ore source is considered from all perspectives rather than simply its potential to deliver value, the concept of ore becomes more flexible. Any ore source that reveals itself to be unprofitable can be eliminated from the mine plan or possibly blended with others to improve its value. The ability to predict mill performance, and thereby profitability, is a powerful tool.In an operation such as Antamina, where managing ore sources, campaigns, and the delivery of a variety of concentrates in a narrow timeline to customers is a daily challenge, prediction is the key to success and improved efficiency."

Jan 1, 2005

The distribution of chrome spinels in a magnetically fractionated ilmenite concentrate sourced from the Murray Basin was characterized by XRF assaying, quantitative electron microprobeanalysis, grain mapping, automated mineral phase clustering, and modal analysis. At least 14 distinct chrome spinel types were present in the concentrate. There is considerable variation in the amount of each chrome spinel type present, although a high-Mg, high-Al phase makes up close to 45 per cent of the total spinel population. Magnetic fractionation results showed significant variation in the composition and relative abundance of spinels reporting to each fraction. Low magnetic field strength fractions (ie. high susceptibility grains) were dominated by chrome spinels that are mid-range in Al and Cr. These spinels have the highest magnetite, ulvospinel and Fe(Al,Cr)2O4components. In comparison, the high field strength fractions (i.e. low susceptibility grains) have the majority of the grains with high-Al contents indicating a higher proportion of Mg(Al,Cr)2O4component. Spinels high in a (Al,Cr)2.67O4non-stoichiometriccomponent are absent at low field strengths but tend to be concentrated in the high field strength, non-magnetic fractions. Intermediate field strength fractions tend to exhibit a broad spread in spinel compositional types. A mild roast treatment of the sample had no clear effect on the distribution of chrome spinels between different magnetic fractions, but it did cause a change in the magnetic properties of the accompanying ilmenite grains. The effect of more extreme roasting conditions on the magnetic properties of the chrome spinels is to be determined.

Jan 1, 2003

By J. Betzhold

Knowing more about an orebody makes it easier to exploit it profitably. Many orebodies are made up of different rock types, alteration zones or mineralogical ensembles: oxides versus sulphides or facies with different metallurgical properties for example. Being able to model the spatial layout of these different facies is vital to good mine planning and management. Kriging cannot be used to generate numerical models of orebodies with complex geometric patterns because it gives too smooth an image. Over-smoothing has the meaning of changing the natural selectivity. Conditional simulations are required to do this kind of model respecting the natural variability: honouring the natural selectivity, dilution and ore loss. Standard geostatistical simulations cannot duplicate many of the complex spatial relationships seen in the earth sciences, such as differently orientated facies, sets of conjugate veins or ore types where certain facies cannot touch. After a presentation of the case study, it will be shown why traditional methods for simulating indicators like the sequential indicator simulations, or the truncated gaussian method, cannot be used to simulate it. Plurigaussian simulations are then introduced and shown to be more powerful than the previous methods in their range of application. This is confirmed by the case study treated; a Chilean copper deposit, for which the plurigaussian simulations are seen to respect the different orientations of the individual facies as well as honouring the facies seen in drill holes, and respecting the proportion of each facies even if this varies in space (e.g. increases or decreases with depth). Key words: geostatistics, indicators, conditional simulation, plurigaussian method, copper variability.

Jan 1, 2000

By Qiang Zhang

Hybrid composites are fabricated by adding two reinforcements into matrix materials so that the expected excellent properties can be achieved through the combined advantages of short fibers, and different size particles (micron or submicron), which provide a high degree of design freedom. In this paper, hybrid preforms were produced with the different size reinforcement of the Al2O3 particles and short fibers. The Al-Si alloy-based hybrid composites were fabricated by preform-squeezing casting route. The structure and performance of composite materials were studied with the Transmission Electron Microscopy (TEM), and Scanning Electron Microscopy (SEM). The results show that the reinforcements, both particles and fibers, distribute homogeneously in the matrix materials, and the properties of composites are found to improve in comparison with the matrix Al-Si alloy.

Jan 1, 2009

Many mines in Canada, the US and S. Africa are reaching the hoisting limit. Very little payload will be possible without compromising safety due the excessive weight. It has been suggested (DeLorme, 2000), that one of the most attractive concepts to enable deeper hoisting is to reduce the allowable factor of safety in the wire rope. Researchers at the Spokane Research Lab are developing new technology to improve hoisting safety and productivity by providing new monitoring and analytical tools. A Shaft Conveyance Monitoring System (SCMS) has been developed which determines hoist rope end load, true conveyance position and acceleration, and rope safety factor, as well as other hoist operating parameters. This information is transmitted to the hoist operator display 20 times per second. Recent field measurements on 45 mm(1 ¾ in.) diameter hoist rope indicate that dynamic forces during loading of a 9000 kg(10 ton) skip may exceed the safety factor of the rope. To improve on the current understanding of the mechanical behavior of hoist ropes, and to help interpret the results from field-testing of the SCMS, a new approach to computer modeling of stranded wire rope is also being developed. Particle Flow Code, PFC3D (Itasca 1995b) is used to simulate the structural behavior of wire rope and the interaction between individual strands when the rope is subjected to static and dynamic end loading. Details of the SCMS, field results from the measured rope loads, and the results of numerical modeling on the wire rope will be discussed.

May 1, 2002

By Brad Simser

The Brunswick No. 12 Mine is a 10 000 tonne per day producer of lead-zinc-copper-silver ore that has been in operation since 1964. Mining of this multiple lens deposit is primarily by blasthole stoping techniques between 400m and 1200m below surface. The combination of a high overall extraction ratio and high horizontal stresses (twice the vertical) has elevated the induced stress regime to levels comparable to much deeper operations. Improved mine design, and a better understanding of how the rock mass responds to mining in high stress environments is essential to improve overall recoveries and maintain safety. Seismic monitoring has proven to be an essential tool at Brunswick, for both short-term safety of workers, and long-term strategic planning. Practical case studies illustrate how seismic data, particularly source parameter information, can be used to measure the rockmass response to mining and improve mining layouts in difficult regions. As the global trend continues towards mining in deeper, higher stress environments (e.g. South African Witswatersrand Basin, Sudbury Basin) and as local extraction and thus ground stresses continue to increase in existing deposits, seismic monitoring will play a critical role in mining safely and economically.

May 1, 2003