Search Documents

By E. B. Wilson

"Although the Operations Research technique of Reliability Theory has been applied with marked success in many fields, including the Apollo spaceship programs, the concept of reliability has not been generally adopted in mining and other heavy industries. Of course, reliability, or the probability that a system will be able to operate without a failure for a given interval of time, does not require the same emphasis in mining as in the aerospace industries. Nevertheless, certain aspects of Reliability Theory can be followed advantageously. For example, reliability calculations can determine the best time to overhaul and whether to retain stand-by units.The usefulness of the pseudo-operations research technique known as Replacement Theory is more readily re-cognized by the maintenance engineers in mining and other heavy industries. One of the least complex models enables the optimum Lifetime of an asset to be determined."

Jan 1, 1970

By C. Kunze

ABSTRACT Although closure sureties cover works that are carried out during the existence of a mining company, certain liabilities are not known when the surety is established and become apparent only in a late stage of the closure phase, or even after the site has been relinquished. This paper supports the concept that these financial risks lend themselves to insurance solutions. Making insurance for unknown liabilities mandatory while defining unambiguous legal conditions could create a viable market for insurance products, provide a sufficient statistical basis for the calculation of premiums, and reduce costs.

Jan 1, 2013

By Joel Werner

Weak metal prices, declining head grade, and increased operational costs are forcing many open pit mining companies to look to their balance sheets for significant cost reductions in order to remain competitive. Maintenance continues to represent a significant proportion of the total operating costs in the mining industry. Compared with the other major cost components of the mining process very little effort has gone into maintenance optimization. The potential payoff from maintenance optimization on the cash cost of the commodity is enormous. A large percentage of these costs are incurred in unscheduled maintenance events, which typically cause serious disruptions to the production process. These maintenance induced production losses can be a significant contributor to the overall operating costs. A structured proactive maintenance approach using the latest advances in technology can achieve dramatic cost reductions and productivity improvements. Remote condition monitoring systems are becoming increasingly commonplace and have the potential to identify problems prior to failure. Detection of equipment degradation prior to failure will enable repairs to be scheduled thereby reducing costs and interruptions to production. Remote condition monitoring technology has evolved rapidly in recent years, with a host of new tools becoming available to assist mine operators in improving their maintenance operations. These tools have capabilities such as: remote real-time vital signs and performance monitoring, alarm/event handling, trend analysis, and maintenance workflow management. When these monitoring tools are used in conjunction with a mine management system the vital signs data can be integrated and associated with maintenance history, predictive maintenance data, operational information, and geographical information. This integrated approach to the management of vital maintenance data will help shift the mobile equipment maintenance paradigm from reactive to proactive. This paper will introduce a proactive approach to the management of the maintenance process and the tools required to facilitate this process.

May 1, 2003

By Ree Llewellyn

"It has been estimated conservatively that the costs of wear damage and friction in the Canadian mining and mineral processing industry amount to over one billion dollars per year. These are mainly incurred through the repair or replacement of worn parts and production losses from related equipment downtime. The selection and application of the most appropriate wear protection components and systems, can thus have a very significant influence on productivity, profitability and global competitiveness.Details are presented of the wide diversity of materials used to counteract the varied and often complex wear attack mechanisms that occur in surface mining. The majority are various forms of steels and irons with generally very high hardness. However, they also include relatively soft elastomers and polymeric products.The main characteristics and applications of the different classes are reviewed. Case studies record significant performance improvements achieved through more judicious selections. Finally, some new developments which reduce maintenance charges by substantially increasing wear component life, are described."

Jan 1, 1996

By C. R. Tang

Due to the current lack of sufficient occupational hazards supervisory staff in China, an occupational hazards supervision regulatory framework is proposed, based on the cloud. Data on respirable dust, noise, heat, toxic and hazardous substances and protection facilities are uploaded to private cloud computing data and service centers to build an occupational hazards supervision system. This system promotes occupational hazards governance. Complex reports are generated. Through the establishment of an occupational hazard supervision data threshold, the dynamic regulation of occupational hazards is accomplished. The main characteristics of this approach are low cost, ease of expansion and maintenance, and strong performance.

Aug 1, 2013

By Iina Vaajamo, Jani Jansson, Lauri Pesonen

In pyrometallurgical operations, structural integrity of a high temperature furnace plays a crucial role in the overall safety, profitability and ecological footprint of the plant. Furnace integrity is related to how reliable a furnace is and it can be compromised, for example, by having poor operating and maintenance practices, an inefficient cooling system and flaws in the overall furnace design. These flaws and poor practices might lead to unexpected shutdowns, production losses, increased emissions, or worse. This paper presents the main factors to consider when engineering a furnace and developing its operating practices, while ensuring safe and reliable operations without compromising process efficiency and quality of the final products. In this respect, Outotec’s solutions for the cooling system and for automation systems like PROSCON, Process Advisor, Sentinel and our Smelting Information Management System, are also introduced.

Jan 1, 2015

By Robert G. Boutilier

So far, most social performance monitoring systems have not gone beyond listing the impacts on various stakeholders. Executives have had to rely on intuition to devise interventions that would improve the impacts. This paper describes a survey process, known as the Stakeholder 360 (S360), which eliminates much of the guesswork. The paper reviews key studies showing that raising the levels of communication, trust, and common vision among stakeholders leads to the acquisition of the resources needed to improve the socio-economic situation. Therefore, the Stakeholder 360 measures the levels of these three factors in the relationships between a company and its stakeholders, and among the stakeholders themselves. In a validation study at a gold mine in rural Papua New Guinea, the S360 produced a socio-political ?roadmap? that showed management and stakeholders alike which relationships need more communication, trust, or common goals/vision. Management used the findings to create alliances that helped the government move forward on a regulatory regime for the mine closure. The community used the findings to focus its planning for life after the closure. An S360 survey conducted six months later revealed a decline in dependence on the mine and an overall increase in levels of mutual understanding.

May 1, 2002

By M. Rizwan

Mine workings are progressing to greater depths as shallow mineral resources are being depleted, and civil engineering projects are nowadays being developed at substantial depths. The threat to tunnel stability posed by rockburst events has increased as a result of these high stress environments. Rockbursts are violent events capable of mobilizing large volumes of rock. In addition to the threat to safety and equipment, rockburst damage can significantly impact on operations, and cause loss of mining production, often the largest cost component of such events. Rehabilitation of such damage requires significant effort and resources. Tunnel walls and roof are usually well supported, but the installation of rock support in the floor is uncommon, particularly in mining environments. In the absence of rock support, floors of the excavations are vulnerable to rockburst damage. New concepts for containing damage of excavation floors by dissipation of the large transient forces using simple techniques or preselected and designed elements of sacrificial floor systems are presented. Two approaches to calculate the demand are presented: estimating load demand by assuming displacement levels and a response modification factor; and using a limit displacement approach to calculate elastic stiffness of the selected elements of the sacrificial support system. The proposed conceptual support systems have the capability of dissipating rockburst energy while retaining sufficient serviceability. It is considered that the concepts presented, for discussion, in this paper are logical and developable into practicable and economic solutions for tunnel floor support in rockbursting environments.

Jan 1, 2015

By C. A. Grandison

The economic evolution from an agrarian society to an industrial and service-oriented economy is apparent to most students of history. The long-term trend is almost taken for granted, it does not require explanation — it is accepted as the nature of man to improve his standard of living. However, there are fluctuations around this trend line which have provoked a great deal of thought. The ability to understand and control these fluctuations would yield many benefits, it would eliminate economic waste and public hardship, and would no doubt make a few fortunes. I f it is not possible to control or eliminate these fluctuations, then a reasonable forecast of the tinting, rate of change and magnitude of the fluctuations would be invaluable to industry and government.

Jan 1, 1976

By I. Kylmakorpi

In non-ferrous metal smelting, when the concentrate entering the furnace contains high levels of moisture, energy requirement for heating and drying increases and large volumes of exhaust are produced. To solve this problem, rotary dryers and flash dryers using direct heating, and also steam dryers using indirect heating have all been used for drying concentrate. The focus of this paper is to present the development and current applications of the Kumera Rotary steam dryer. The advantages of this technology are numerous, including reduced heating requirements, environmental friendliness, operation reliability and minimum maintenance needs; making it a top choice for drying concentrate.

Jan 1, 2008

By L. Tikasz

The primary purpose of ore hauling model studies is to capture the variability of the ore delivery ? stockpiling process in order to improve the estimation of equipment capacities and achievable throughputs. The operation of a mine-to-site ore delivery system is the subject of a number of challenges. Typically, ore is hauled by a given combination of trucks, conveyors and trains. In addition, ore loading, ore transferring to another means of delivery, stockpiling, reclaiming, and further deliveries involve many other types of equipment. The concurrent operation of all these units is scheduled; nevertheless, they are subject to planned maintenance and random breakdowns. To support our engineering design work on ore hauling operation, discrete event type models were built for each specific task. Then, due to recurring demands, an ore hauling library was gradually compiled. The now available model library allows fast and efficient simulation of various mine-to-site hauling arrangement, adaptable to various mining and mine construction operations (e.g. bauxite, iron ore, copper ore and coal).

Aug 1, 2013

By J. W. Rogers, S. K. Schwartz

"The Cape Breton Development Corporation (CBDC) is a federal Crown corporation which operates two coal mines (Phalen and Prince Collieries), a coal preparation plant, a railway, a central workshop and a deep water shipping facility.The Sydney coal field consists of 11 major seams, which range from 0.8 m to over 3.7 m in thickness. Of the 2.4 billion tonnes of known coal resources in the field, approximately 550 million tonnes can be mined with present mining technology. These parameters define reserves which extend more than 8 km beneath the ocean to a depth of 1200 m. With today’s design and present high production faces, the colliery life is projected at approximately 20 years."

Jan 1, 1996

By Michael T. McCaffrey

The wide range of potential feed materials, process steps, and products in metallurgical facilities means that standard equipment might not be available to adequately meet the project technical and economic needs. Custom designed equipment should be considered only after rigorous research precludes purchasing standard equipment. However, the decision to use custom equipment introduces a new element of risk into the project. To manage the risk, custom equipment design should be developed through the same front end loading (FEL) phases as project development. If more than incremental development of custom equipment is required, appropriate test work or pilot trials are required to test key uncertainties. Important activities during custom equipment design include maintaining clearly defined performance objectives, conducting appropriate reviews, carefully crafting commercial and intellectual property agreements with design and fabrication partners, and assembling a multidisciplinary team with sufficient development expertise.

Jan 1, 2015

By P. Tracy

An advanced real-time monitoring system, called a "Tapblock Diagnostic System" is under development to help furnace operators manage the operation and maintenance of their tapblocks. The life of a water-cooled tap block in a smelting furnace ranges from several months to several years, depending on the operating conditions. Tapblocks are typically replaced at regular maintenance intervals; a strategy based largely on historical records and not on the actual condition of a particular tapblock. The Tapblock Diagnostic System monitors the tapblock throughout its life and accumulates probable wear events to help the operator assess the residual integrity of the tapblock. Benefits of this system include the ability to provide early warnings of tap block wear to provide improved safety and maintenance planning. Using cooling-water flow together with copper and water temperature measurements, the system performs calculations that compare the present tapblock performance with the expected operating envelope using a multivariate statistical method (Principle Component Analysis). The operating envelope is pre-calculated for a wide range of operating conditions using transient thermal modeling (Computational Fluid Dynamics). A state indicator in the form of a green, yellow and red light is used to inform operators of the tapblock performance and health status.

Jan 1, 2007

By Ed McConaghy, P. LaRochelle

The Ambatovy Nickel Project comprises the development of mine, hydrometallurgical processing facilities and necessary infrastructure in Madagascar, positioning Ambatovy as one of the world’s largest producers of nickel and cobalt from lateritic ore. SNC-Lavalin successfully provided comprehensive Engineering, Procurement, Construction Management (EPCM) services for this major capital project which, apart from its sheer size, scope, and engineering design, represented significant location, infrastructure, labour, environmental and climatic challenges. Today, the project has reached 90% of its nameplate capacity and is in its final performance optimization stage. This paper will discuss the significant project management effort that was required to successfully address the complexity of this major project. It will cover the main project management control systems and the engineering tools and processes used during the detail engineering, procurement, and construction phases to achieve optimum project execution.

Jan 1, 2015

By G. Mihaylov

The basic principles of systems analysis are presented. A model has been designed to determine the location of the Main opening in the presence of three or more stock orebodies. The necessary condition is to find a location for the Collection point which is an essential element in opening up each orebody (stock). The model takes into account the total transportation costs from each orebody to the collection point. Three variants are considered provided that the orefield is divided into two levels at least: - a collection point is designed at every level; - a collection point is designed at the lowest level, i.e. where the so-called concentration level is formed; - the collection point is located at a point between the planes of the two levels; The effect of the depth of mining and mine output on determining the method of opening up the orefield has been analyzed by considering a vertical and/or an inclined shaft. A function has been constructed which allows for investigating in both a static and dynamic regime the capital costs for constructing the whole complex including the shaft. The character of the function does not allow finding the global limits. Therefore, it is of particular importance to specify the limiting conditions. In this case these are the flow capacity of development openings and the shaft. The basic groups of cost and natural indicators for assessing and selecting an optimal technological solution have been systematized. The combined analysis of the two approaches to finding the location of the Main opening and determining the mining method enables us to determine when an inclined shaft is best, and the depth at which opening by a vertical shaft has no alternative. Thus, a transition area is formed for which the selection of an optimal technological solution requires an analysis similar to that proposed in this paper. Conclusions are finally drawn which serve as a basis for determining the areas of application of each opening, including the use of a combined scheme of mine opening. The approach presented can be used in both investigating the possibilities for opening up new orefields and reconstructing existing ones in cases when the mining operations go deeper.

Aug 1, 2013

By Dale C. H. Nevison

One of the most intensive of material rivalries is the confrontation between zinc die castings and plastic injection moldings. Pressed hard by the plastics industry, zinc die casters are learning how to make parts with less material yet without sacrificing quality. The key to this new trend is the technique of Thin Wall die casting. The obvious benefits of Thin Wall are lighter weight and lower cost. Again, obviously, these are the very selling points that put plastics into many appliance and automotive parts formerly made of zinc. One of the factors that has been most conducive to the outstanding growth of plastics has been the increasingly prevalent concept that "adequate" properties are sufficient, especially if there are cost advantages. Most of modern design today is oriented around the reasonable life of a product, rather than indefinitely extended life. This is simply an acknowledgment of the existence of a design environment that pervades many areas, reflecting the life-cyclic desire for change. Too often, so-called "weight-saving" materials end up being very costly - not only in production, but in durability and dependability. Change for the sake of change usually doesn't effect a change for the better. In the majority of cases, the best bet is to design in traditional materials and minimize the material needed, while maximizing the efficiency of the production process. Component prices of products to be produced from either plastics or zinc must be studied in detail to determine which material will produce the lowest cost of manufacture. It is not uncommon for two parts, similar in appearance at a casual look, to have a considerable difference in energy requirements and production costs. Detailed cost estimates of the advantages of each material should therefore be prepared for zinc and plastic parts before the final design and material selection decisions are made.

Jan 1, 1978

By O'Halloran. Gerard F.

"ECSTALL MINING has installed in their plants the most modern equipment in the mining industry. At the minesite, digital blocked frequency controls are used to monitor all crushers, conveyors, ventilation equipment and pumps from underground. Distant pumping stations are monitored and controlled by radio. Modern friction skip and cage hoisting systems have been installed with static power supply designed for automatic operation. Rotary-type compressors of recent design are in service in place of the conventional reciprocating-type units. At the concentrator, the 800- and 1500-hp synchronous motors driving the grinding mills have static field excitation and pneumatic clutches, still meeting modern-day concepts, having been• installed in 1966. The maintenance work load has increased annually for the past eight years. The modern plant, with all the present-day sophistication, must have a welltrained and well-organized force of skilled workers, and a maintenance system which will supply realistic facts and guidelines. This presentation will review the relative location of plants, utilities, maintenance and services, plant maintenance control and mechanical control. It is the hope that enough information will be presented to weigh the size of the job and how the resources are utilized for controlled maintenance."

Jan 1, 1974

By A. K. Watt

"The availability of fresh water to meet present and future needs in Ontario is of concern to an increasing number of people. Rain and snow are the source of our potable water and provide, on the average, some 180,-000 billion gallons of water annually. This amount is reduced to 94 billion gallons a day as a result of the evaporation and transpiration of water and our inability to construct the necessary reservoirs for capturing surplus stream flow.The water used for domestic, irrigation, public supply and industrial purposes amounts to some 7 billion gallons daily at present and will reach 21 billion gallons daily by the year 2000; however, only about one-fifth of the water used is actually consumed, and this, along with the possibilities of water re-use, improves the water supply picture still further.The need for adequate pollution control has accompanied industrial and urban expansion and is an important factor in the extent to which our surplus water is used. In the 10-year period since the formation of the Ontario Water Resources Commission, the cost of water and sewage works constructed in the Province has exceeded one billion dollars. A special effort is now being made to control the industrial pollution situation.Numerous federal and provincial agencies are engaged in hydrologie studies in the Province, providing in-formation of benefit to those involved with water resources management."

Jan 1, 1967

By W. J. Blackstock

Introduction To The great majority of people, the term 'strip coal' has little or no meaning, or if it has any significance it is thought to refer to a poor grade of coal that had to be accepted during the war because no other fuel was available. Few people in the Province of Alberta realize the magnitude of our coal stripping industry, and fewer realize that strip coal has been available to domestic consumers for at least forty years. Among the first in the field of strip coal mining in Alberta were the Tofield Coal Company, Ltd., and Sterling Collieries Company Ltd. It was not until the advent of World War II, with its huge drain on industrial and domestic coal sup? plies produced by the underground mines, that some other source of coal was seriously sought. The tremendous shortage of manpower du ring this period of National emergency made it imperative that any increase in the coal production must be procured on a high tonnage per man-hour basis. It was therefore natural that the highly mechanized strip mine should be eagerly encouraged and subsidized by the Governmental agency - the Emergency Coal Production Board - under the very able direction of Mr. G. A. Vissac.

Jan 1, 1949