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By N. Shi, T. G. Joseph

ABSTRACT: A prototype test dipper (at 1/20th volume and a geometric operating scale of 2.85) was compared during field trials against a conventional dipper with the same tare weight using the same test shovel. Both dippers followed similar dig trajectories, invoked by the shovel operator. A Microsoft® Visual Basic-embedded spreadsheet was used to interpret qualitative visual and quantitative numerical loading data collected on the hoist and crowd dig response. Overall the concept dipper, even with a 50% greater capacity, provided indications of a smoother dig cycle with lower peak hoist loading events and a lower energy per unit excavated.

Jan 1, 2011

By Donald Leroux, Colin Hardie

"New or improved mathematical models of mineral processing machines are published almost on a monthly basis. Often, these models can be calibrated from bench-scale test results and programmed using spreadsheet software to simulate different designs and operating conditions in open-circuit configuration. However, since mineral processing plants frequently operate comminution, separation and/or extraction machines in closed-circuit configurations, open-circuit simulations often have limited applicability.The simulation of closed-circuit configurations necessitates the programming of an iterative loop to bring the circuit to equilibrium. This can be done by using spreadsheet software but often requires advanced programming skills. As an alternative, LIMN® software, which simplifies the programming of closed-circuit configurations within spreadsheets can be used. This software was specifically designed to turn a Microsoft EXCEL® spreadsheet into a closed-circuit modeling and simulation platform with minimal programming.During the past few years, the Mineral Processing Group at the Noranda Technology Centre, has used this software for numerous projects which include the simulation of multi-stage cyclone circuits, closed-circuit regrinding and locked-cycle flotation tests. Using these projects as examples, the flexibility and the easy to use nature of the LIMN® software is demonstrated.INTRODUCTIONMineral processing engineers routinely have to make predictions regarding comminution and separation processes. Predicting the appropriate dimensions of equipment and the process response to changes in operating mode are probably the most common situations that they face. In all cases these predictions are expected to be rapid and accurate.Predictions made by engineers are frequently based on mathematical models. Many first principles, empirical, semi-empirical, steady state and dynamic models of mineral processes can be found in the literature. In fact, new or improved mineral processing models are continuously being proposed and in spite of this variety, process engineers often have to either develop their own or tailor existing models to suit their particular needs."

Jan 1, 2003

By G. E. Veins

This paper summarizes an investigation in which beneficiated ilmenite ore was smelted in a continuous, three-phase, 250 kv.a., open-top electric furnace. Minus %. inch ore was smelted, using the standard method. Fine ore, in the order of minus 14 mesh, was smelted in the briquetted form by the open bath method, and in the unagglomerated form by the cold dry-top method. The latter was shown to be superior. The data obtained .are discussed at some length. During the investigation, slag aver-aging 82.5 per cent Ti02 was produced over a period of 87 hours, the maximum being 85 per cent. Such slag should .be particularly attractive for the production of titanium tetrachloride, from which titaniurn metal is produced. The advantages of using paper-mill bark for producing a furnace charge of low bulk density, as required in cold dry-top smelting, were emphasized.

Jan 1, 1957

By K. Krishnapisharody, S. Clark, M. Barati

Different gas purging methods to metallurgical baths have been applied to date, among which are top lancing and bottom blowing through tuyeres or porous plugs. Among these, the porous plug bottom blowing technique has shown higher efficiency in gas utilization than tuyeres and top blowing, due to smaller bubble size and lower liquid velocity. However, the studies related to bottom stirring of metallurgical baths are limited to slag-less or thin slag-covered melts. In particular, there is no examination of stirring ability in conditions similar to Falconbridge's Slag Make Converter, where the bath is covered with a thick slag layer and a stream of solids is charged on the bath from top. This study was undertaken to investigate the application of gas purging through a porous plug in stirring in and melting of the solid feeds. The spreading behaviour and melting time of a solid layer forming on a plume created by stirring were calculated using the existing models. The results show that formation of a thick solid layer, specifically in areas beyond the plume region is very likely. Nevertheless, the thickness of the layer and melting time do not appear unreasonably high. It is predicted that by proper controlling of gas flowrate and plug configurations, successful solid charging through the mouth can be practiced.

Jan 1, 2007

By S. Deonarain, L. S. Schultz

"This paper details the process and methodology followed to rehabilitate a rectangular ventilation shaft, situated in the Free State region of the Witwatersrand Gold Fields in South Africa. The shaft consists of seven compartments where self-mining of the sidewalls had taken place and damage to the decayed steel work in the shaft had taken place, thus limiting access down the shaft. The paper will provide some insight into the successes and challenges encountered during the project and may provide some learnings for future projects of a similar nature. INTRODUCTION The ventilation shaft forms part of the Phakisa Mine, situated in the Welkom area of the Free State province of South Africa, and is located in the Southern part of the Witwatersrand Basin, one of the world’s largest known and richest gold deposits (Figure 1).As is typical in South African gold mines situated in the Witwatersrand basin, the shaft is 1 770 metres deep (below collar). The shaft was sunk during the early 1940’s and comprised a rectangular shape with 7 compartments, used for both rock hoisting and men and material winding, respectively, with a single lift “Mary-Anne” compartment. Early in 2003, the mine decided to change the shaft from a downcast hoisting shaft to an up-cast ventilation shaft. The conveyances, ropes, winders and headgear (head frame) were removed and replaced with a high volume fan delivering 323m³/s of air at a pressure of 4.2Pa on surface. The up-cast velocity in the shaft was 6.5m/s, however this reduced significantly with the scaling of the shaft and the restrictions at shaft bottom. Although Harmony had converted the shaft from a downcast service shaft to an up-cast ventilation shaft some years back, the shaft steel work in the barrel of the shaft was left intact. Over the years, the steelwork in the shaft had decayed (rust and grime) and portions of this steelwork fell down the shaft. Concurrent with the decaying steel work, portions of the shaft lining had collapsed and it was getting progressively worse."

Jan 1, 2019

By Ellie Condolios

Hydraulic hoisting offers a number ~f attractive features over conventional hoisting methods: small shaft space requirements; great flexibility of layout, including pick-up or delivery of the material at points distant from the mine shaft; low investment and operating costs. However, limited practical experience with this type of hoisting dictates that careful design and, frequently, extensive testing be done by competent engineers before large-scale installations are built. This paper covers the following: basic laws and design criteria for hydraulic hoisting installations; a description of a coal hoisting installation which has been in industrial operation since 1960, with a vertical lift of 600 feet and an annual capacity of 500,000 tons of -3 ~-in. coal; and a tentative appraisal of the process, including cost estimates. THE transportation of solids in water flowing through a pipe-line has, for a number of years, been common practice in dredging, public

Jan 1, 1963

By B. Wasmund, M. Y. Solar, I. Candy

The nickel laterite industry is divided into two camps when it comes to the grade of the ferronickels produced. One group, led by Falcondo and Cerro Matoso, markets high-grade ferronickels in the range of 35 to 40% nickel, while another group, led by SLN and the Japanese smelters, favour lower grades in the range of 20 to 25%. Because the ores processed by these smelters vary widely in terms of nickel content and iron to nickel ratios, it is probably more accurate to classify these smelters in terms of their iron recovery: Falcondo and Cerro Matoso smelt at lower reduction potentials and thus recover only 15 to 30% of the iron in their ores, while SLN and the Japanese smelters are very reducing and recover 45 to 65% of their iron. Low reductions generally imply higher slag losses and lower nickel recoveries, but also lower power and reductant requirements; higher reductions, the reverse. The question is, therefore, whether an economically optimum ferronickel grade exists for processing any given ore. This paper proposes a methodology for determining this optimum grade and concludes that nickel laterite smelters should favour low reductions and production of high-grade ferronickels.

Jan 1, 2008

By D. F. Coates

Slope problems arise on mining properties from cuts for roads and railroads and from open pits. When it is 'realized that 1,000,000 extra tons of waste may have to be mined as a result of an average slope being reduced by 1 ° it is easy to appreciate that the slope problems connected with open pits are of far greater importance than the others. The type of slope failure that can occur can be classified in different ways. The most useful classification would be one that separates the causes in such a way as to provide a basis for studies to deal with problems of prevention and control. Using this criterion the types of slope failures are classified into four groups. Having classified the problems in this way an understanding can be gained of the various mechanisms involved in failure ..

Jan 1, 1961

By Mark W. Booth

THIS paper deals with the subject of inbye power as the mechanical . engineer sees it, and invites discussion, particularly from the electrical engineer. At the outset, it will be necessary to clear the ground a little by some definite statements. In this question of compressed air versus electricity for the transmission of power and driving of machinery in underground workings, we must see that there are definite fields that compressed air on the one hand, and electricity on the other, can fill to much greater advantage than the other, and in which there can be little or no direct competition, at least for the present. It is under conditions where these fields overlap, and as to where the line must be drawn between the two, that the respective merits of each must be considered. Steam was the first means used to transmit power from the surface of a mine to drive underground machinery, and so long as distances were short and means possible to ensure fairly efficient use of the steam, and where the fire hazard was not in evidence, it gave fairly efficient service. I have in mind an instance during my own connection with the mines-a duplex pump at the shaft bottom at Princess colliery, driven by steam, and which used the steam compound and condensing; and, but for the mechanical difficulties, it was a not inefficient proposition. The steam was taken direct from the surface boiler-plant through a line down the shaft, and used directly at the pump, being in effect a straight conversion from coal to steam to work done. It was the mechanical arrangement, and failure of the pump in that direction, that led to its removal and replacement by something better in the way of an electrically driven turbine pump. Given modern mechanical arrangements, such as a steam-turbine drive on a high-speed turbine pump, and all other parts made in accordance with best practice in the art of steam generation and use, a steam-driven unit fully as economical would have been obtained. But the central electric supply station, and all that that means or promises (not always the same), turned the scale against steam.

Jan 1, 1936

By A. Probst, N. Moores, J. A. Finch

"In 1994 McGill and INCO (Sudbury operation) initiated transfer of technology originally developed to detect level in flotation columns to thickeners. A conductivity probe was installed in a concentrate thickener to monitor the mud-line and solids load. The probe consisted in a vertical tube with 32 equally-spaced electrode rings connected in pairs to give 31 conductivity cells. Conductivity was measured as a function of depth (so-called conductivity profile) from which the mud line and % solids could be inferred. The probe was installed in October 1994 and has been successfully detecting profiles since then. This communication includes a description of incidents and experiences during this technology transfer process including: probe installation and start-up; software modifications to accommodate operating conditions and operators' needs; calibration procedures to adjust to changes in performance as a consequence of long term use; and preliminary observations on the last stage, still in progress, signal interpretation and use to facilitate operation, particularly by providing early reaction to upstream disturbances.IntroductionThickening is one of the basic unit operations in mineral processing and hydrometallurgy used to separate suspended solid particles from a solid-liquid dispersion by gravity settling. As the dispersion enters the thickener, the solids settle and clarified water overflows the top. A thickener, which may be continuous or batch, is basically a large vertical cylindrical tank provided with devices to feed the dispersion and to remove the settled solids. The tank provides residence time for the particles to settle. The dispersion enters the thickener through the feedwell whose function is to dissipate the momentum of the feed stream and to create relatively quiescent conditions around the entering point. Rotating rake arms move the settled solids towards the discharge point located at the bottom centre of the tank.There are normally three distinct zones in a thickener: a top layer of clear water, a middle layer called a sedimenting zone in which particles are settling, and a bottom layer called a compression zone in which particles are pressed together as a consequence of the weight of accumulated particles. Proper operation of a thickener requires two simultaneous conditions: no solids in the water overflowing the top and the target solids content in the underflow pulp. To achieve these conditions is difficult because sensors for detecting the sediment line (interface between clear water and sedimenting zone) and the solids content in the compression zone are not commercially available."

Jan 1, 1998

By W. Petruk

Mineralogical studies and concentration tests were conducted on samples from an oolitic iron deposit from the Peace River district in Alberta to determine what concentrate grades and metal recoveries could be obtained. The samples assayed 32 to 37 wt. % Fe, and consisted of goethite, nontronite, ferruginous opal, siderite , quartz, amorphous phosphate and illite . Flotation with fatty acids yielded the best over-all results. A flotation concentrate from a composite sample of the iron horizon assayed, by weight, 43.0% Fe, 12.3% SiO2 , 1.9% CaD, 0.9% MgO, 4.5% Al2O3 and 2.0% P2O5 and lost 17.2% on ignition, for an iron recovery of 48.8% and a silica rejection of 80%. When heated to drive off the water, the concentrate assayed 52 w t. % Fe and 14. 8% w t. % SiO2

Jan 1, 1977

By J. A. Pigott, R J. Hall

The International Nickel Company of Canada, Limited operates five underground mines on the rim of the Sudbury Basin in the northern part of the Province of Ontario. Four of the mines, the Frood-Stobie, Creigh-ton, Murray and Garson, are located on the south range of the basin with-in a radius of IO miles of the centre of the city of Sudbury. The fifth mine, Levack, is on the north range about 30 miles northwest of the city. The ores are mined primarily for nickel and copper, and the principal minerals are pentlandite, chalcopyrite and pyrrhotite. In 1960 the total ore production was in excess of 16 mil-lion tons, 95 per cent of which was produced from the five underground mines and the balance from the Frood-Stobie Open Pit. Mining at this open pit is nearing completion and underground production has been expanded to replace the open pit tonnage.

Jan 1, 1961

By V. Coffin, T. Cienski

"(Figure 1) Reagentized pulp enters into the column at about 1/4 of the distance from the top. Inside the column it meets with a downward flowing stream of water and with an upward flowing mass of air bubbles. Flotation takes place in this counter current system while at the same time fine gangue particles are washed off the froth before it reaches the overflow lip at the top of the column. The main operating features of the column flotation are as follows:a) No moving parts. Solids are kept in suspention not by an agitating action of a propeller but by settling down against the rising air bubbles.b) Wash water. Spray pipes are installed a few inches below the froth surface and deliver required volume of water. The purpose of this water is twofold:(i) it keeps in balance the flow of material through the column and(ii) it washes rising froth in the froth layer as well as removes unwanted fines attached to the bubbles at the lower flotation section. As a result the concentrate produced is of higher purity than in the conventional flotation. Column is characterized by very high up-grading. However, even temporary disruption of wash water supply results in a drastic drop of concentrate grate.c) Flow balance. (Figure 2) For the correct operation volume of the underflow (tail) is larger than that of the feed. The difference is made up by the wash water. This difference called bias is predetermined and ranges from some 4 to 15 USGPM depending on the size of the unit and process requirements."

Jan 1, 1981

By R. A. Nemchek

ABSTRACT Concentrator plant design has evolved from large numbers of small grinding mills to small numbers of large mills. Consequently, plant performance often hinges on the productivity of a single large semi-autogenous grinding mill. Industry attempts to address the grinding mills’ critical nature frequently result in specifications that can be made simpler, more economical, and better focused on the project’s goals. This paper surveys current specification writing practices and proposes an improved approach recognizing that product design, procurement, manufacturing, and quality are interrelated in a successful project. The lessons learned here can apply to all types of machinery specifications.

Jan 1, 2014

By Michael Boyle, John Zeni

"The Blind shaft boring method is a mechanised process of excavating large diameter vertical shafts downward from the surface. It is a rotary drilling technique eliminating any requirement for personnel to enter the shaft or access underground workings during drilling and lining phases. Excavated material is delivered to surface carried by a flow of circulating fluid through the centre of drill rods. The drill assembly is suspended from a large A-frame rig and powerful winch at ground level providing vertical thrust to a hard rock cutter head. INTRODUCTION The Southern Coalfields Ventilation Shaft was constructed at a mine, 45 km north-west of Wollongong. The 5 m finished diameter (6.2 m drilled) shaft reaches a final drilled depth of 517 m, the deepest, fully lined blind bored vent shaft to date in Australia. Operated by a mining company in the Southern Coalfields, the expanding mine required a new ventilation shaft and associated surface infrastructure to service future operations. An assessment of future ventilation requirements for the coal seam operations identified a need to improve the capacity and reliability of the existing underground ventilation system in order to ensure a safe and efficient underground working environment. Installation of the new upcast ventilation shaft was determined to be the most cost effective and reliable solution to provide adequate ventilation for underground operations. The completed shaft is smooth and fully lined with steel/concrete composite liners that are hydrostatically sealed. The shaft lining is designed to meet the mine ventilation requirements for a service life of 20 years. The shaft intersects the top of the working section of the coal seam at approximately 513 m of depth. This includes the shaft collar depth and shaft bottom profiled intake section.PROJECT METHODOLOGY AND INDUSTRY BEST PRACTICE The shaft was drilled using the blind bore method, an innovative construction technique and an alternative to the traditional methods of sinking deep and large diameter shafts, such as raise boring and conventional drill and blast shaft sinking. The blind bore method allows the shaft to be drilled from the surface down without anyone having to enter the shaft or the mine during the construction process. This is by far the safest method of shaft construction and is especially suitable for difficult ground conditions where there may be unstable or water-charged strata. As this method involves drilling from the surface downward, shafts can be completed ahead of the underground mine development. Thus, allowing underground operations to focus on development and production without the conflicts of managing ventilation priority for underground contractors and mucking out spoil from excavation workings."

Jan 1, 2019

By Rodrigo Toro, Ivan Yutronic N

"The Copper Concentrator Plant of Compañía Minera Doña Inés de Collahuasi (CMDIC) is composed of three grinding lines, the third one being the largest. Due to the capacity feature of the third line, specially its SAG mill, it is a priority that the advanced process control team of the Company deploys a supervisory control strategy that allows this unit to operate in an optimal way, in order to achieve the maximum productivity at minimum cost. It is in this kind of tasks where advanced control applications play a key role in obtaining the best economic profit of the process.The advanced process control team, formed by people from Informatics, Automation and Operations of CMDIC have assumed the challenge of generating the transition from a manual SAG Mill 1011 operation (40 x 22 feet, the largest copper SAG mill of the world), to a fully automatic SAG Mill using a multivariable control strategy instead of a rule based on expert control system (widely used in industrial mining process control applications).Therefore, CMDIC decided to work together with Honeywell APC Team implementing an advanced automatic control strategy for the SAG Mill 1011, using for this purpose a technology called Model Based Predictive Control (MPC), based on a variety of control methods that uses dynamical models of the process, obtained from input/output data, in order to print the process knowledge into a group of mathematical relationships that links the constraints (controlled variables) with available commands (manipulated variables) and measured disturbances.The main objective of the advanced control strategy is to ensure process government, tending to throughput stability and optimization, by the execution of coordinated control actions, proactively avoiding measured disturbances effects and the SAG mill overloading.The most important benefits of using a multivariable control strategy are: the automated operation of SAG mill 1011 (that was manually operated before the implementation of this application), a safer, more coordinated and more stable process operation, achieving through this an increase of throughput and a decrease of specific energy consumption, controlling the amount of oversize material production, power consumption, mill loading, noise and torque. In addition to the operational results, this challenge has consolidated a control team, with the participation of engineers and operators, diminishing the typical implementation time and achieving a greater use of the application in a short time."

Jan 1, 2010

By Youjun Tao

Falcon centrifugal gravity separation tests were conducted to study desulfurization and de-ashing performance with different size fractions of a high-sulfur Chinese -0.5mm fine coal in a dense medium. Performance indicators such as combustible recovery, ash and sulfur rejection, and desulfurization efficiency were used to evaluate the separation efficiency. The results show that for -0.5 mm coal particles, all performance indicators except ash rejection are higher for the Falcon concentrator than for flotation. More specifically, for the +0.125 mm size fraction, Falcon centrifugal separation produced better ash and sulfur rejection performance than froth flotation. However, the Falcon concentrator also showed higher combustible recovery but lower ash and sulfur rejection than froth flotation for the -0.125 mm size fraction.

Aug 1, 2013

By P. F. Venus

In December 1977, a large pillar was removed by blasthole mining methods at lnco's Creighton No. 3 mine. Although the 2,363.000-ton blast was not a size record for a single underground blast at Inco, it did represent a significant departure from conventional blasthole mining. In terms of the application of nominal 6-inch-diameter boreholes underground, coupled with bulk slurry explosives, the magnitude of the blast is considered a first and very important development. The application of large-diameter boreholes in underground operations was first tried successfully in 1973. Since that time over 13/4 million feet have been drilled in this adaptation of an open-pit technique to underground operations. The blast, which required 708 holes, totalling 131,500 feet of drilling, was loaded in a six-week period, using special slurry handling techniques developed jointly by Inco and CIL. Inco operating and engineering personnel consider this application of large boreholes and slurry explosives for blasthole mining a very important milestone in modern mining technology.

Jan 1, 1978

By B. Caldwell

"The CompanyCardinal River Coals is jointly owned by Luscar Ltd. and the Consolidated Coal Company of Canada (Consol). The Luscar mine is operated by Luscar Ltd. and is located 40 km south of Hinton near Cadomin, Alberta (Fig. 1). The plant sits on the old townsite of Luscar, Alberta, which was founded in order to develop the coal in 1912 (Fig. 2). Initially, the coal was mined by Luscar Ltd. for heating and steam generation and used quite heavily by the railways for their steam locomotives. In 1955, the mine was decommissioned as the demand for coal for tl1ese purposes had dropped off. In 1969, the mine was re-established by Cardinal River to provide metallurgical coking coal for its customers in Japan. The coal is mined from the 13m thick Jewel Seam by open pit methods at a 10 to 1 stripping ratio. The run-of-mine coal is then cleaned to meet customer demands.The PlantThe clean coal preparation facilities at Cardinal River were extended in 1980 in order to increase the feed rate from 450 t/h to 800 t/h. The extension is a separate plant which can be operated on its own or in parallel with the old plant. In addition, modifications have been made to the fine coal circuit (hydrocyclones added), the coarse refuse circuit, (refuse bucks replaced by a refuse conveyor which backfills a pit), and the fine refuse circuit (solid bowl refuse centrifuges, refuse classifying cyclones, and hydra-rake thickener no longer utilized) since the plant was built in 1969. The plant production of 3 M t per year with a yield of 78% is achieved by first screening and breaking the run-of-mine material to a top size of 1 ½ in. The feed is then slurried, sized, and processed in three different washing circuits. The washed coal is mechanically dewatered, thermally dried, and then stored in a 14 500 t capacity silo or on a 300 000 t stockpile. The fine refuse is thickened and pumped to the same pit to which the coarse refuse is being conveyed"

Jan 1, 2000

By J. Olson

"A model was developed to use near-infrared (NIR) analysis of pulverized ore samples to estimate the recoverable gold content for ores from the Barrick Cortez Hills underground mine. Current routing practices use a ratio of the cyanide soluble gold content and fire assayed gold (CN/FA) to classify ores as oxide or refractory. Prediction accuracy of the NIR model was equivalent to the CN/FA ratio. Prediction accuracy was improved by combining the CN/FA ratio and the NIR spectra. Bootstrap validation estimates the root-mean-square error to be 9.92% with an estimated r-squared value of 0.893. This model will allow more accurate estimates of the variability in recoverable gold content throughout this mine. These data will aid in building an improved geo-metallurgical model or in making better informed routing decisions during the production cycle.INTRODUCTION The contained gold of an ore available for cyanidation is often related to subtle variations in the mineralogy. It is difficult and expensive to collect enough mineralogical information in order to predict how the variable mineralogy will impact the metallurgical results and project economics throughout the life of the mine or mill. Near-infrared spectroscopy may be an effective tool to rapidly and inexpensively collect discrete, quantitative mineralogical data for minerals that contain transition metal oxides, metal sulfides with semi-conduction properties, rare earth metals, and some chemical groups having di-pole covalent bonds such as carbonates, sulfates, and various types of clays (Hunt, 1977). Near-infrared spectroscopy can be a powerful tool for geo-metallurgical characterization of deposits where the presence of these minerals has direct or indirect relationships to metallurgical results such as grindability, regent consumption, or recovery. Near infrared spectroscopy is a rapid analysis that measures the intensity of reflected light in the near-infrared spectrum. The ranges for the ASD-Panalytical units used in this study extend through the visible spectrum and into part of the UV spectrum, reporting reflection by wavelength from between 350 nm to 2500 nm. Absorption peaks visible in this range are a result of interactions with outer valence elections or chemical bonds. The location and intensity of the peaks vary depending on the chemical composition and crystal structure of a solid indicating the presence and abundance certain minerals (Hunt, 1977; Clark, 1984)."

Jan 1, 2017