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By J Slade, R Trueman

Unplanned dilution has the potential to seriously undermine the economic viability of a mine, and in some cases results in mine closure. The effect of stress damage on dilution has become increasingly relevant as mining depths increase. In the case of narrow vein mining, the incremental extraction of long-hole rings has the potential to result in a moving high stressed zone at the stope brow. This leads the hanging wall and footwall to experience a spike in the stress to strength ratios as the brow passes. In some cases, the stress to strength ratio may be high enough to result in fracturing or damage to the rock mass. The aim of the study described in this paper was to investigate whether stress damage results in a significant increase in dilution. The study involved analysis of overbreak from 410 case studies from the Kundana Gold mine in Western Australia. Site personnel had already undertaken calibration studies of the stress levels that result in rock mass damage. This calibration, in conjunction with numerical modelling showed that stress damaged stope walls at this mine had on average 50 per cent more overbreak than stope walls where stresses had not exceeded the damage criterion. For a design mining width of 1.5 metres, and with both walls impacted, this represents 36 per cent increase in dilution. After adjustment for possible sources of bias the difference reduced to an average 0.10 metres per stope wall, representing 13 per cent dilution for the mining width under consideration. The potential for stress damage related overbreak should therefore be considered as part of any assessment of narrow vein dilution.

Jan 1, 2005

By S Wotherspoon

At Kalgoorlie Consolidated Gold MineÆs (KCGMÆs) Fimiston Operations, located on the periphery of Kalgoorlie Boulder in Western Australia, roughly 7.5 million tonnes of rock are broken each month for the extraction of gold. With the close proximity of neighbours to the mining operations in the Chaffers Cut Back, special blasting techniques and tools were employed by KCGM to manage the blast induced vibrations and noise in this area. The i-konTM initiation system coupled with OricaÆs complementary modelling and analysis tools offered the complete blast management package. With these tools KCGM management and Orica Mining Services commenced an investigation into the benefits of electronic initiation. Prior to the commencement of electronic blasting, initial modelling was conducted to examine the vibration time waveforms and their frequency content, as these were expected to have an impact on vibration interaction with structures such as large buildings and urban dwellings. This work looked at results measured for a previous conventionally (pyrotechnic) initiated blast in the area and compared it to the results obtained when the blast was modelled with electronic initiation and faster timings. The predicted peak particle velocity (PPV) and structural vibration factor (SVF) were calculated. From the results it was concluded that the investigation into using i-konTM electronic initiation system and SHOTPlus«-i blast design software had some real potential to improve blast vibration management on the cut back. The use of the electronic initiation system and complementary software allows intricate timing designs to be accurately placed into blasts. The system has a number of working modes that allow either the precise design timings to be logged automatically into each detonator or to be manually logged where a variation from the design exists. Where such variations from the design occur, the electronic system permits the actual timings used to be uploaded back into the design file. This allows both design and real actual timings to be stored for future analysis or reference.

Jan 1, 2004

Christmas Island contains large deposits of phosphate minerals varying from high-grade calcium-phosphate (apatite) to lower grade iron and'aluminium phosphate (crandallite/millisite). The surface material is dominantly C-grade (Fe/Al) phosphate profiling into B-grade, a variable mixture of C- and A-grade ores, before reaching the high A-grade phosphate (apatite) which overlies a limestone Karrenfeld Base formation. A-grade ore is the basic phosphate used for the manufacture of superphosphate and phosphoric acid, whilst B-grade contains amounts of iron and aluminium which are unacceptable for these acidulation processes. Research into methods of separating the finer iron and aluminium phosphates from the coarser calcium phosphates has led to the development of wash-screen processes enabling recovery of 50 to 60%, as A-grade phosphate. Developmental stages included laboratory investigations, mineralogical studies, pilot tests leading the initial 20 tph prototype production unit and the current 100 tph production wash/screen plant, commissioned early in 1970 at Christmas Island.

Jan 1, 1971

By Okura T, Hino J

Coal utilization for copper flash smelting in Japan was initiated due to the sudden upheaval in the price of oil in the last ten years. A major portion of the heavy fuel oil has already been replaced by coal resulting in a corresponding decrease in energy costs. In addition to energy cost savings, an interesting metallurgical phenomenon was observed in flash smelting operations. Unlike oil combustion, coal is not burned completely in the shaft. A considerable fraction of coal particles remain on the surface of slag and are burned at the settler. Chemical investigation has shown that oxygen potentials at the settler have consequently decreased, bringing the slag and matte phases into reducing conditions, thus oxidation and reduction can coexist in one flash smelting unit. As a result, a decrease in magnetite and copper contents in the slag, elimination of furnace hearth build-up and dissolution of intermediate layer between matte and slag have been observed. In general, these led to improvements of furnace operations. However, thermodynamic investigations have shown that some minor elements such as As, Sb, Bi and Pb concentrate from slag to matte. Results evaluated on the basis of thermodynamic data relatively agree with practical observa- tions. Consequently, for coal utilization in flash smelting operations it will be necessary to control oxygen potentials from the stand- points of copper loss in slag and minor element Distributions.

Jan 1, 1987

By R E. Gerald II, B Zhang, T Sander, J D. Smith, J Huang, R J. O’Malley, H Tekle

In the steelmaking process, mold fluxes are essential for ensuring thermal insulation, refining, and the efficiency of continuous casting. Real-time understanding of the in-service composition of slags and fluxes are crucial for optimising the steel production process and improving the quality of the final product. An in situ fibre-optic Raman probe that enables the study of the structure, composition, and viscosity of molten slags and fluxes at steelmaking temperatures has been developed and demonstrated both in the lab and in foundry scale experiments. The focus of this study is on the structural, compositional, and property analysis of molten fluxes in a laboratory setting, with the aim of applying this technology for in situ monitoring during industrial production. Raman spectra were successfully collected at various temperatures from 1000°C to 1400°C in real-time and analysed using a deconvolution algorithm to isolate and quantify peaks in the spectra associated with the specific structures of molecular components in molten and solidifying flux. The research successfully combines in situ Raman spectroscopy with high-temperature viscosity data, specifically targeting CaO-CaF-SiO2-Al2O3 based mould flux systems. Specified ratios of the deconvoluted Raman peaks, such as Al-O-Al/Si-O-Si ratio, shows good correlation with the flux chemistry, while the Q3/Q0 peak ratio shows good correlation with viscosity. A ruggedised Raman probe system was also developed and demonstrated in an 80 kg induction furnace. Ultimately, the goal of this work is to demonstrate in situ slag and mould flux analysis in industrial processes, such as in the continuous caster or electric arc furnace (EAF).

Aug 21, 2024

The South Wall Base Case Design for Mt Whaleback indicated that along portion of the South Wall a cigar shaped synclinal keel, contain- ing 14 800 m', of Dales Gorge Member ore, would be unkeyed and bed- ding undercut. The dry "ore lobe" slope would be 60m high, unbenched and approximately 170 m long. Stability analyses using specific design parameters established that artificial reinforcement could stabilise the slope and be economically justifiable. To implement the slope design reinforcement for such a complex geo- logical structure it was necessary that all functions pertaining to slope excavation be integrated and co-ordinated within the Mine Geotechnical Section. The objective being to minimise slope damage and thereby optimise the effect of design reinforcement. The successful excavation of the ore lobe in 1988, three years after the introduction of artificial reinforcement, was achieved by strictly main- taining the following parameters. 1. Accurate Geological Model 2. Controlled Perimeter Blasting 3. Controlled Excavation Techniques 4. Quality control -Reinforcement Installation 5. Additional Reinforcement.

Jan 1, 1989

BECAUSE of the attention given in recent years to the flotation process, there is an extensive range of equipment available to any staff detailed for: the design of a flotation mill. This statement applies not only to the flotation machines, but also to equipment for crushing and grinding, elevating the pulp, dehydrating of concentrates, and the methods of driving the various equipment.Distributed through the Proceedings and Transactions of various metallurgical societies and journals there are many excellent descriptions of flotation mills, their equipment and performance.Whilst these articles describe-in many cases in detail-the equipment in the mills to which they refer, the reasons which govern the choice of each particular equipment are not usually given.

Jan 1, 1929

In many metal mines in China,the 70B2 series of fans has been used for main fans for a long time.These fans generate higher static pressures than are required for the relatively high equivalent orifices of the ventilation systems of many of the mines. As a consequence, their running efficiency is common only around 30%. The loss of power is significant.

Jan 1, 1988

Financial theory often takes some time to penetrate industry and when it does it can result in a paradigm shift in valuations and mental models. The Black Scholes option valuation was first published in 1973, although the authors were only awarded a Nobel Prize in 1997. The valuation of real options has been applied to the oil and gas industry for some time, however it has only recently been more widely applied to the non-oil, mineral resource sector. The use of real option valuation (ROV) for the valuation of marginal and short mine life resource projects is a more useful valuation tool than the conventional DCF, NPV valuation tool. The application of ROV has major implications for corporate strategy. It generally favours equity over debt funding and non-hedging over hedging. A retrospective assessment of the successful development of the Lennard Shelf Operations demonstrates the concepts of implementing real options and the value destruction of limiting operational flexibility through debt and hedging activities.

Jan 1, 2003

By P Barrette

The manual gravimetric drying moisture determination methods currently employed by most mineral processing plants fail to provide timely and accurate information required for automatic control. The costs associated with transporting and handling concentrates represent a major portion of the overall treatment price. When considering the cash flow of a mining operation that is governed by both the smelter contract, with moisture penalties and the quantity and quality of the concentrates shipped, any tool that provides real-time feedback on the process is vital (Edwards, RP 1994). The introduction of an on-line moisture sensor would become a welcome addition to the process control field instrumentation package now applied. A novel on-line determination system for ore concentrate moisture content would replace the tedious manual procedure. Since the introduction of microelectronic-based control systems, operators have strived to reduce the treatment costs to the minimum. Therefore a representative and timely determination of on-line moisture content becomes vital for control set points and timely feedback. Reliable sensors have long been on the æwish listÆ of mineral processors since the problem has always been that you can only control what you can measure, (Konigsmann, 1990). Today, the task of moisture determination is still done by the classical technique of loss in weight utilising uncontrolled procedures. These same methods were introduced in the earliest base metal concentrators. Generally, it is acceptable to have ore concentrate moisture content vary within a range of seven to nine percent, but controlling the moisture content below eight percent is a difficult task with a manually controlled system. Many times, delays in manually achieving reliable feedback of the moisture content results in the moisture varying from five to twelve percent before corrective actions can be made. This paper first reviews the traditional and widely available methods for determining moisture content in granular materials by applying physical principals and properties to measure moisture content. All methods are in some form affected when employed on mineral ore concentrates. This paper introduces and describes a unique and promising novel on-line moisture sensor employed for mineral processing de-watering applications, which not only automates the tedious tasks but also results in reliable moisture feedback that can be used in the optimisation of the de-watering process equipment such as pressure or vacuum filters and fuel-fired driers. Finally, two measurement applications will be presented to indicate the usefulness and to summarise the measurement requirements for the proposed method of employing drag force and mechanical properties of the material itself to determine the moisture content. The commercial model of the equipment is described with the features and benefits to the users summarised.

Jan 1, 2003

A laminar-flow furnace was used to study the combustion of four flotation concentrates (chalcopyrite, pyrite, galena, and sphalerite) in air at temperatures up to 1400¦C. A special- Iv developed two-colour pyrometer was used to measure the temperature of individual chalco- pvrite and pyrite particles as they underwent combustion. Chalcopyrite and pyrite ignited with very high rates of reaction at air tempera- tures above 480 and 600¦C respectively, forming molten products. Galena and sphalerite required temperatures in excess of 700 and 1200¦ respect- ively to attain equivalent rates of reaction. The high rates of reaction for galena and spha- lerite were caused by vaporization. Temperature measurements for chalcopyrite and pyrite are reported here, together with vaporization measurements for chalcopyrite, galena, and Sphalerito

Jan 1, 1980

By Marois R, Hauff P, Kowalyczk P, Lipton G, Bedell R, Neville R, Edmundo G, Ehling M, Kern R

The Canada Centre for Remote Sensing (CCRS) has developed an airborne sensor, the SWIR Full Spectrum Imager (SFSI) which detects in the Short Wave Infrared range of the solar spectrum from 1220 to 2420nm. In June of 1995, a demonstration flight was undertaken in the state of Nevada with the support of the companies listed above. The focus of the flight was to collect image data over well known mineral deposits with the objective of evaluating the applicability of this sensor to alteration mineral mapping. Some of the Nevada sites chosen include Cuprite and Goldfield, volcanic hosted acid sulfate systems; Yerington, a structurally complex porphyry copper deposit; and Virginia City, a Quartz- Sericite-Pyrite vein system with advanced argillic pods. Ground spectral data was collected with the PIMA-II spectrometer. Solar reflectance calibration was done by Desert Research Institute personnel at Virginia City and Cuprite. This paper will discuss the configuration of the sensor and present image and ground data for Goldfield and Virginia City.

Jan 1, 1995

The art of flotation may be divided into two distinct branches, namely:-1. Collective flotation.2. Selective flotation.(1) Collective flotation is applied when all the valuable minerals in an ore are required in one concentrate, leaving ,only gangue minerals in the tailing. The method is applicable, for instance, to such ores as auriferous copper sulphides associated with gangue minerals only, or to silver lead ores low enough in zinc and other valuable minerals.(2) Selective flotation is applied when there are present in an ore two or more valuable sulphides, which cannot be subsequently efficiently treated unless they are separated from one another as well as from the gangue. For example, a silver-Iead-zinc ore, or a copper-gold-iron ore; where the iron is not required with the copper gold concentrate.In order to make these operations practicable chemical reagents have been developed, having power to exert definite actions on the various minerals when brought into contact with them in a water pulp.COLLECTIVE FLOTATION.In order to bring about collective flotation it is generally necessary to add to the pulp a frothing agent and an activator or activators for all the minerals which it is desired to float.SELECTIVE FLOTATION.The object of selective flotation is to activate the mineral which is to be floated, and at the same time to prevent all other minerals from floating.

Jan 1, 1936

A brief descri;tioki is given of nuclear power reactors and their fuels. These fuels are made from a variety of uranium compounds such as uranium dioxide, and uranium carbide as well as uranium metal and its alloys. The various processes used to produce some of these compounds from yellow cake are outlined. Using the natural uranium, heavy water reactor by way of illustration, fabrication of fuel elements is dis- cussed and the characteristics of U02 powder required for this partic- ular fabrication are indicated. The flowsheets and equipment presently in use overseas for production of this type of U02 powder are described. Possible areas where improvements might be made to this conventional process are enumerated and some details are then given of the programme of work which has commenced at the A.A.E.C. Research Establishment to gain experience in the general field of nuclear grade UO20

Jan 1, 1968

By Roberts C

The satisfactory testing and characterisation of mineralisation amenable to heap leaching, is of prime importance to successful operation of a project. This paper outlines a methodology for assessing material suitability. A general model is used for classing material types for suitability for treatment and for economic analysis. The four levels of these are overburden, oxide, transitional and unoxidised materials. During exploration, reverse circulation (RC) drilling can be used effectively to define these zones by a combination of logging, analysis and provision of cuttings for column leach and bottle roll trials. RC cuttings can he used effectively for column leach trials, when calibrated against conventional processing-sized samples, obtained from surface. Tbis allows metallurgical testing to depth and definition of transitional ore types and the base of oxidation, accurately and economically with an acceptable density of samples. The accurate prediction of base of oxidation and variations in recovery with depth and ore types can be used to develop 'economic' pit designs with zones of variable recovery. Petrological studies of leaching results and examination of mineralisation types carried out on concentrates, provide information on gold distribution and physical and chemical constraints. The examination of concentrates can be particularly useful for types of mineralisation when overall gold content is frequently at or below one pan per million. Explanation of anomalous recovery of gold grains in dense goethite and solution-robbing by carbonaceous material can be identified by use of petrological and scanning electron microscope. An understanding of the role of the host rock in leaching characteristics can also he provided by petrology where siliceous or clayey materials can require significantly different treatment.

Jan 1, 1994

Mining is a high risk, high capital and potentially high reward undertaking. A large proportion of the risk comes from a lack of definition of the orebody (which also provides some of the potential) and the unpredictable nature of the market. This makes the planning process difficult but encourages the development of a robust yet flexible mining system. The system should be capable of absorbing some deviation from the anticipated concept without a significant impact on profitability. The mine planning process tends to consist of a series of related but discrete stages. For instance, the pit shells are designed, a schedule for the pit shells is created, a plant fleet is chosen to achieve the schedule and a financial analysis is carried out on that scenario. It is likely a few iterations are carried out using various mill throughputs to produce a favoured financial result. The problem is that handing results from stage æBÆ for use in æCÆ doesnÆt encourage a flexible system. æCÆ is likely to be built for exactly æBÆ. Unfortunately, in mining, æAÆ (the orebody) has the highest potential for variability and impacts everything else downstream. æDÆ the market also has high potential for unplanned variability. These variations can spread and æreverberateÆ through the whole mine process. For example an unexpected increase in ore oversize impacts all downstream mine processes to the primary crusher which may in turn create problems back æupstreamÆ by restricting throughput rate. Also an unexpected drop in demand or price could require modifications to the planned production rates. This paper looks at how mining process simulation can be used to support the development of strategies to counteract unforseen circumstances or alter production to match fluctuations in demand and price.

Jan 1, 2003

By L M. Lobato, J C. S Seoane, F J. Baars

The Carajßs Province presents several volcano-sedimentary sequences that comprise the Itacai·nas Supergroup. The rocks represent bimodal volcanism, and clastic and chemical sedimentation in relatively unstable basins subject to recurrent structural events with subsidence and volcanism. The Grpo Parß Group represents one of these sequences with mafic volcanic rocks that enclose discontinuous jaspilite lenses, with development of large high-grade orebodies (Fe >65 per cent). This unit is named the Carajßs Formation and presents peculiar characteristics compared to other iron districts in the world, thereby departing from the classic Lake Superior or Algoma iron formation types. Owing to the dense vegetation, lack of outcrops and harsh landscape, the structural analysis of the district can only be accomplished by combination of regional field work, detailed structural work on the open pits, and remotely sensed image interpretation, in this case Landsat ETM7, JERS-1 images and the SRTM digital terrane model. The regional trend of the several sequences of the area is approximately N-S and the structure is dominated by a flattened flexural fold system with axes moderately dipping WNW, intersected by several strike-slip faults subparallel to their axial plane. The Serra dos Carajßs represents an s-shaped synform-antiform pair, herein named the Carajßs Fold. This regional structure is partially disrupted by the Carajßs Shear Zone that divides it in the northern (Serra Norte) and the southern (Serra Sul) Ranges and also probably prepared the terrane with the development of pathways for mineralising hydrothermal fluids forming large high-grade massive iron bodies. Syntectonic granitic bodies played an important role in the structural evolution of the area as well. They caused localised ductile flattening deformation and thermal contact metamorphism in surrounding terranes. The Estrela pluton, for instance, was responsible for the discontinuity of the regional trend between the Serras do Rabo and Leste. The Carajßs Province is regionally the upper crustal product of a very shallowly eroded dome-and-keel geometry of Neo-Archaean volcano- sedimentary units intruded by syntectonic calc-alkaline intrusives and overlying pre-existing infracrustal rocks. The lithostructural data suggest continental-margin back-arc basin development and closure in an oblique collision belt, with N-S shallow crustal shortening, parallel to the inferred pre-existing strike of the stratigraphy.

Jan 1, 2005

By Mark C

Designing coal pillars to provide resistance against overburden loads has long been an aim of rock mechanics engineers. The need for accurate pillar strength models has become.more urgent as greater overburdens are encountered and pillar sizes grow larger. Current pillar design models differ widely in their predictions of the trend in pillar strength with increasing pillar width- to-height ratio. The goal of this paper is to evaluate current pillar strength theories, using a comprehensive data base of stress measurements from coal pillars. The stress measurements indicate that coal pillars maintain relatively high stresses near the ribline, and that the stress gradient within the yield zone can be approximated as a straight line. Several problems are identified for further research, including calibration procedures for different types of stress cells, strain softening behavior in the yield zone, and measurement of stresses in the cores of very wide pillars.

Jan 1, 1992

The Auscoke project has reached-a stage where a pilot plant nominally able to produce 100 t.p.d. of coked briquettes is being brought on stream during Nov. 1971 . The targets for this stage of the project are to establish the technological and economic value of Auscoke for the iron blast furnace, and to verify the commercial feasibility of large scale plants. The project originated at the B.H.P. Central Research Laboratories (C.R.L.) and work to date has shown that using a two stage contin- uous process, strong large coke can be produced at good productivities from medium or low volatile poorly caking coals. General features of the pilot plant and processing are discussed.

Jan 1, 1972

Inefficient conveyors suffer carryback, leading to the build-up of materials on idlers, and other expensive components. They spill and leak material at loading zones and transfer points, causing accumulations that can damage the belt, wear moving components, and increase both cleanup labor and maintenance expense. They wander or mistrack, spilling material and en- dangering personnel and conveyor components, including the belt itself. And through these inefficiencies, they multiply an operation's hidden costs-the dollars lost because of missed production, of increased downtime, of the expense for the replacement of prematurely worn or damaged equipment. In this paper, the author will examine the importance of belt conveyors to mines and process plants He will trace the state-of-the-art in systems for cleaning belts, and controlling the release of fugitive material from conveyor transfer points, by exploring the roots of the problems, and demonstrating solutions that have been proven to be effective. Included in these systems to improve material handling are transfer point stabilization and sealing systems, dual belt cleaning systems, and belt training idlers.

Jan 1, 1991