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By Patrick Pelletier, Pierre-Alexandre Bossé, Julie Fournier, Gianni Bartolacci, Jayson Tessier, Ahmed Bouajila, Carl Duchesne

"This paper summarizes research into the study of the control of flotation processes based on froth images. The use of numerical image analysis techniques for the extraction of significant patterns (froth structure and colour) from industrial flotation froths is discussed.First, the froth was analysed by the use of the Multivariate Image Analysis (MIA) method to extract the spectral variation contained in a RBG image. The Partial Least Squares (PLS) was applied to develop the empirical model for the prediction of froth grade. The results of this application are illustrated using one industrial case study.Second, the froth was also analysed by Gray Level Co-occurrence Matrix (GLCM) and Wavelet Transform Analysis (WTA) to extract features related more to morphological aspects. Since there is useful information hidden in froth texture, these methods are used as texture descriptor to classify different types of froths.Third, a control strategy based on a froth structure indicator was developed and implemented on an industrial zinc flotation circuit. The feedback controller uses a reagent flow-rate in order to maintain the froth structure at its set point. Process improvements obtained with the implemented control strategy are highlighted.Finally, the feasibility to implement a hybrid control strategy consisting in a froth structure supervision controller based on the froth concentrate grade estimated by MIA and recovery inferred by image analysis is discussed.INTRODUCTIONThe development of control strategies to achieve satisfactory control performance has always been a great challenge for engineers and the need for improved process diagnosis, control and optimization has become more and more evident for the mineral processing industry in the last decades. That is why new process variables need to be measured particularly in highly multivariable processes such as flotation. This industrial process is subject to a wide variety of disturbances mainly generated by frequent and sometimes abrupt changes in physical and/or chemical ore characteristics and also, due to some irregularities in manual process operating procedures. A flotation circuit scheme is always a complex network of more than two dozens slurry streams. Information about those streams (% solid, metal content analysis and flow rates) is important for process diagnosis performance evaluation and control. Also, because of the grade decrease and increasing complexity of the new processed ores, more instrumentation outputs and more powerful and significant pr"

Jan 1, 2005

Scale build-up in titanium palladium alloy spent electrolyte heat exchangers in the residue treatment plant commissioned at Risdon, Tasmania in 1971 was shown to be a mixture of manganese dioxide and anhydrite (CaSO4). The manganese dioxide was deposited as a result of thermal decomposition of permanganate ions present in the spent electrolyte. It was shown that deposition of manganese dioxide and associated anhydrite scale could be prevented by prior reduction of permanganate ions to the manganous (Mn++) state by the addition of ferrous ions. In the plant this was conveniently accomplished by injecting into the inlet line to the heat exchangers sufficient zinc plant solution containing ferrous sulfate to decolourise the spent electrolyte. This action prevented deposition of such scale for another 21 years, until the heaters were finally decommissioned in March 1992. Measurements indicated that addition of the reducing solution lowered the anodic potential of the titanium alloy by 200 - 300 mV (depending on the solution resistance), but that it was still +300 to 400 mV with respect to a standard calomel electrode. It was shown that, if necessary, a small impressed current could be applied to provide anodic protection. Before scale deposition was overcome by the addition of ferrous sulfate solution, badly scaled heat exchangers were cleaned by recirculating a solution of hydrogen peroxide in spent electrolyte or dilute aqueous sulfuric acid, after laboratory testing of a variety of possible solvents for the scale. Corrosion tests indicated that attack on the titanium alloy by the acidic peroxide cleaning solution was insignificant.

Jan 1, 2005

By N. R. Andrade-Gonzalez

In this paper, the effect of magnesium and strontium additions on the heat treatment behaviour of cast A319,2 alloy was investigated, Permanent mold samples were heat treated at 495 °C for 4 and 24 h, then quenched in hot water and aged at 180 °C and 220 °C for different temperatures, It is found that multiple aging peaks are present in the age-hardening curves of Al-Si-Cu alloys, mainly when Mg and Mg-Sr are added, The results of electron probe microanalysis (EPMA) observations reveal that the age-hardening behaviour is related to the precipitation sequence of alloys, For the Al-Si-Cu alloy, the first aging peak is the result of the high-density GP zones, while the subsequent peaks arise from metastable phases, Obvious intervals during the transition from GP zones to metastable phases may be the main reason of the formation of multiple aging peaks, It is seen that addition of Mg (-0,40 wt %) leads to the precipitation of coarse Al5Mg8SioCu2 particles. When modifying the high Mg alloys, Cu-intermetallics segregate in areas away from the growing Al-Si eutectic regions, Modification with strontium retards the precipitation of the silicon out of the matrix.

Jan 1, 2005

By Jim Rozek, Robert A. Gee

The Epping to Chatswood Rail Line project is the largest publicly funded infrastructure project in New South Wales. Construction commenced in November2002 with opening scheduled for 2008. The work includes 13 route km of twin TBM driven 7.2 m diameter lined running tunnel, three cross-overs and three new underground stations. The new stations have platform caverns of 20m span with similarly proportioned concourse caverns alongside. The ground is bedded sand stone and shale with high horizontal stresses. Predicted stress-relief induced ground movements during staged excavation led to innovative use of rock anchors for permanent support.

Jan 1, 2005

By J Harmse

This paper deals with the modernisation of the brakes on an electrically coupled Blair multi-rope hoist and covers the removal of the old calliper brakes and hydraulic control system, and its replacement with brake discs, disc braking units and hydraulic control systems. The paper covers the braking requirements of the hoist, which is made up of two electrically coupled single-drum hoists, together with the theory behind the choice of brakes and control systems supplied. The paper also covers the project logistics that were required in order to install and commission the new brakes and control systems with the minimum disruption to production on the only rock hoist on a major production shaft. Items covered include the modifications to civil works, pre-installation of bearing lubrication systems, brake discs and hydraulics and the interfacing of the new hydraulic control system to the existing electric control system. It had to be designed to be compatible to a new electric drive and control system due for installation at the end of 2005.

Jan 1, 2005

A metallurgical balance drawn around a mineral processing plant or smelter must involve all process streams crossing the plant boundary. Modern sampling theory, as formulated by Gy, and sound statistical method can be used to determine the uncertainties in the observed assays for the set of balance analytes and in the mass flow rates of the process streams for the balance period. These uncertainties can then be used together with the material balance equations to arrive at adjusted component mass flows that satisfy the material balances exactly. To determine whether or not the data is consistent with the level of uncertainty in the data and with the material balance equations, a goodness of fit test is applied. This goodness of fit criterion is the principal tool to quantify the quality of the material balances. The mathematical structure of the statistical material balance problem poses a number of challenges. For example, while the variances of the adjusted component mass flows do not vanish, the variances of the sums of the adjusted component mass flows about each balance node do vanish, simply because the balancing computation demands that the balances close exactly. Even though it can be shown that the variances of the adjusted component mass flows are always lower than the estimates for the corresponding unadjusted component flows, it is still not possible to construct a confidence interval on the component mass flow into (and out of) a balance node using the adjusted component flows. On the face of it, such a confidence interval is exactly what is most desired from the balance calculations. The problem arises because the balance problem is a data adjustment rather than a parameter estimation problem. It is possible, however, to calculate the recovery of a component to a product stream and determine a confidence interval for the recovery value. It is also possible to calculate an uncertainty in the mass flow of any balance species in any process stream, before and after balancing.

Jan 1, 2005

By Haydn H. Murray

A hydrothermal bentonite located in the high Sierras in Nevada is being mined and processed to produce a natural dietary supplement. The minerals present are smectite, gypsum, jarosite, quartz, feldspar, kaolinite, goethite, hematite and zeolite. The clay material was analyzed for respirable crystalline silica, asbestiform minerals, heavy metals and dioxin. No asbestiform minerals are present and the crystalline silica, heavy metals and dioxin are all less than the maximums set by Federal and State agencies. The clay material was analyzed chemically for all major, minor, trace and rare earth elements. The geology, applications and analyses will be discussed in the paper.

Jan 1, 2005

By S Sondashi, F. J. Chidley, W. A. Grobler

Some of the challenges facing the flotation of base metal sulphides are the opening of new and varying ore bodies as well as maintaining essential skills in plants. Flotation reagent research focuses not only on improving flotation grade and recovery, but also on producing reagents robust enough to cope with changes. A group of recently developed co-collectors, activators, depressants and frothers are described together with a summary of results measured on base metal sulphide ores.

Jan 1, 2005

By Ji-He Wei

Keywords: stainless steel, AOD refining, side and top combined blowing, mixing characteristics, water modeling The fluid mixing characteristics in the bath during the side and top combined blowing AOD (argon-oxygen decarburization) refining process of stainless steel have preliminarily been investigated on a water model unit of a 120 t AOD converter. The geometric similarity ratio between the model and its prototype (including the side tuyeres and the top lances) was 1:4. On the basis of the theoretical calculations for the parameters of the gas streams in the side tuyeres and the top lances, the gas blowing rates used for the model have more reasonably been determined. The influence of the tuyere number and position arrangement, and the gas flow rates for side and top blowing on the characteristics has been examined. The results demonstrated that the liquid in the bath underwent vigorous circulatory motion during gas blowing, without obvious dead zone in the bath, resulting in a well mixing effectiveness. The gas flow rate of the main tuyere had a governing role on the characteristics, a suitable increase in the gas flow rate of the subtuyere could improve mixing efficiency, and the gas jet from top lance could make the mixing time prolong. Corresponding to the oxygen top blowing rate specified by the technology, a roughly equivalent and good mixing effectiveness could be reached by using six side tuyeres with an angle of 27 degrees between each tuyere, and five side tuyeres with an angular separation of 22.5 or 27 degrees between each tuyere. The relationships of the mixing time with the gas blowing rates of main-tuyeres and sub-tuyeres and top lance, the angle between each tuyere, and the tuyere number have been obtained.

Jan 1, 2005

By W. J. Birch, M. Kirke

Despite increasing competition from mechanical methods of tunnelling, the drill and blast method is often still the most viable method of excavating tunnels in strong and abrasive rock. To advance a tunnel using drill and blast, explosives are loaded into boreholes in the rock and detonated according to a prearranged sequence. On detonation of the explosive, the rock is fractured and displaced from its original position, leaving behind the desired void. Among the secondary effects of a tunnel blast are ground vibrations caused by elastic disturbances that propagate away from the blasted tunnel face. The possibility that such ground vibrations may cause permanent damage to property and substantial nuisance has generated significant opposition to the use of drill and blast, particularly in urban areas. It is therefore essential that the blasting engineer is able to predict Peak Particle Velocity (PPV) vibration levels at locations in the vicinity of the blast site. Such predictive capability enables the engineer to design blasts so as to ensure that ground vibrations can be kept within acceptable levels. The objective of this project was to analyse data obtained from the ground vibration monitoring program undertaken during the drill and blast excavation of a hard rock tunnel in Central England. Seismograph recordings of tunnel blasts contain a vast amount of information that cannot possibly be expressed using a single PPV value. The main focus of the study was to investigate whether predictive capability could be improved by using scaled distance models derived for selected PPV components relating to specific detonator timings in a given tunnel round. This study has established a method of analysis that can unlock this information for predictive purposes. By permitting the extraction of sub-event Peak Particle Velocity (PPV) values and allowing Scaled Distance (SD) models to be derived for individual period numbers or groups of period numbers, the method has the potential to vastly improve PPV prediction from tunnel blasting. The method established could also help diagnose blasting problems and help target blast design modifications, resulting in improved efficiency and excavation rates.

Jan 1, 2005

By Dalva L. Moellenberg

Introduction Hard rock mine closure (often referred to as decommissioning), mined land reclamation and financial assurance requirements are receiving considerable attention by governments and organizations around the world. In the United States, federal agencies and the states continue to consider and make changes to laws governing mine closure and mined land reclamation, most of which were originally enacted in the mid-1970’s through the mid-1990’s. Internationally, a number of prominent groups and various countries currently are considering new laws, regulations and policies for mined land reclamation. For example, the European Union has conducted a review of existing European laws concerning mining wastes and mine water and is considering new directives concerning mine waste and mine water management and liability schemes that are likely to significantly impact mine closure and mined land reclamation. Many countries, particularly those outside of North America, Europe, and Australia, have recently adopted or are considering new mine closure and reclamation legislation and regulations. These include significant hard-rock mining countries such as Chile, Peru and South Africa. This paper identifies recent developments in hard-rock mine closure and mined land reclamation laws in the United States, focusing on several of the more significant and controversial developments. It also discusses some of the more significant international efforts to consider mine closure and mined land reclamation laws and policies and some of the notable conclusions and trends from those efforts. The focal issues discussed in this paper include requirements for the reclamation of open pit mines, including backfilling; consideration of and measures to address the mining of sulfide ores and potential for acid mine drainage; and new requirements for the estimation of closure and reclamation costs and for financial assurance for closure and reclamation.

Jan 1, 2005

By S C. Dominy

The Bendigo Goldfield is located in the state of Victoria, Australia, and is one of a number of quartz-reef fields that make up the greater Central Victorian Goldfield. At Bendigo gold particles are characterised by their very coarse nature, ranging from below 100 to over 10 000 ¦m in size. Some 60 per cent of the gold occurs in particles greater than 1000 ¦m in size. This characteristic ensures that the mineralisation is very challenging to both sample and evaluate. Diamond drilling provides a measure of geological structure, but is a poor measure of in situ grade, understating it by up to 75 per cent. Drilling combined with on-reef development, bulk sampling and geological interpretation has been used to define Indicated Mineral Resources. For grade control, a balance had to be sought between sample representivity, cost, turn around time and practicality. Sampling of extreme nugget effect deposits generally requires the use of bulk sampling in order to be representative. However, the cost and turn around time is significant. As a result, a 50 kg micro-bulk sampling system has been introduced that attempts to overcome these problems by providing a fast, practical method that can discriminate between ore and waste. As the mine passes into production, grade control will increasingly become dependent upon geological data collection and interpretation.

Jan 1, 2005

By Nii Allotey Odunton

One of the primary responsibilities of the International Seabed Authority?s Secretariat (the Secretariat) is to assess the quantities of metals present in seabed polymetallic nodules in the International Seabed Area under the Authority?s jurisdiction. To carry out this responsibility, the Secretariat periodically undertakes an assessment of the reserved areas in the Clarion-Clipperton region of the northeastern Pacific (CCZ) using the data submitted by the registered Contractors and maintained in the Authority?s POLYDAT database. The results of its most recent assessment demonstrated that the information submitted by the Contractors, though satisfactory for some purposes, does not permit the in situ quantities of metals in these areas to be estimated with a degree of confidence that is comparable to many land-based mineral resource estimates. Our strategy is to divide the work into two distinct but closely related efforts; one to draft a Prospector?s Guide that provides a narrative description of the key geological and oceanographic data that may be related to deposit abundance and metal content, and another that we call the Geological Model, that summarizes and documents the quantitative resource assessments accomplished in the project.

Jan 1, 2005

By Steven W. Hunt, Isabelle Lamb, Steven B. Fradkin

Groundwater control is generally an important consideration and significant source of risk during most tunneling projects. Proper baselining of groundwater conditions requires: 1) a thorough understanding of the geological environment; 2) a focused site investigation; 3) identification of construction and adjacent property damage risks associated with inflows and short and long term piezometric level changes; and 4) consideration of contractual issues including restrictions on means and methods and pay items for associated work. This paper provides an overview of groundwater baselining issues and risks based on selected design studies and construction case histories.

Jan 1, 2005

By J Austin, R Bitencourt

Differences between the long-term model (LTM) and mine geology system (MGS) grade control block-outs on a blast block scale can impose difficulties to planning crusher feed grade and tonnes on a monthly to weekly blend basis. Detailed geological input to short-term planning has been integral to improve the performance and reduce risk in six-week to three-month production schedules and local variability in tonnage and grades is often not accurately represented in the LTM. The challenge of producing to combined target specifications from different mine sites in an integrated mine to ship business has been reduced with the creation of blast blockout-based short-term model. These short-term blast block models (STBBM or STM) are robust predictive tools created for upcoming benches of current mining areas by firstly collecting data from the pit in the form of bench and face mapping and projecting the structure and stratigraphy down to the next bench. A wire-frame of the projected contacts based on material destination from production blockouts is created and then checked against the LTM. Blast block data from the bench above including assay results and material logging is extracted and validated according to the projected wire-frames (geozones). Individual blast blocks and a full block model are created for each bench production defined by the STP (bench plans). Data output from the STM is in a compatible format for import into scheduling specific software packages. Additional information is incorporated into the STM to allow querying of drill penetration rates, predicted powder factors, material hardness and feed type to further aid in the production planning process and cost forecasting. To date, reconciliation of the STM has been pleasing and certainly an improvement on the LTM, especially in areas where variability is higher due to geological complexity. Short-term predictions derived from in-pit geological observations allow mine planners to more confidently decide on mining block sizes and schedule tonnages and grades, reducing the risk component attached to developing production schedules based directly upon long-term orebody models and mine plans.

Jan 1, 2005

By Scott A. Shuey

Keywords: E-Waste, Pyrometallurgy Many might think addressing the issue of e-waste is a new area of study. Electronics disposal has been discussed in some circles for at least the past 25 years. The recycling of electronic waste (e-waste) tends to be a rather complex undertaking when considering the intimate bonding of materials in the average printed circuit board. The development of a recycling process is further complicated when considering the wide variety of products being generated under the heading of ?electronics.? Focusing only on the primary constituents (polymers, Cu, Al, Fe, etc.) tends to lead one to fairly simple flowsheets. Ignoring trace elements, and the various halide species generated, will lead process engineers down a development path that is sure to cause material handling issues. Researchers at Colorado School of Mines are modeling the complex chemistry that exists within the body of e-waste?comprising 39 of the known elements. An understanding of the systems thermodynamic behavior will result in the development of a more robust, long-term process for the recovery of valuable materials from the e-waste stream.

Jan 1, 2005

By M. P. D. Ingunza, Júnior Santos, F. S. D. Araújo, A. L. C. Araújo, J. Y. P. Leite

Wastewater sludge is a problem for environmental control and it is necessary alternative researches for its reuse. Industries can research the association of clay and sewage sludge as a source of ceramic mass. This procedure can contribute for the industry sustainability including in its raw materials, wastes of environmental concern. This paper presents the results of sewage sludge and clays characterization being analyzed particle size distribution (sedimentation), mineralogical (X-ray diffraction), chemical composition (X-ray fluorescence), thermal analysis, density, and Atterberg proprieties (liquid and plastic limit; plasticity index) and also their applications in ceramics. Results were used to determine moisture for mass of raw material and sewage sludge and there were realized tests of fired in kiln at temperatures used in ceramic industry for bricks production. In the test pieces were analyzed the properties for application as bricks.

Jan 1, 2005

By A. R. Biggart, A. Walters, G. J. E. Kramer

The Owner Procurement Process or OPP is a proven, viable alternative contract delivery method that is potentially applicable to many tunnel projects. Using the OPP, the owner specifies and procures major tunnel construction items such as tunnel boring machines and tunnel linings and provides them to a tunnel excavation contractor in order to manage risk and accelerate project schedule. However, due to industry perceptions regarding potential owner risk, it is seldom considered or is rejected out of hand. In fact, past performance demonstrates that the process significantly minimizes owner, contractor and over-all project risk and mitigates the impact of any claims and differing site conditions. The paper outlines how the process should be structured to achieve schedule, cost, quality and risk management benefits. Potential and perceived disadvantages are discussed and how the process can be structured to mitigate or avoid them. The planned implementation of this process on the tunnels for the Silicon Valley Rapid Transit Project in San Jose, California is discussed.

Jan 1, 2005

By M Dunglison, P M. Cameron

Simultaneous mass-balancing of a mineral processing flow sheet results in adjustments to each data point that reflects the accuracy and precision across the full set of data. In this way, all the good work that goes into designing the sampling and analysis protocol for each sample point is leveraged in order to produce a æbetterÆ set of balanced numbers for every sample point in the circuit. Few operating plants employ whole of circuit balancing techniques to produce reported operating results. This situation is changing with the application of mass balancing technology which utilises redundant data for production accounting and metal reconciliation from product to ore source across multiple phases and multiple time periods. Mine and plant data can now generate credible information to improve productivity. Mine and plant personnel can now use consistent data sets for review and planning. Decisions based on balanced data can be made quicker and with increased confidence.

Jan 1, 2005

By G A. Partington

Recent research has highlighted the potential of a relatively new style of gold mineralisation related to granite intrusion. New discoveries in Alaska, Central Europe and Asia and Eastern Australia with total resources of 1600 t Au offer attractive targets for regional exploration in areas which may have been overlooked in the past. A spatial information system was developed to target granite-gold systems in eastern Australia and the West coast of New Zealand, using well constrained geological and exploration models derived from current research. Target areas were recognised in Queensland, New South Wales, Victoria, Tasmania and on the West Coast of the South Island of New Zealand that have similar spatial data relationships to known granite gold mineralisation elsewhere in the world. The second phase of the modelling better constrained the regional scale target areas by including more detailed geological, geochemical and geophysical data in the GIS to develop prospect-scale targets and to allow the acquisition of tenements over these areas. A geological review of each target area was carried out in the field to put the GIS models into context. The fieldwork has highlighted the potential for this style of mineralisation in New Zealand and will increase investment in mineral exploration and development in New Zealand in the near future.

Jan 1, 2005