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By Ehab Gomaa, K. A. El‑Nagdy

Backfilling material such as tailing (mine wastes) mixing with cement or gypsum has grown throughout the world’s underground mines. However, despite their growing popularity, the typical hydraulic and mechanical fill types utilized in many mines still exist. Deep underground mining has increased due to the lack of commercial minerals nearby. Mine wastes were considered the main part of backfilling to prevent environmental pollution, ground subsidence after mine abandonment, and mine collapse during deeper extraction phases. The cemented backfill technique is the principal technique used in underground mines, which include cement with fly ash and/or filter dust, cement with tailing material and fly ash, gypsum with fly ash, and synthetic anhydrite with fly ash and have been reviewed. It has concluded that a backfilling material must be selected based on further goals, available material near the mine site, and economic factors. This paper analyzes different backfill material mixtures to create a technique that will increase safety in underground mining conditions and foresees an appropriate formula that gives high uniaxial compressive strength. The multiple linear regression (MLR) on the collected data from the experimental works to construct the relationship between the uniaxial compressive strength (UCS) of the mixture and the components of the backfilling and the prediction formula for expected compressive strength was obtained. The results revealed that the predicted regression equation was robust and reliable to predict the (UCS) for the new components of the filling (cement (CE), filter dust (FD), water content (WC), and time (T)).

Oct 3, 2023

By Y. J. Son, S. S. Nageshwaraniyer, K. M. Kim

"This paper reports on the development of a simulation-based framework for obtaining optimal blast design parameters for a hard-rock mine. To do this, a conventional medium-sized hard-rock mine was taken as a case study. The mine has two pits containing hard and soft rock types. The proposed framework contains a combination of regression analysis using Excel software by Microsoft and discrete-event simulation using Arena software by Rockwell Automation, applied to construct a model of the material-handling network of the mine. Specifically, blasting parameters are estimated by Excel-based regression analysis, processes including blasting and haulage from pits to crushers are modeled by a Forward Blasting simulation submodel, and material-handling operations including crushing, storage in stockpile, and haulage via conveyors and into SAG and ball mills are modeled by a Crusher to Ball Mill simulation submodel. A Reverse Blasting submodel is then used to obtain the optimum blast design corresponding to a target P80 particle size. Using the proposed framework, an economic analysis was performed to demonstrate the cost savings that could be realized for each rock type as a function of specific explosive energy. IntroductionIn a modern hard-rock mine, various processes such as drilling, blasting, crushing, grinding and mineral liberation are optimized to increase productivity, a practice known as mine-to-mill (MTM) optimization. Blasting is important in MTM optimization as it is the first comminution process and has an impact on all downstream processes (Julius Kruttschnitt Mineral Research Centre, 1996; Nielsen and Lownds, 1997; Nielsen and Malvik, 1999; Chung and Katsabanis, 2000; Kim and Kemeny, 2011a; Kim and Kemeny, 2011b).Two main research topics have emerged in the area of blasting design: (1) identifying the optimal target blast fragmentation at each shot and (2) controlling the blast fragmentation for that target. As part of an MTM optimization study, Kim and Kemeny (2011a; 2011b) developed a site-specific blast fragmentation prediction model that can be used to identify the target blast fragmentation and can be incorporated into MTM optimization. They also reported methodology for assigning model parameters easily and with minimal human bias."

Jan 1, 2015

By Donald L. Bott

A computer model called the Quality Compliance Model was developed to optimize the mine planning and sequencing in area coal mining with respect to the limit on pounds of sulfur dioxide per million BTU imposed by regulations. The objective of the model is to maximize the amount of high sulfur coal mined from various benches while meeting the specified compl'ance standards. Given multiple seams and multiple benching operations, the mining sequence from each pit is simulated. The rate of mining is controlled such that the in-pit blending will maximize the usage of high sulfur coal and meet compliance standards. The compliant coal can be stockpiled for usage at a later date, or it can be disassociated. This calculation can be based on any given rate of production, i.e., from as small a unit as a unit train to as large as monthly or yearly production.

Jan 1, 1982

By Stanislaw Nawrat, Waclaw Dziurzynski

An increasing concentration of coal production, especially in the circumstances of intensive methane inflow makes the coal mine managing staff apply new techniques of safe mining. It paves also the way for scientists to develop new directions of investigations and implementation of state-of -the- art technical solutions. Simultaneously, it could be noticed that the funds assigned for expansive 'En situ ' investigation are continuously decreasing. Better and better results are reached when applying computer technique in calculations of the parameters of ventilation process. Recent theoretical and experimental investigations of air and gas (methane) flow in longwall areas with caving, combined with the implementation of methane drainage system allowed to create, a mathematical model and consequently to elaborate a computer supported numerical simulation of discussed phenomena. The mathematical model has been modified and the simulation program was prepared in such a way that the software is convenient for a user looking for an optimal solution. The paper presented the methodology of optimal choice of following parameters: - ventilation system - rate of flow through the wall. The procedure takes into consideration keeping a safe level of concentration methane in air flowing through the longwall as well as the criterion of maximum methane concentration within the methane drainage pipe line. Results of variant computer simulation regarding the longwall with caving are shown in graphs and tables.

Jan 1, 1995

By A. I. Kalugin, A. A. Abramov, D. E. Kozlov

As a result of thermodynamic analysis of a mineral-sodium, oleate-water system, flotation and adsorption tests at various pH values, and sodium oleate concentrations, it has been established that due to regularities of phosphate-containing minerals (fluorapatite, hydroxyapatite, carbonatapatite) flotation cannot be explained by the formation of alkali-earth metal oleates on their surface. This paper presents a novel theory that connects optimal conditions for mineral flotation with zero charge of its surface, which can explain the regularity of minerals flotation observed. The quantitative physicochemical flotation models developed based on the theory are suitable for improving industrial processes, conditioning of recycling waters, and application in automatic control systems at the plants. Key words: apatite, oleate, flotation, modeling, control, and regulation.

Jan 1, 1999

By Wei Bin, Liu Zhe, Liping Xiao, Jichi Bai

The Acid Mine Drainage has characteristics of low pH, high concentrations of heavy metal ions, such as Fe2+, Mn2+, Cu2+ and Zn2+. In this paper, the composite particles that consisted of bentonite and steel slags were used to dispose the Acid Mine Drainage. Bentonite is the mineral materials and can adsorb heavy metal ions excellently. The steel slags are alkaline and industrial solid waste for the treatment of the Acid Mine Drainage. The main influencing factors, such as adsorbent dosages, shaking rates, concentrations of heavy metal ions, temperatures, adsorption time and pH value were studied by the static experiment. Increasing the adsorbent dosages and the concentrations of the heavy metal ions, speeding up the shaking rates, raising the temperatures, extending the adsorption time and improving pH would improve the removal efficiencies of heavy metal ions. Through considering the removal efficiencies and the treatment costs, the optimum reaction conditions for the four kinds of heavy metal ions were obtained. The adsorbent dosage 21 mg/L, the rotational speed 120 r / min, the temperature 25?, adsorption time 100 min and the initial wastewater pH 7. The four kinds of heavy metal ions existed independently in the simulated mine wastewater. The highest initial concentrations of Fe2+, Mn2+, Cu2+ and Zn2+ were 150 mg/L, 100 mg/L, 170 mg/L and 140 mg/L respectively. The removal rates were 93.42%, 92.64%, 93.86% and 95.17% respectively. The determination of the particles’ SEM-EDS Microscopic characterization showed the composite particles could play a part in neutralizing, absorbing and the chemical precipitation. The acidity decreased notably and the heavy metal ions of Fe2+, Mn2+, Cu2+ and Zn2+were adsorbed and precipitated effectively. The research results can extend the practical engineering application of the composite particles.

Jan 1, 2017

By J. C. Yingling, R. Kumar, J. Sottile

The capability for on-line measurement of the quality characteristics of conveyed coal now enables mine operators to take advantage of the inherent heterogeneity of those streams and split them into wash and no-wash stocks. Relative to processing the entire stream, this reduces the amount of coal that must be washed at the mine and, thereby reducing processing costs, recovery losses and refuse-genera¬tion levels. In this paper, new ap¬proaches for optimal control of the segregation process using time-se¬ries models and empirical distribu¬tions are presented and demon¬strated using field data.

Jan 1, 2000

The capability for on-line measurement of the quality characteristics of conveyed coal now enables mine operators to take advantage of the inherent heterogeneity of those streams and split them into wash and no-wash stocks. Relative to processing the entire stream, this reduces the amount of coal that must be washed at the mine and thereby reduces processing costs, recovery losses, and refuse generation levels. In this paper, new approaches for optimal control of the segregation process, using time series models and empirical distributions, are presented and demonstrated using field data.

Jan 1, 1998

By Thien Sok, Yaojun Lu, Craig Gilbert, Jeremy Scott

Feedwells play a pivotal role in gravity thickeners, governing flow distribution, feed dilution, and flocculation condition during solid–liquid separation. This study presents an optimized design and digital prototyping framework for FLSmidth’s E-volute and E-Duc Feedwell systems, integrating advanced computational fluid dynamics (CFD) with quantitative criteria introduced at SME2024. Building on established FLS technologies, a series of novel configurations were developed and systematically assessed under full-scale and site-specific conditions. CFD provided quantitative insight into flow distribution, feed dilution, and flocculation efficiency, enabling iterative refinement of design parameters. The optimized feedwell demonstrated superior hydraulic performance, enhanced mixing, and improved flocculation outcomes. Beyond the specific design advances, the work highlights CFD as an effective and economical tool for digital prototyping, facilitating early identification of design limitations, reducing dependence on physical trials, and accelerating innovation. The methodology underscores the value of simulation-driven design in advancing feedwell performance and improving thickener technology.

Feb 22, 2026

By Y. Xi

This paper offers an algorithm to determine the optimal panel size with the objective of minimizing the overall stripping cost. The approach is presented both in analytical form for regular layers of coal and overburden, and in graphical form for the cases of irregular and multiple coal seams. When the optimal panel width needs to be changed due to some circumstance, we prove in general that increasing the panel width is better than reducing it in both economics and operational efficiency.

Jan 1, 1994

By S. J. Jung

The prime criteria in the design of underground openings with complicated geological structures is ground control. Stability of underground openings for deep mines is critical because incorrect orientation or geometry of shaft, stope, and accessways often results in the failure of openings due to high stress conditions. Current design procedures for complicated orientation and geometry of mines are rapidly becoming inadequate as mines are being developed. In this study, finite element method has been used with optimization criteria to design more stable and safe underground openings.

Jan 1, 1993

By Karl P. Norrena, Clayton V. Deutsch

Ore and waste cannot always be visually separated. The distinction between ore and waste may need to be made on the basis of blasthole sampling. Hand drawn dig limits or computer-generated contour lines do not account for uncertainty, economics or equipment. Geometric methods for interpreting grade information such as the polygonal or triangulation methods share the same limitations as contouring. Geostatistical techniques exist for the realistic modeling of grade variations and uncertainty. Decision analysis techniques exist for the binary classification of ore, and waste blocks in the presence of this uncertainty. Block-by-block classification is not enough; mining equipment cannot exercise free selection of blocks. There is a need for procedures to determine optimal dig limits that account for (1) the uncertainty in the grades, (2) the economics of risk-qualified decision-making, and (3) the ability of the mining equipment to dig to specific limits. This paper presents a procedure for optimal determination of dig limits that account for these constraints. Simulated annealing (SA) is used with modest computational requirements because the number of variables is relatively small. The solution of the optimization problem is dig limits that maximize profit under multiple constraints. The method is illustrated with different constraints and tested against hand drawn dig limits in a "Dig Limit Challenge," which illustrates the efficacy of the new method.

Jan 1, 2002

By M. E. Gershon

Conventional methods of drill hole site selection are reviewed briefly. Two approaches using geostatistics are then discussed, both of which have been shown to yield improved results. Finally, a branch and bound algorithm is described which will select the best locations for drilling from a user specified number of possible drill sites. Two options are discussed. First, the user can specify a maximum drilling investment or a maximum number of drill holes and the program will select the locations yielding the minimum estimation variance. This amounts to getting the most for a given investment. Alternatively, a maximum tolerable estimation variance can be specified and the program will select the number and location of the drill holes to obtain the desired information at a minimum cost. Another benefit of the approach is the quantification of the tradeoffs between investment and information obtained.

Jan 1, 1985

By Mark E. Gershon

Conventional methods of drillhole site selection are reviewed briefly. Two approaches using geostatistics are then discussed, both of which have been shown to yield improved results. Finally, a branch and bound algorithm is described which will select the best locations for drilling from a user specified number of possible drill sites. Two options are discussed. First, the user can specify a maximum drilling investment or a maximum number of drillholes and the program will select the locations yielding the minimum estimation variance. This amounts to getting the most for a given investment. Alternatively, a maximum tolerable estimation variance can be specified and the program will select the number and location of the drillholes to obtain the desired information at a minimum cost. Another benefit of the approach is the quantification of the tradeoffs between investment and information obtained.

Jan 1, 1983

By K. Norrena, E. Magri

An important problem in mine operations is the classification of material as waste, low-grade stockpile and ore. This classification must often be made with blasthole data that are widely spaced and that have sampling errors. Geostatistical-simulation techniques combined with basic economic principles allow a procedure for classification that maximizes the expected profit. Geostatistical-simulation methods (Gaussian, indicator or annealing-based) allow the integration of hard and soft data in the creation of alternative, equally probable realizations of the mineral grades. At each location, for each realization one calculates the "profit" if the block were to be classified as ore or waste. The optimal classification is the one that maximizes expected profit (a maximum profit selec¬tion or MPS procedure). In this paper, the authors discuss the theoretical justification of the method and implementation details. The use of blasthole data from different types of mineral deposits, that is, different levels of continuity, are considered. The authors also show the efficacy of the procedure with different levels of sampling error. The increased revenue due to the MPS procedure and improved sampling is shown. The paper shows the geostatistical-simulation procedure and the uncertainty in block grades that result from incomplete and imperfect sampling. The optimal classification is presented. Optimal block classifications are transferred to realizable dig limits by hand-drawing polygonal boundaries. The results of the proposed method are compared to classification based on kriging. Limitations and areas of future work are identified.

Jan 1, 2000

An important problem in mine operations is the classification of material as waste, low-grade stockpile, and ore. This classification must often be made with blasthole data that are widely spaced and that have sampling errors. Geo-statistical simulation techniques combined with basic economic principles allows a procedure for classification that maximizes expected profit. Geostatistical simulation methods (Gaussian, indicator, or annealing-based) allow the integration of hard and soft data in the creation of alternative, equally-probable, realizations of the mineral grade(s). At each location, for each realization, we calculate the "profit" if the block were to be classified as ore or waste The optimal classification is the one that maximizes expected profit (a Maximum Profit Se-lection (MPS) procedure). We discuss the theoretical justification of the method and implementation details. The use of blasthole data from different types of mineral deposits, that is, different levels of continuity, is considered. We also show the efficacy of the procedure with different levels of sampling error. The increased revenue due to the MPS procedure and improved sampling is shown. We show the geostatistical simulation procedure and the uncertainty in block grades that result from incomplete and imperfect sampling. The optimal classification is presented. Optimal block classifications are transferred to realizable dig-limits by hand-drawing polygonal boundaries. We compare the results of the proposed method to classification based on kriging. Limitations and areas of future work are identified.

Jan 1, 1999

The authors summarise the development and recent advances in the reconstruction and visualisation of three-dimensional objects from point data and describe applications to the reconstruction of orebody shapes from drill-hole and other data. In particular, Dijkstra's algorithm is proposed and implemented as a means of optimal reconstruction of complex orebody and topographical shapes from irregularly located sample data. The surfaces of the shapes are constructed from triangular tiles and the algorithms proposed by the authors are guaranteed to find the optimal set of tiles that "best" construct the surfaces on the basis of specified objective criteria. The algorithms are illustrated by applications to a complex silver/gold/zinc/lead deposit.

Jan 1, 2002

By G. ALBORNOZ, S. Utili, A. AGOSTI, C. VALDERRAMA, R. PELL, N. Morales

The steepness of the slopes of an open pit mine has a substantial influence on the financial return of the mine. The paper proposes a novel design methodology where overall steeper pitwalls are employed without compromising the safety of the mine. In current design practice, pitwall profiles are often planar in cross-section within each rock layer; i.e., the profile inclination across each layer tends to be constant. Here instead, a new geotechnical software, OptimalSlope, is employed to determine optimal pitwall profiles of depth varying inclination. OptimalSlope seeks the solution of a mathematical optimization problem where the overall steepness of the pitwall, from crest to toe, is maximized for an assigned lithology, geotechnical properties, and factor of safety (FoS). Bench geometries (bench height, face inclination, minimum berm width) are imposed in the optimization as constraints which bind the maximum local inclination of the sought optimal profile together with any other constraints such as geological discontinuities that may influence slope failure. The obtained optimal profiles are always steeper than their planar counterparts (i.e., the planar profiles exhibiting the same FoS) up to 8° depending on rock type and severity of constraints on local inclinations. The design of a copper mine is first carried out employing planar pitwalls, secondly adopting the optimal pitwall profiles determined by OptimalSlope. The adoption of optimal slope profiles leads to a 34% higher net present value and reductions of carbon footprint and energy consumption of 0.17 Mt CO2 eq and 82.5 million MJ respectively due to a 15% reduction of rockwaste volume.

Feb 9, 2022

By G. ALBORNOZ, S. Utili, A. AGOSTI, C. VALDERRAMA, R. PELL, N. Morales

The steepness of the slopes of an open pit mine has a substantial influence on the financial return of the mine. The paper proposes a novel design methodology where overall steeper pitwalls are employed without compromising the safety of the mine. In current design practice pitwall profiles are often planar in crosssection and the profile in between ramps especially tend to be planar and defined by a constant inter-ramp angle. Sometimes rock layers exhibiting different strengths require the inclination of the profile to vary with depth, but the inclination across each layer is usually constant. Here instead, a new geotechnical software, OptimalSlope, is employed to determine optimal pitwall profiles of depth varying inclination. OptimalSlope seeks the solution of a mathematical optimization problem where the overall steepness of the pitwall, from crest to toe, is maximized for an assigned lithology, geotechnical properties and Factor of Safety (FoS). Bench geometries (bench height, face inclination, minimum berm width) are imposed in the optimization as constraints which bind the maximum local inclination of the sought optimal profile together with any other constraints such as geological discontinuities that may influence slope failure. The obtained optimal profiles are always steeper than their planar counterparts (i.e. the planar profiles exhibiting the same FoS) up to 8 degrees depending on rock type and severity of constraints on local inclinations. The design of a copper mine is first carried out employing planar pitwalls, secondly adopting the optimal pitwall profiles determined by OptimalSlope. The adoption of optimal slope profiles leads to a 34% higher net present value and reductions of carbon footprint and energy consumption of 0.17 Mt CO2 eq and 82.5 million MJ respectively due to a 15% reduction of rockwaste volume.

Mar 2, 2022

By G. ALBORNOZ, S. Utili, A. AGOSTI, C. VALDERRAMA, R. PELL

The steepness of an openpit mine’s slopes has a substantial influence on the mine’s financial return. This paper proposes a novel design methodology where overall steeper pitwalls are employed without compromising the safety of the mine. In current design practice, pitwall profiles are often planar in cross section within each rock layer: that is, the profile inclination across each layer tends to be constant. Here, instead, a new geotechnical software, OptimalSlope, is used to determine optimal pitwall profiles of depth-varying inclination. OptimalSlope seeks the solution of a mathematical optimization problem where the overall steepness of the pitwall, from crest to toe, is maximized for an assigned lithology, geotechnical properties and factor of safety (FoS).