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By Allan R. Ide

It is a great pleasure for me to speak-before such a prestigious group as the American Institute of Mining, Metallurgical and Petroleum Engineers. The substance of my talk today is the handling of coal and petroleum coke: their characteristics and environmental problems, and how we were able to correct the problems, prescribe the cure and enjoy the benefits. When coke first became a by-product derived from the oil refineries everyone would have been very happy if someone had offered to take this pro- duct off their hands. Unfortunately, there was no market at that time, and no one seemed interested. Soon thereafter, it became a sellable product and began to be shipped to many countries in the world. This was when all of the pollution problems began. I will be talking briefly about some of these problems and showing a short film on this subject afterwards.

Jan 1, 1984

By G Le Juge, K Waldock

The current suite of bulk mining explosives has been available to the industry for over 20 years. The flexibility and performance of ammonium nitrate based emulsion blend explosives were accepted by the mining industry in the early 1980s. These water resistant explosives rapidly displaced the water gels and slurries developed during the previous two decades. However, since the 1980s there has been no equivalent step change to the basic formulation or application of bulk explosives, although there has been a continuous process of refinement with respect to stability, handling characteristics and most significantly, cost. In the 1980s explosives supply contracts were awarded based on technical evaluations, usually accompanied by field trials. Technical personnel from both mining companies and explosives suppliers dominated the negotiations and there was a strong focus on explosive energy and blasting requirements. Today, explosives from alternative suppliers are difficult to differentiate on the basis of energy so the focus has shifted to aspects of service and price û bulk mining explosives are now largely treated as a commodity and the negotiations are dominated by commercial personnel. Commercial pressures from large mining companies have seen a substantial reduction in the real price of explosives. However, this has come at a cost. In order to reduce manufacturing costs, emulsion formulations have changed. In general they are not only cheaper, but also less energetic. Powder factors have had to increase to achieve the same blasting results, especially in hard ground. It is debatable whether the mining companies have achieved all of the economies they were seeking. This paper discusses these issues and argues that the mining industry would benefit from taking a more technically driven approach to meeting their blasting requirements. Recent trends towards more open contracts between the mining companies and their suppliers can be extended to explosives. To achieve this, mining companies will need to acquire sufficient technical knowledge to take a more pro-active approach to specify the characteristics of the explosives required to maximise the economic performance of their operations.

Jan 1, 2004

By A. S. Broesder

"With depletion of global ore deposits, there has been an increasing industry trend towards mining of lower average grade deposits in order to meet global demand, resulting in increased processing cost, energy usage and water usage. Consequently the industry is seeking pre-concentration technologies to reduce costs, increase production in existing operations and potentially enable the economic mining of previously uneconomical deposits. This pre-concentration can also advantage downstream processing and metal recovery. CSIRO has developed a large scale magnetic resonance based technology for the rapid quantitative detection of selected copper, iron and arsenic minerals in bulk ore. The technology is suited to measurement on large primary conveyors for enabling “pod” based sorting. The approach used in high tonnage sorting is to not sense and divert individual rocks, but to instead measure groups of rocks (“pods”) carried continuously on a single primary conveyor that can be diverted by conventional mechanical means. Bulk ore sorting operates by removing barren ore pods from a stream of crushed ore based on a bulk sensor measurement at a pod resolution of ~1 – 10 tonnes. The sorting process is based on the intrinsic variability of grade during the mining process that often occurs at the few tonne scale, and for instance, is common in many porphyry copper deposits. The MR technology has been proven in the laboratory for a wide range of copper, arsenic and iron minerals. A full scale prototype sensing system has been demonstrated in a trial at an Australian copper mine. Implementation trials of commercial MR based bulk sorting systems are progressing during 2018.INTRODUCTION An increasing trend in the mining industry is the exploitation of larger lower-grade deposits to meet global demand. Low-grade deposits involve increased processing cost, energy and water usage and increased tailings. There is therefore growing interest in technologies that enable more efficient extraction of low grade deposits. Water intensity of mining activities in a context of water scarcity, and the environmental and health implications of mine tailings are existing challenges, which are only made worse by the progression to lower grade orebodies. There is therefore also an interest in safer, cleaner and less wasteful extraction and production to ensure community well-being and environmental resilience."

Jan 1, 2018

By Javier Ramirez

"Recent R&D pilot plant testing was done to validate a full industrial scale system for recovering residual magnetite from the tails of an iron ore concentration plant. The recovery system is based on an autogenous heavy media separator treating a tailings slurry at 0.45% solids by weight. A 3,100 m3/h capacity concentrator was installed based on the testing findings. Excellent metallurgical results have been observed in two years of continuous operation. This experience is the basis for the proposal of a novel process consisting of the preconcentration of base metals ores; the idea being to obtain a heavy bulk concentrate of the polymetallic minerals and discarding in one step the light gangue mineral components. The bulk concentrate then proceeds to conventional froth flotation. The reduced volumetric flow of the bulk concentrate allows a reduction in the size of the subsequent flotation circuit. A prerequisite for the heavy media separation is a fine size grinding of the ore and a correspondingly high degree of liberation of the mineral species to be recovered. A process scheme is also presented in which the gravity concentrator works in conjunction with a companion tailings thickener for process water recovery. The underflow from this thickener, having paste consistency, can be sent to a tailings dam or mixed with Portland cement for mine backfill. The process water in the system is managed at an estimated recovery in excess of 98%. Additional R&D work using this novel approach is being considered by a large iron ore concentrator for removal of liberated silica from the final concentrate; and for upgrading 3.5 million tons of a marginal hematite reserve owned by the mining company.INTRODUCTIONGravity preconcentration (static and dynamic) of sulphides prior to froth flotation has been and is being practiced at various concentrator plants (Asarco´s Young Mill: heavy media cone; Mount Isa: DSM cyclone; Afton Mines: Denver jigs; Tsumeb Mine: Reichert cone) (Burt, 1984). The idea behind installing preconcentration equipment is to reduce the volume of feed processed on flotation, thus requiring smaller flotation plants although other advantages may be of importance, such as obtaining richer concentrates due to higher grade feed, better process water and energy management, and reduced flotation reagent consumption.The SedconTM solid/liquid separator is a versatile process unit patented in Mexico (MX/u/2007/000305). As a gravity device, it may be classified as an autogenous heavy media dynamic concentrator. Figure 1 depicts the Sedcon (Sedimentador de conos) separator. The four main components are as follows: the feedwell for efficient mixing of the pulp with dilution water and flocculant (and coagulant for water clarification); the inner cones (passive elements for solid/liquid separation); the discharge underflow cone; and the scraper mechanism. The standard discharge cone is a 60° inclined cone for general applications. For paste tailings thickening applications, a deep cone with a 69° inclined cone is used."

Jan 1, 2016

By J. Visman

"The Compound Water Cyclone is a concentrator for the wet processing, in bulk, of finely divided materials such as slack coal, fine ores and mineral sands. It was originally developed by the Fuels and Mining Practice Division of the Mines Branch, Department of Mmes and Technical Surveys, Ottawa, for the cleaning of friable slack coals and slurries.Since its introduction in the coal industry in 1962, its application to other materials has also been studied, with special emphasis on simplicity of operation and low over-all cost per ton of finished product .In this paper, a description is given of commercial two-stage units presently available for the processing of granular materials, including wastes a1:1d other low-grade products. A pneumatic control system is used for operating the cyclone under back pressure .and for automatic cut-point adjustment. An account is given of results obtained on coal mineral sands and ores in the Wes tern Regional Laboratory of the Department of Mines and Technical Surveys. Results of several industrial applications are discussed."

Jan 1, 1966

By I M. Platten, Y Xie

Complex gold deposits are generally characterised by variable geometries, strong structural controls on grade distribution and a high-nugget effect. The use of diamond drilling and fire assays in this environment often results in an understatement of grade. Bulk samples are likely to be the closest estimators of true grade, and may be required to evaluate geological/grade risk during resource estimation/feasibility studies. Any bulk sampling program requires appropriate planning and implementation. The planning stage should attempt to delimit the extent and nature of mineralisation; characterise mineralogy and metallurgical properties of the ore; and define bulk sample size and how it will be sampled/processed. The approach to sample processing will be governed by the results of metallurgical testing and geological knowledge. Careful design of sampling protocols must be undertaken through material characterisation, understanding of gold particle sizing and the application of GyÆs Sampling Theory.

Jan 1, 2008

By H. Thalenhorst

For an advanced mineral exploration project that has a ?nugget? issue making the assessment of the deposit grade difficult, a bulk sampling program using a sample tower can provide information that is otherwise not obtainable prior to actual production. This information includes the verification of predicted resource grades for the bulk sample tonnage (and, indirectly, of the methods and parameters used for the grade estimate), confirmation of the physical and grade continuity of the mineralization, and geotechnical data for a future mining operation. The information gathered will improve the input of a feasibility study, particularly with respect to expected mining grades, which are the key economic parameter for most mining projects. The bulk sample rejects can be used for pilotscale metallurgical testwork. Bulk sampling is also useful in cases of potentially biased drill-hole assay results and in the reliable determination of ore grade before shipment of ore from production or development operations to an external beneficiation plant. This paper presents a practical bulk sampling and sample preparation protocol, lists design features for the sample tower, examines the sampling errors that will be encountered, provides information on quality control procedures, and looks at the costs and benefits of such a program, based on the experience of undertaking bulk sampling programs during the period of 1985 to 2008.

May 1, 2010

By H Kurth, L Balzan

The potential for bulk diversion was identified and quickly implemented following the development of bulk sensing technologies applied to conveyed flows. In the early 1980s real time analysis of ash in coal was intended to improve the understanding and control of quality variability. By the end of the 1980s approximately 5% of coal analysers installed were being utilised for bulk sorting; diverting flows to create stockpiles to improve blending flexibility and boiler feed consistency, diverting waste material, or bypassing the beneficiation process when the coal met product quality criteria. In the 1990s bulk sensing and sorting utilising natural gamma detection was applied to conveyed waste in gold-uranium mineralisation and allowed ore to be recovered and processed that would otherwise have been discarded. Further applications developed in the iron ore sector where product quality ore could be diverted to bypass beneficiation and save significant unnecessary processing costs and improve recovery by avoiding process inefficiency losses. Plant capacity was freed up to be utilised by material that required processing. Similar benefits became evident in the phosphate industry and in base metals where multi-elemental analysis using Prompt Gamma Neutron Activation Analysis provides ideal opportunities to representatively measure 30 second conveyed increments at high accuracies. This has been successfully adopted in copper, nickel, platinum and lead-zinc to improve waste removal after primary crushing to eliminate unnecessary expense and improve plant efficiency. The benefits include increased output from existing operating capacity, significant reductions in consumable costs and generation of fewer detrimental waste streams. The paper outlines the technologies and discusses case studies covering the above commodities, demonstrating the immense value that representative real time measurement of conveyed flows can create. Measurement data concurrently provides multiple benefits in operational performance besides sorting, through ore reconciliation, ore blending, feedforward control and metal accounting, adding further value.

Nov 10, 2020

By French D

In presenting this paper may I preface my remarks by recognizing the presence here to-day of the many delegates from the overseas mining communities throughout the world. That is to say - those delegates not representative of Companies resident in Australia. This does not mean that my comments following are directed solely to the Australian exporter - far from it. The Company which I represent is internationally based. The experiences we have had in dealing and negotiating with our good friends the mineral cargo shippers vary very little in any operational area. However for the purposes of this exercise this address is based on some of our experiences within the Australian trade scene with the emphasis on the fact that we believe it has application to all trading areas.

Jan 1, 1989

By J E. Powalisz

Obtaining a representative sample of bulk materials in process industries is critical to providing valid data for process control and custody transfer (valuation). The accuracy of a sample, that is to say how well the sample represents the material in the process, is directly related to how well the process can be controlled and to how much a product may be worth. Sampling accuracy then is in fact related to bottom line profitability.Sampling theory offers information and equations on how to take a representative sample from a process, however, the actual practice of extracting a sample from the process can be more of an art.Key sampling variables include product specifications such as bulk density, particle distribution, material conveyance, practical sampler location, sampler type and sample frequency and volume/mass.This paper discusses basic sampling theory, sampling methods, types of samplers, how to develop a ‘real world’ sampling system and current manual and automated samplers.Key points include ‘practical precision and variance’, material properties, flow properties, direct sampling versus indirect sampling, sampler types and applications.CITATION:Powalisz, J E, 2014. Bulk solids sampling, in Proceedings Sampling 2014 , pp 179–188 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 29, 2014

By H. F. Broicher

Introduction In April 1998, AIS Sommer GmbH of Germany delivered the first laser-induced fluorescence (LIF) analyzer to the mining industry. LKAB's Kiruna iron ore mine in Sweden shared the costs and the risk of building the prototype. This marks the beginning of LIF analysis as a technique for quality control in mining and mineral processing. Photoluminescence analysis is well established. In most laboratories, fluorescence spectrometers are standard equipment for quality or pollution control. LIF is being used in several applications, including combustion studies and particle image velocimetry. However, it has mostly been used in laboratory environments. The availability of rugged lasers for industrial use brings this powerful tool to the forefront of production, even in the rough conditions found in mining and minerals processing. Laser-induced fluorescence Basics. Fluorescence of naturally occurring minerals has fascinated man since scientific investigation of this phenomenon commenced about 200 years ago. However, importance in industrial application and peripheral activities. Hand sorting of ore under ultraviolet (UV) lamps is seen as an archaic method. Long gone are the days when geologists set out at night with UV hand lamps to find valuable ore deposits, especially those of tungsten. Today, fluorescent minerals are considered collectors' items and museum exhibits. In the late 1960s (Hemphill, 1968) and during the 1970s, attempts to use lasers for excitation of fluorescence in minerals led to the development of an airborne fluorosensor (Seigel and Robbins, 1980). However, this prospecting technology did not gain industry acceptance and vanished from the market. During the past seven years, ongoing research of the LIF of minerals resulted in new findings that give good reason to revive the interest in fluorescence and its use in the mineral industries (Broicher and Zydek, 1995; Broicher, 1998). Fluorescence is defined as the short-lived form of photoluminescence, in which matter emits visible radiation during and after irradiation with light – the fluorescence generally being of a longer wavelength than the irradiation. Fluorescence of matter is described by: • the absorption spectrum, • the emission spectrum, • the decay curve and • the quantum efficiency. The absorption spectrum shows the fluorescence intensity in a fixed spectral band as a function of the excitation wavelength, while the emission spectrum shows the fluorescence intensity at varying emission wave- lengths for a fixed excitation wavelength (Fig. 1). The decay curves describe the exponential decrease of the fluorescence intensity with time. The quantum efficiency is the ratio of irradiating energy to emitted energy. Re- cent research has found that: the quantum efficiency of minerals can be measured and evaluated,

Jan 1, 2000

By William W. Magnus

The Eastern Magnesia Talc Company has always had the problem of adequate storage at its various mines and mills of not only crude ore and finished product but also material in process. An opportunity arose a couple of years ago with the decision to build a new mill at West Windsor, Vermont, (Figure 1) to come as close to providing adequate space for ore and the ground talc in the new plant as money and judgement would allow. Since our engineering staff did not have the time to design and engineer the new facility, an architectural firm with complete engineering staff was retained. Our original thought was to contract all phases of the construction and installation, however, and I think this is a most important point for any small firm such as ours, we found that with good supervision we, as the contractor, could do the job faster and at a lower cost than the construction firms that bid on the work. For some 50 odd years Italian talc has had a virtual monopoly in the body powder area of the cosmetic industry. Due to the purity, superior lubricity and whiteness, naturally occurring in the talc from Italy, no talc in the Western Hemisphere could capture any but a very small part of the market. When the Italian supply was cut off during World War II, the United States' largest consumer of this talc decided that it was time to develop a domestic source of a satisfactory replacement.

Jan 1, 1965

By D. Shuck

Incorporation of a 2,727 mtpd, $5.7 million flotation circuit into the Mclaughlin flowsheet was completed in November 1991. This capital addition reduced overall operating costs and improved the gold recovery of the low grade refractory reserves over that expected for direct cyanidation. In addition, flotation provided a means to generate a sulfide concentrate which is utilized to supplement feed to the pressure oxidation circuit.

Jan 1, 1994

By Harry Verakis, Thomas Lobb

Widespread use of ammonium nitrate compositions for mine blasting operations has led to various bulk transport vehicles designed especially for the explosives industry over the past half century or more. The advancements in explosives technology and continuing developments in bulk transportation have resulted in a variety of blasting agents and, more recently, oxidizers being transported and used from specially designed bulk transport vehicles. It is estimated that about 2000 bulk transport vehicles are used in mining operations. Many of the bulk vehicles carry about 15,000 to 33,000 pounds (6808 to 14,968 kilograms) of payload and some can carry up to 50,000 pounds (22,679 kilograms) for large open cast mines. Thus, it is imperative that detailed knowledge and safety instructions are available from the blasting personnel and mine management should an unplanned incident such as a fire occur with a bulk transport vehicle at a mine site.

Jan 1, 2008

By C. H. Perbix

[On Pier D in the Port of Long Beach, California, the Port of Long Beach has built a new bulk cement distribution terminal. The facility is operated by Pacific Coast Cement Corporation, who designed the complex and leased it from the Port of Long Beach on a 40-year lease. At one bulk cement is unloaded from vessels carrying from 12,000 to 30,000 t. The unloading is performed with pig speed mechanical unloading equipment and delivered into a concrete silo complex with, a capacity of 50,000 t. From the silos, bulls cement is loaded into trucks for delivery. The facility was completed in September 1981.]

Jan 1, 1983

By W. K. Hitchcock

Anecdotal evidence suggests that re-entering a sealed heating poses a significant hazard, whereby the original heating is rejuvenated at an accelerated rate forcing withdrawal and re-sealing of the area. Bulk-scale laboratory experiments using a two-metre column confirm these mine site observations. A high volatile bituminous coal from New South Wales, Australia was allowed to develop a significant hot spot before being inerted with nitrogen and allowed to cool. Air was then allowed back into the coal after the nitrogen was turned off and a hot spot developed almost immediately at the same location as the original hot spot before it quickly migrated towards the air source within a day. Two more re-entries were simulated. Each successive re-entry developed a broader hot spot and took longer to reach thermal runaway. These results clearly show the behaviour that can be expected when trying to recover a section of an underground coal mine that has been sealed due to a spontaneous combustion event.

Jan 1, 2009

By James J. Roettger, Robert J. Mitchell

"The results of a series of model stope pours designed to investigate working pressures on bulkheads during hydraulic pouring of classified tailings backfill are reported. Total bulkhead pressures and fill water pressures were monitored under the condition of a fully saturated backfill. Similitude of the model testing is discussed and equations are developed to estimate bulkhead pressures under prototype conditions. The model results show that good base drainage, combined with a bulkhead setback, can reduce the expected bulkhead pressures to values such that timber or concrete block structures should be capable of supporting a saturated backfill. Introduction Bulkheads are used in underground running operations to block drift openings in order that hydraulically placed sand backfill can be contained in stope pours. Whenever possible, the sand fill is designed to have sufficient percolation rate so that excess hydraulic transport water will gravity drain out through the bulk headed drifts. This avoids costly decanting systems. Early bulkhead design assumed that the bulkhead pressure could be as high as 0h = Hy where H is the fill height and ""y is the saturated unit weight of the fill (Thomas et al., 1979)(1). A typical design pressure for a 50 m fill height would be 1250 kPa giving a design force of 12,500 kN on a bulkhead located in a drift of 10m2 in area . Typical bulkheads were 1 m thick heavily reinforced concrete structures formed and poured into a notched drift. Not only were these expensive structures but the associated problems of inside drainage systems and curing time delays increased production costs. As experience with bulkheads for large bulk pours increased and fill pressure measurements became available [see, for examples, Libby et al., 1975(2), Askey et al., 1978(3)] , 'free drainage' timber and concrete block bulkheads were designed. Substantial savings have been realized using these types of bulkheads but greater engineering design and monitoring of backfill pours is necessary to ensure that backfill pressures do not exceed the bulkhead design pressures.The effective and total stress components of fill pressure, the engineering concepts associated with the 'free drainage' design and some detailed design considerations have been discussed by Smith and Mitchell (1982)(4) . It is important to the safe use of these designs, however, that the basic engineering concepts be demonstrated and communicated to those responsible for the day-to-day backfill operations. This paper describes and explains observations from a series of model studies designed to measure bulkhead pressures in a saturated fill."

Jan 1, 1984

By Richard A. Busch, Roy L. Soderberg

Large, high, open stopes resulting from vertical crater retreat (VCR) and similar methods are usually filled with sand tailings to support the stope walls and make it possible to mine the pillars. The hydrostatic head resulting from these high stope fills demands extremely heavy bulkheads in the crosscuts to withstand the pres- sure. Occasionally, these bulkheads fail because there are no drains or the installed drains are inadequate. Costly flooding of the mine and loss of life result from these failures. With proper design of blanket drains and filters, the fill can be made failure-proof, requiring only a minimum bulkhead, designed specifically for zero water retention. The effectiveness of the blanket drains can be increased by laying perforated pipes on the bottom of the crosscut within the blanket drain. These drains can have a safety factor of 10 with minimal expense. When the water is properly drained, the hydrostatic pressure on the bulkhead is reduced to zero, leaving only the lateral pressure of the sand. This lateral pressure is partially dissipated by arching and shear against the crosscut walls and consolidation of the tailings as the water is drained. The bulkhead should be placed at least one cross-cut diameter back from the collar of the drawpoint.

Jan 1, 1983

By John Garcia

IN some districts of the bituminous coal field the problem of construct-ing bulkheads to seal off water under pressure is becoming increasingly important. Recently this matter has been brought very much to the front by the loss of a large Illinois mine due to failure of a bulkhead that separated it from several old, flooded mines. As this great misfortune has provoked much inquiry about proper bulkhead design, it-is felt that a description, of the successful and extensive water-sealing practice at three mines that have different natural conditions will be of considerable interest to those connected with properties having a present or future water problem and to engineers that may have to design safe bulkheads of economical construction. These three mines are the Saxton and Dresser, near Terre Haute, Ind., and the Hegeler, near Danville, Ill. All three have water conditions that make it necessary to regularly seal off all worked-out sections of the mine, and there are considerably over a hundred bulkheads in each. As far as the writers know, these three mines are the only ones in the bitu-minous coal fields of the United States with anything like so large number of water seals and experience, although a number of other mines are known to have a few bulkheads. More detail will be included herein on the Saxton mine than on the others, as the writers are more familiar with it.

Jan 1, 1937

By Greg J. Hasenfus, Allison M. Haines, Joshua M. Silvis

The floodable volume of longwall gob can be of great importance in developing accurate coal mine operation plans, particularly for mine water management and environmental control strategies. Given the inaccessibility and difficulty in direct measurement of gob characteristics following gob recompression, hydrologic, geomechanical, and spatial data and principles were used to solve for the porosity and height of the residual gob using a mathematical model framework and bulking-based techniques. Based on this approach, gob porosity of Appalachian longwalls appears to be tighter than previously reported, ranging between 4.99 and 14.31%. Residual gob height, as normalized with respect to mine extraction height, ranges between 1.90 and 2.45. A novel, bedding-based bulking approach is ampliative with respect to existing roof caving and bulking fundamentals, as it has greater explanatory value compared with the traditional, lithologic-based bulking application. The efficacy of using the residual gob characteristics determined by the mathematical model and bedding-based bulking is examined using a causal comparative method, whereby time series prediction of historical groundwater rebound is compared with observed mine pool elevation data. Prediction accuracy is significantly improved using a prototype model to calculate void volume of longwall gob, specifically, the dependence of porosity of the gob material upon the longwall width to overburden depth ratio for movement basins of subcritical and critical panel widths. The potential implication of these findings toward hydrologic, geomechanical, and ventilation studies of longwall gob could be significant.

Aug 13, 2021