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By Bern Klein, Malcolm Scoble, Justin Widdifield, Andrew Bamber

"It has been suggested that the pre-concentration of ore underground can bring positive economic and environmental benefits to underground mining, particularly at extreme depth. The integration of mineral processing systems for coarse waste rejection and disposal into the underground mining environment has a substantial impact on the economics and operation of the mine. A case study for the integration of underground pre-concentration at Falconbridge’s Thayer Lindsley and Fraser Copper operations in Sudbury, Ontario is discussed, with particular focus on ore evaluation, system design, integration, and impacts on the operation. Conclusions as to the overall feasibility and potential impacts of underground pre-concentration are presented.INTRODUCTIONObjectivesA scoping investigation has been conducted for Falconbridge Ltd on the Fraser Copper Zone and Thayer Lindsley mines in order to develop a better understanding of the operations, and to do a preliminary evaluation of the potential for pre-concentration of the ore underground. The objective was to develop a conceptual design and evaluation of a pre-concentration system for each site. The results are to be used as the basis for a more detailed future study.Underground Pre-ConcentrationThe pre-concentration of ore to reduce the quantity and improve the quality of material transported to the processing plant is not a new concept and has been in practise at several mines including the American Zinc Company in Mascot Tennessee (Munro et al, 1982), the Sullivan Mine in British Columbia and presently at Xstrata’s Mt Isa lead-zinc mine in Australia, as well as at several PGM mines operating in the South African Bushveld. For each of these mines, a high degree of waste rejection was achieved at a coarse particle size with good metallurgical recoveries. The benefits arising from the surface pre-concentration of ore are well documented in the literature (McCullough et al, 1999; Miller et al, 1978; Munro et al, 1982; Schena et al, 1990; Sivamohan & Forssberg, 1991)."

Jan 1, 2006

By J. Visman

"Cyclone separators of different design are being used in increasing numbers in the coal industry of today. One recent addition, the Compound Water Cyclone, is finding application in the North American and Australian coal fields for the beneficiation of coking coals and for the reduction of sulphur and ash in steam coals. In this paper, the combination of specific-gravity separation, thickening, classification and water recovery are discussed. All of these operations can now be accomplished by means of cyclones that are effectively combined in circuits of compact design. In the layout of such integrated plants, three main sections are distinguished, namely: a Main Section for cleaning the plus-28-mesh fractions; an Effluent-Beneficiation Section for treating the minus-28-mesh fractions; and a Water-Recovery Section, where the wash water is reconditioned, and the fine solids are removed in a semi-solid state as slugs or pellets. Depending on the nature of the coal and the specifications of the purchaser, water-cyclone circuits can be flexibly combined with HM Cyclones and froth flotation, as well as with ancillary equipment for dewatering and drying."

Jan 1, 1968

By Chelto. D. Smith

With the pressure on mine and metallurgical managers to take accountability for responsible corporate governance in their operational area, it is no longer acceptable to rely on central departments in the organization to manage safety, health and environmental impacts of the company?s processes. Environmental impacts exist because of the production or mining process. Some of the inputs to the process are natural resources and some of the outputs of the process are the inputs to the environmental control equipment, plant and the environment itself. Environmental management therefore needs to be incorporated in production management to effectively control and reduce the impacts. Many aspects of environmental management are identical to production management and the systems to manage them will likewise be very similar. By examining key components of these two management systems a decision can be made whether environmental management and production management are structurally similar and can be integrated into a combined IT solution.

May 1, 2009

By Jerry Danni

In order to remain viable today, corporations must view the environment as a strategic issue, and integrate environmental management throughout the organization. Corporate programs that used to be based primarily on regulatory compliance now must emphasize strategic environmental management systems, and must integrate these environmental systems with basic business functions. The mining industry today is global, and must have an organizational structure that can embrace different cultures, physical settings, and regulatory regimes. Sound environmental management practices are not different from good management principles. An effective environmental management system should be a complementary system to an organization?s overall management framework, integrated and aligned with the existing management structure. Integrating environmental management into core business functions is just good business. An effective environmental management system is a critical component of a company?s commitment to environmental, social and economic accountability. This paper presents the elements of the Kinross Gold Corporation strategic environmental management system and discusses the integration of the environmental management system into the core business functions throughout the Company

May 1, 2003

By W. J. Mcgaughey, M. A. Vallée

"Abstract -The application of geophysical technology to resource delineation aims to improve the quality of resource/reserve estimates by integrating high-resolution survey methods, geophysical modeling and inversion with three-dimensional representations of geological and mineral deposit data. The use of geophysics can cost-effectively improve a geological interpretation based only on geological and sampling data. Success depends upon the ability to use geological visualization and modeling software, first to develop a three-dimensional geological model and then to modify it interactively by integrating geophysical data with the geological and sampling data.The high resolution required for mineral delineation geophysics results in a focus on borehole seismic and high-frequency electromagnetic methods. Borehole wireline logging is used to develop an understanding of the relationship between physical properties and geological description. Data from core samples and borehole wireline logs allow the construction of a three-dimensional physical property distribution, consistent with the existing geological interpretation. The three-dimensional physical property distribution is used for both geophysical forward modeling (to compare to field data) and as a starting model in iterative inversions.Advanced visualization techniques allow the simultaneous viewing of the three-dimensional physical property model, the geological information and data from which it is derived, and the geological interpretation and the geophysical results. Geophysical results may be simulated responses from a forward model or the output from a numerical inversion in the form of an updated physical property distribution. Iterative refinement of the geological interpretation is required to ensure consistency with the geological and geophysical data. The key to success with this approach is that all relevant geological, geophysical, and rock property data reside in a common, visual model of the earth.Examples from massive sulfide deposits illustrate the benefits obtained by the integration of geophysical and geological data."

Jan 1, 1998

By William Shaw

Conditional simulation is now an accepted tool for managing ore block design at a number of operating mines. It provides a way to consider the quality of data, local continuity and economic risk in defining ore and waste across the cut-off boundary. In addition a computer based system can ensure consistency in making decisions to meet multiple criteria such as cut-off grades, minimum ore-block size and contaminant grade limits. The development of a procedure for using multiple criteria allows ore blocks to be defined using alternative strategies depending on the specific production requirements. This has introduced the opportunity to define ore blocks for different destinations based on their material types and opens the way for geometallurgical modelling to be incorporated into grade control.

Oct 1, 2009

By Nirmal Weerasekara

Mill liners serve the dual purpose of protecting the shell from wear and transferring the rotary motion of the mill to an effective grinding action. As the liners wear, the efficiency of energy transfer changes, so there is balance between liner profile for wear and for milling efficiency. A tool that can simultaneously predict the evolution of the liner profile and the associated change in milling efficiency should prove most useful in optimal liner design. This paper presents such an approach, based on measured 3D liner profile data informing 3D DEM simulations of charge motion and liner wear modelling.

Jan 1, 2012

By Nirmal Weerasekara, Jochen Franke, Malcolm Powell, John Favier

Mill liners serve the dual purpose of protecting the shell from wear and transferring the rotary motion of the mill to an effective grinding action. As the liners wear, the efficiency of energy transfer changes, so there is balance between liner profile for wear and for milling efficiency. A tool that can simultaneously predict the evolution of the liner profile and the associated change in milling efficiency should prove most useful in optimal liner design. This paper presents such an approach, based on measured 3D liner profile data informing 3D DEM simulations of charge motion and liner wear modelling.

Jan 1, 2012

By Maya Kamenetsky, Khoi Nguyen, Natalee Bonnici, Steve Walters, Claire McMahon, Julie Hunt, Ron Berry

"The analysis of meso- and micro-scale textural attributes has been undertaken on ore samples from the Ernest Henry iron oxide-copper-gold (IOCG) deposit in NW QLD. Quantified textural data including grain size, shape and mineral association have been extracted from classified images of core with the aim to better predict potential mineral processing behaviours such as comminution, liberation and flotation. Data have been extracted from images of intact core at meso- and micro-scales using high resolution continuous images collected using automated core-logger technology, SEM-based and optical microscopy platforms.The results of this study will show examples of quantified size, shape and mineral association data from meso- and micro-scale classified images. Analysis of the data shows that there are domains of variable grain size and mineral association that can potentially be related to crushing and liberation behaviour. The trends that are observed at the drill-core (meso-) scale are consistent with those at the micro-scale. The results from the micro-scale analysis show that the domains defined at the core-scale have clearly different chalcopyrite sizes and shapes as well as variable bulk mineralogy.INTRODUCTIONInnovations in technology have allowed automated extraction of information about mineral shape, grain size and mineral association, i.e., texture, from meso- and micro-scale images of intact rocks. The overall aim of this research is to investigate trends in quantified textural data that can potentially give an early view of processing parameters such as predicted grind size and liberation behaviour."

Jan 1, 2009

The integration of mining and mineral processing technologies into new advanced mining systems is considered to offer several benefits, including selective mining, reduction in waste, increased productivity, flexibility, and improved resource utilization. This paper focuses on underground hardrock mining and the integration of pre-concentration technologies into future mining systems as representing realistic, shorter-term integration options. Control of fragmentation to optimize grinding, pre-concentration of ores, in situ leaching, and modular mining/mineral processing systems are possible with existing technology. Current research is directed toward development of integrated underground systems that minimize surface activity and minimize or eliminate surface waste disposal. Results from a simulation model of an integrated underground pre-concentration system are presented.

Jan 1, 2002

By Zhen Lei

In Alberta, Canada, heavy industrial projects are constructed using a prefabrication approach: spools and pipes are produced in the factory, and are assembled into modules that are transported to the industrial plants for installation by mobile cranes. Planning the onsite mobile crane operations is critical to the project budget and schedule. However, due to the large magnitude of industrial projects, manual heavy lift planning is tedious, and the results are not particularly responsive to site changes. This paper introduces an integrated mobile crane management system developed by PCL Industrial Management Inc., in collaboration with the University of Alberta, which investigates crane location selection and path checking for field module assembly. The project information is stored in a database, and the proposed system retrieves data, performs the calculations, and records the results back to the database; the calculations involve automatically selecting locations for the mobile crane, considering the crane capacity, lifting range and utilization. Lift paths for modules are checked for feasibility based on selected locations, satisfying the site and crane configuration constraints, and crane walking paths are planned if needed. The designed system is tested in an industrial project to validate the effectiveness of the system.

Aug 1, 2013

By Laura Mottola

This paper outlines a framework for ensuring the success of the implementation phase that follows research and development of new mining technologies and systems. It is based upon recent and past lessons learned that have demonstrated the critical challenges to effective technology transfer, which frequently receive inadequate attention within the culture of the mining business. The paper focuses on mining automation implementation challenges and then outlines a Roadmap which is proposed as an integrated framework to deal with the key aspects of people, process and technology. This framework is built upon: assembly of a Strategic Team to develop a Roadmap; fully understanding the business requirements of the technology initiative; defining Key Performance Indicators in a Balanced Score Card; performing a Stakeholder Analysis to identify the affected groups; and finally developing a master Project Plan to execute the Roadmap.

Oct 1, 2009

By Nima Nabavi

Shovels and excavators have significant blind spots due to their large sizes, increasing the chances of collision with other surrounding equipment such as haul trucks, loaders, and dozers. While a camera surveillance system is very useful in preventing collision, it can benefit from two additional features: (i) the ability to display the distance of the closest object within the view, and more importantly (ii) the ability to warn the operator if objects are getting too close. After a comparison between few different technologies, it is explained how these features can be provided by integrating rugged pulsar radar sensors with a camera system. The specific radar technology is already field proven in the harsh mining environments. Motion Metrics International Corp. has developed this exact product, which combines its 4-camera surveillance system (ViewMetricsTM) with a series of rugged radar sensor elements, named ViewMetricsTM-Radar. The radar system employs intelligent CAN bus communication to reduce wiring, hence improving hardware reliability with built-in troubleshooting features. A USB connection is the only hardware bridge between the radar sensors and the embedded computer. As such, an existing ViewMetricsTM system can be easily upgraded to ViewMetricsTM-Radar. As addition of new interfaces to the cab could result in operator distraction, this paper explains how ViewMetricsTM-Radar reduces distraction compared to other radar collision prevention systems.

Oct 1, 2009

Despite the claims of energy efficiency and the considerable development that has gone into dramatically extending rolls? life and facilitating rolls? change-out, in the six years since the last SAG conference, only a few HPGR operations have entered the realm of mineral processing. Risk barriers to the take-up of new equipment or processes are: a massive increase in materials handling issues as well as in the number of pieces of equipment required, low total circuit potential energy savings, and similar or higher capital costs. An alternative route is to make use of the complementary strengths of the HPGR and SAG in hybrid circuits. Minimising materials handling issues, providing an ideal balanced feed to the AG or SAG mill, and improving controllability through shifting grinding load as the RoM feed changes, are all potential major advantages to this approach. Conceptual circuit layouts, based on real measured ore and equipment data, are presented here to illustrate the potential production upside, the reduction in operating costs and the reduction in the physical and energy footprints.

Jan 1, 2012

Despite the claims of energy efficiency and the considerable development that has gone into dramatically extending rolls’ life and facilitating rolls’ change-out, in the six years since the last SAG conference, only a few HPGR operations have entered the realm of mineral processing. Risk barriers to the take-up of new equipment or processes are: a massive increase in materials handling issues as well as in the number of pieces of equipment required, low total circuit potential energy savings, and similar or higher capital costs. An alternative route is to make use of the complementary strengths of the HPGR and SAG in hybrid circuits. Minimising materials handling issues, providing an ideal balanced feed to the AG or SAG mill, and improving controllability through shifting grinding load as the RoM feed changes, are all potential major advantages to this approach. Conceptual circuit layouts, based on real measured ore and equipment data, are presented here to illustrate the potential production upside, the reduction in operating costs and the reduction in the physical and energy footprints.

Jan 1, 2012

By Jose A. Caceres

Mine planning and mineral processing optimization are usually treated as two unconnected problems, especially at open pit and panel caving mines where the cut-off grade is practically the only variable optimized and analyzed for in the planning proposes. Using existing planning tool, the output is a reserve consumption strategy privileging higher grades. With the earlier consumption of the highest grades, every year produces revenues which are closer to the cost and potentially even below cost. However, there are other ore characteristics that can also affect the profitability of the operation. A new methodology has been developed, incorporating the grinding and flotation relationship into the mining economic models for the simultaneous analysis and optimization of the throughput-work index-recovery relationship through changes in the mining limits, sequence and redefinition of the reserve consumption strategy. A mine-site that implements this new planning strategy, can expect to increase the NPV from 5 to 15% depending on the actual operational settings. Two case studies have been developed, showing how the inclusion of the work index in the economic model changes the phase and mining sequence in an open pit mine and the caving sequence and the optimum column height in a panel caving mine.

May 1, 2004

By M. Honarmand, Z. Moezifar, H. Ranjbar

Abstract - The Sar Cheshmeh area covers an area of 640 km2, and is located in the southern part of the Iranian Volcanic-Sedimentary Belt. ETM+ images have been used for alteration mapping. The Crosta method was found useful for enhancing exposed areas containing hydroxyl and iron oxide minerals. However, field checking has shown that this method is not able to identify all the known areas of hydrothermal alteration. Many of these altered areas are also not clearly resolved in the geophysical data. In order to improve resolution of such areas, integration of remote sensing and geophysical data may be helpful. The Darrehzar Cu deposit was chosen as a control area. The data have been divided into two sets: explanatory and target variables. The explanatory data are Landsat hydroxyl and iron oxide images and airborne geophysical data (K, U, and Th total counts, and total magnetics). The target variables are rock geochemistry and ground geophysics. Data analysis and integration of geophysical and remote sensing data were performed using directed principal components. This technique is found to be useful for the delineation of hydrothermally altered areas with more confidence.

Jan 1, 2002

By P. Roman, L. Daneshmend

"During the last decade, mining companies have been overwhelmed by technological solutions to perceived problems. This is particularly true with information technology where rapid advances have resulted in a professional climate characterized by technomania — the perception that failure to adopt emerging technologies will result in a loss of competitive advantage. This paper describes the applicability of structured analysis and design techniques as an appropriate methodology for integrating emerging technologies in the mining industry. The potential of this approach to improve overall mine effectiveness through improved communication and co-ordination between operations and maintenance is discussed. IntroductionA strong working relationship between the operations and maintenance departments in both open pit and underground mines is fundamental to the overall success of the mining endeavour. Unfortunately, for many mines, this characterization is far from accurate. Short-range production targets dominate the day-to-day management of the mines. This can be seen in Bostwick and Buchanan’s (1993) report on American Barrick Resources efforts to achieve an aggressive 415 000 tpd mining program at their Goldstrike operation in Nevada. When production managers do not meet their quotas, the finger is often pointed at maintenance. As a result, a confrontational culture can develop between the two organizations, resulting in a lack of cooperation that exacerbates the problem. Historically, production planning has taken priority over maintenance planning. This is reasonable since production is the primary purpose of the mine with maintenance serving in a support role. This basic relationship remains intact today. However, the trends toward mechanization, increasing levels of automation, and larger equipment, have resulted in increased reliance on the equipment used in the mine. As a result, downtime costs now go well beyond the direct labour associated with the repair of the machine. Lost production costs due to downtime resulting from failed equipment are becoming an increasingly important factor in determining a mine’s overall economic performance."

Jan 1, 2001

By R. Heikkilä

In this paper the utilisation of building information models (BIM) and construction automation on building sites is discussed. A lot of research has been carried out to develop new applications for using BIM to assist construction site planning, different operations and logistics. The methods of production control and management on site utilize BIM together with machine control and navigation systems. In Finland machine control systems and the automation of construction equipment is widely used in infrastructure construction. Recently similar methods have been introduced also in building construction. This paper describes some latest Finnish examples where BIM-software is used for the planning, execution and control of building construction operations. University of Oulu has studied methods and technologies to capitalize BIM-models. The research has been mainly in infrastructure construction but the activities have recently been extended to building construction. In this paper a BIM-based tower crane operation and control system is discussed as a case study. The aim of this study was to highlight the potential areas were automation can increase the crane productivity and improve site operations and logistics. The construction site managers and tower crane operators interviewed in this study were experienced in using BIM-models on site.

Aug 1, 2013

During heap leaching of secondary copper sulphide ores operated at low heap temperatures and high levels of leach solution salinity, copper recovery is usually unsatisfactory, due to a slow chemical and bacteriological leaching of the covellite minerals either formed from leaching of chalcocite or naturally occurring in ores. A laboratory test program was conducted to investigate the effect of leach solution temperature in the range of 20 to 50°C on copper extraction during stirred reactor, bottle roll, and short column leaching of fresh or heap leached secondary copper sulphide ores. It was demonstrated that increasing heap temperature is an effective approach for improving recovery of copper from secondary copper sulphide ores. A review of the technologies available for heating heap leach solution or decreasing solution salinity to improve copper recovery from secondary sulphide ore indicates that an integration of copper concentrate pressure leaching with heap leaching is potentially a cost-effective approach. A copper flotation concentrate sample was tested through pressure oxidation with the use of heap leach solutions of varying strengths for the repulping of the concentrate in order to examine its effect on pressure oxidation performance. The test results indicate that use of heap leach solution of high salinity in the pressure oxidation process does not cause a negative impact on the process performance for copper extraction, sulphide oxidation, and recovery of gold (if present) from pressure leach residue, and has additional advantages of removing the bacterially inhibitory aluminum from heap leach solution and generating more acid and ferric iron in the pregnant leach solution. A flowsheet configuration for full integration of the copper concentrate pressure oxidation with heap leaching of secondary copper sulphide ore is proposed and discussed.

Jan 1, 2014