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By Peter Heine

Diavik Diamond Mines Inc. (DDMI) has treated systems development as an integral part of the construction project when it built Canada?s second diamond mine. Fully aware that the proper collection and processing of operational data is needed to drive business decisions during production and planning, key Performance Indicators (KPIs) were defined to effectively manage operations when the mine went into production. The Production Information Management System (PIMS) allows KPIs to be measured, reported, and transferred to other systems in a reliable and convenient manner. PIMS provides a mechanism to collect real time production data from the various control systems around the site and acts as a tool to ?drill-down? and establish the important cause-effect relationships that impact the value of a KPI. Thus PIMS provides a data collection, storage, management, and an environment in which cause-effect relationships can be analysed and statistically verified. This understanding of the real cause-effect relationships, close to the source of the data and in the context of the operation, can be used to improve both operations and maintenance performance. The PIMS includes the PI Database implementation, its associated external interfaces with the various Control Systems, Cleaning Packaging Weighing System, Environmental System, Enterprise Asset Management (EAM) System, and Diamond Tracking System (DTS), as well as laboratory data collection, custom applications (downtime tracking, data reconciliation) and user clients. The interface with the EAM system provides material flow quantities and equipment availability on which the plant performance reports are based. The transfer of equipment usage to the EAM system is fed into the maintenance notifications and work orders functionality in the EAM. The environmental system interface provides the mechanism for capturing water consumption data required to generate the various regulatory reports. The interface to the cleaning-packaging-weighing system provides the mechanism for capturing batch data for transfer to the DTS for diamond product tracking at the production splitting facility in Yellowknife. The PIMS lab application provides a means of getting sample data into the system for critical metallurgical metrics, and the data reconciliation application provides a means of manually verifying the data before it is published or passed onto other systems.

May 1, 2003

By P. Amelunxen, E. Herrera, L. Hill, J. Vanderbeek

It is well-known that the particle breakage mode that occurs in a semi-autogenous mill is significantly different from that which occurs in a ball mill, enough so to warrant very different lab scale breakage tests and scale-up models. This phenomenon, at the plant scale, leads to changing process constraints depending on the particular properties of the ore. For example, hard or coarse ores might bottleneck the SAG/AG mill throughput, while the ball mills might constrain throughput when milling soft or fine ores. Because the power draw of a ball mill is fairly constant compared to that of a SAG/AG mill, periods of SAG/AG mill bottlenecks lead to increased ball mill circuit specific energy consumption and a finer grinding circuit product size, which together constitute a loss of efficiency of the overall process. Because HPGR circuit throughput is less sensitive to changes in ore hardness, this situation is less common or severe in those circuits. Furthermore, the ball mills are somewhat decoupled from the upstream crushing circuits through the use of surge bins, which also helps to mitigate this effect. As a result, ore hardness variability constitutes a significant cost penalty that should be applied to SAG mill/ball mill/pebble crusher SABC circuits when evaluating the relative economics of different grinding circuit configurations. Nevertheless, the issue is by-and-large ignored, because most current HPGR trade-off studies are based on averaged ore hardness parameters. This paper provides an estimate of the magnitude of this penalty for a typical operation by using Monte Carlo simulation methods and plant data from Freeport-McMoRan’s autogenous, semi-autogenous, and HPGR-based comminution circuits. A case study from an in-house 96K t/d sulphide project is presented to illustrate the concept. It was found that by including variability effects, the trade-off NPV of the HPGR circuit over that of the SAG mill circuit increases to $84 million from negative $33 million, effectively reversing the original decision of selecting a SAG mill circuit for the fixed hardness case.

Jan 1, 2012

By J. C. O'Rourke

"Gibraltar Mines Ltd. has been operating its open pit copper mine for fifteen years. In that time over 140 million tons of waste and low grade material has been placed on the mine waste dumps. Laboratory and in-situ testing indicated that enough leachable copper was recoverable from the dumps to justify a leaching operation which would include the construction of a solvent extraction-electrowinning plant. The plant, which was commissioned in October, 1984 was designed to process 3,000 usgpm of dilute copper solution to produce 5,000 tons per year of high quality cathode copper.This paper deals with the start up and initial year of operation of Gibraltar's SX-EW plant. The three areas: leaching solvent extraction and electrowinning are presented with emphasis on the innovations which were made to help overcome the problems unique to die Gibraltar operation.THE LEACHING CIRCUITThe mines waste dumps are leached to produce a pregnant copper solution as feed to the SX-EW plant. To achieve this the dumps are sprinkled with a mildly acidic solution which percolates through the dump. In travelling through the dumps the solution contacts the surfaces of the liberated copper minerals and disolves the soluble copper into the form of copper sulphate. The leaching reaction is achieved by a combination of bacterial action to oxidize the suphides and solublization of the copper into the acid solution.For the bacterial action to occur the dumps must be at or near the ideal pH of 1.9 - 2.1 and the necessary elements of the reaction must be present. Because a bacterial reaction is involved there is a lag time between the time when the conditions for bacterial growth are achieved and when the bacteria are in their active growth phase. Laboratory tests with Gibraltar ore indicated that bacterial action takes two to three months to reach its maximum rate. See figure 1.The expected lag time for the planned rate of bacterial leaching prompted Gibraltar to start irrigating the dumps in late June 1986 for a plant start up in early fall. The lag time proved to be longer than expected and the dumps took until November to start producing copper at the expected rate. See figure 2."

Jan 1, 1988

By Michel Ruel

Most plants do not track how their systems perform. Optimization is the easiest way to benefit from your control systems. We suggest an approach in four phases. The first phase is to assess all equipment to determine the performances for instruments, valves, variable speed drives, and other equipment. The second phase is to remediate instrumentation problems, including the ones pertaining to valves, variable speed drives, analyzers, transmitters. When equipment is in order, loops are put back in automatic mode. If a loop oscillates, use standard default values for this type of loop. The third phase consists in validating the control strategies, properly configuring the systems (control system, programs and parameters, HMI, alarms), and then tuning the loops and control strategies. The fourth phase consists in analyzing the process and expected performances in order to optimize the control loops and control strategies. If performance is not sufficient, a decision tree will be presented to determine the right approach: advanced regulatory control, model predictive control, or fuzzy logic control. Once all steps have been completed, control performance monitoring software is used to sustain the results and pinpoint equipment or loops not performing as stated. Alarm management and rationalization could also be performed after auditing the alarm system, if needed. Examples from plants will be used to demonstrate how this step-by-step method is applied and produces results. INTRODUCTION Maximizing what you already have is the best investment to remain competitive. This article aims to show the benefits of a systematic approach using modern tools to improve plant performance. We at BBA suggest dividing the work in four phases, and a subsequent phase can begin when the previous one has progressed: Assess, Remediate, Stabilize, Optimize, or add advanced control. This approach has been successfully applied to several sites. Examples and illustrations from these plants demonstrate how this step-by-step method is applied and produces results. Under the BBA method, there are four questions to answer before proceeding to the next step. For each control strategy, you should ask the following questions: Assessment: Does it work? Remediation: Do you use it? Stabilization: Is it stable? Optimization: Does it perform? Do you need advanced control?

Jan 1, 2019

By P. Mattar

The geotechnical importance of studying fluid flow through porous media and soils in particular, becomes evident when dealing with groundwater movement in surficial geomaterials that can be initiated by hydraulic gradients that develop during construction activity, groundwater extraction, impounding of reservoirs and groundwater recharge during adverse climatic events. In a geotechnical context, rocks are regarded as virtually impermeable materials, with comparatively greater resistance to flow of water through their pore structure. The importance of the permeability of rocks comes to the forefront when deep geologic formations are used in geoenvironmental activities for disposal of hazardous and toxic materials. The permeability of the rocks encountered is of critical importance to these geoenvironmental activities since the movement or transport of the hazardous materials during their eventual release will be largely governed by the permeability characteristics of the geologic formation. The estimation of the permeability characteristic of geologic formations is a non-trivial exercise since the measure of permeability can be influenced by the scale at which the measurement is made. Regional-scale and borehole-scale estimates of the permeability can be greatly influenced by the inhomogeneities, including fractures, fissures, solution channels and other anomalies that are present in naturally occurring geologic media. These anomalies are considered to be site specific and can only be determined in a reliable fashion by either conducting tests at the appropriate scale or in the regional-scale through inverse analysis of tracer movement patterns in rock masses. The estimation of the permeability of intact units of a geologic medium has important geoenvironmental applications in connection with storage of wastes since the units in which repositories will be located should be sparsely fractured and the sealing of the fractures and fissures are a prerequisite to developing an efficient solution for storage. The intact permeability of geomaterials is therefore regarded as an important property that influences efficiency and reliability of geoenvironmental solutions for deep geologic disposal. The permeability of geomaterials such as concrete and cementitious grouts are also important to many geoenvironmental and infrastructure applications where durability of structural materials in general and cements used for sealing deep boreholes and other access shafts employed in waste management endeavours is influenced by the permeability characteristics of these materials

May 1, 2009

By S. Konetschnik, Lux Degel, R. Degel, T. Haslinger

UrbanGold and its partners from Mettop and SMS group have developed a novel technology for the recovery of valuables from all non-ferrous metals’ fractions of WEEE (Waste Electrical and Electronic Equipment), with a special focus on low qualities which are commonly landfilled or incinerated. The technology is marketed under the brand name “UrbanGold Flex” to illustrate the high flexibility in respect of plant design and raw material portfolio, allowing also the processing of low grade material and materials with high caloric values. The process of the technology’s centrepiece, a modified and enhanced bath smelting furnace called “HENRI”, was investigated in numerous pyrometallurgical trials as basis for a scale-up towards a capacity of up to 100,000 tons of WEEE-concentrates per year. All relevant facility components have been evaluated in respect of references, fall-back options, as well as exit strategies (alternatives) to minimize risks when establishing a novel technology. A spin-off within the development is the “UrbanGold Compact” technology which can be seen as optimization of state-of-the-art smelters by using an optimized TBRC as primary processing unit. As an UrbanGold Compact plant will be the first industrial scale reference of UrbanGold’s technologies, it is also explained in the publication. As precious metals recovery is of major (economical) importance when recycling WEEE, major attention has been given to minimize the losses of these valuables. These measures, as well as a sophisticated way of utilizing waste heat as far as possible, result in interesting business cases with gross profits of up to 20% or even more. INTRODUCTION Over the past years, the demand of electrical and electronic equipment has increased dramatically with technological progress. Innovations on the technology of electronic devices led to a shorter usage and lifespan and thus boosted the generation of Waste Electrical and Electronic Equipment (WEEE). WEEE is one of the fastest growing waste streams, growing at 3 to 4% per year worldwide and is expected to reach more than 52 million tons per year by 2021. Currently, about 45 Mt of these wastes are estimated to arise worldwide, and the trend is rising (Baldé et al., 2017).

Jan 1, 2019

By R. D. Lindsay

Originally the focus of Deak Resources Corporation Business Plan was to establish a method for treating small gold and possibly base metal mineral deposits located in the Kirkland Lake - Noranda area of Northeastern Ontario, Northwestern Quebec at a central treatment facility. Since the establishment of this original business plan in 1988 other processing options have availed themselves for handling the base metal ores off site at a central facility which may preclude their processing at Deak.The site selected for the Deak processing plant was Kerr Addison's Virginiatown operation. At the time this property was acquired from the Receiver following Golden Shield Resources' Bankruptcy in 1989 the mill had been processing in the order of 1, 100 SDT per calendar day through one processing module; a module originally designed to process 1,500 SDT/day of a free milling gold ore. This tonnage level however had not been achieved since 1966 when an average throughput of 1481 SDT per calendar day was recorded.In order to realize Deak's overall Business Plan it would be necessary to expand the mills processing capabilities to provide:(1) A 2200 SOT per day circuit capable of processing a free milling, medium work index gold ore;(2) a 1 ,000 SDT per day flotation and/or cyanidation circuit capable of processing refractory gold bearing materials containing refractory minerals (i.e. copper) that should be removed prior to cyanidation; and possibly(3) a 1200 to 1500 SDT/day base metal circuit capable of processing the broad range of Deaks' Base Metal Property ores. If this circuit were introduced it would be completed in two tonnage phases.Further, it was recognized when operations resumed under Deak in 1990 that the existing tailings dam was suitable for, and had sufficient capacity for additional gold tailings with necessary physical modifications and changes in disposal techniques (including the construction of containment storage cells) that would allow storage for an additional 3.4 million tons of gold ore tailings approximately 1.0 million of which has been deposited since 1990. The focus of Deak's long term tailings disposal strategy is to acquire the Barber Lake Basin which is currently adjoined to our main tailings system which will provide an additional 10 million tons of storage capacity.

Jan 1, 1993

By R. H. McCorkell

"Sample drops were evaporated on Lexan disks on which fission tracks were etched and counted after neutron irradiation. [U] = 0.01 ppb could be measured. This method is rapid, cheap, simple and accurate when sufficient control and checking is possible, but several types of error were encountered in its use, the natures and sources of which were investigated but not always determined. The most troublesome were ""annealing"" processes which sometimes altered the fission tracks so that they were not fully revealed, or acquired varying appearances, after etching. Several different annealing processes seemed to exist and seemed to be produced by alteration of the Lexan surface by dissolved components in the solutions and, perhaps, by radiation and local heating during neutron irradiation. The appearances of the etched tracks varied with the natures of the droplet solutions even when annealing appeared to be absent, and for this reason, standards are best prepared by additions of known amounts of U to sample solutions. Contamination of sample droplets by U-containing dust from the air is best avoided by preparing the disks away from areas where other U-analysis is being carried out.IntroductionFission tracks are regions of radiation dam age produced in solids by the fission of atoms such as 235U. They can be enlarged to sizes visible through optical microscopes by etching surfaces through which they pass with solvents in which the solids are slightly soluble. A sample to be analyzed for U may be placed against a film of a solid of negligible uranium concentration (the track detector) and irradiated with thermal neutrons in a nuclear reactor to fission 235U. The track detector is then etched and the number of tracks per unit area, ?, which is proportional to the uranium concentration of the sample, c, and the neutron do se, n, is found by counting through a microscope. Uranium in solutions ha s been measured by evaporating drops on track detectors, irradiating, etching and determining the number of tracks per drop, T(2,3,4,5). Extensive test s of this method are reported here."

Jan 1, 1983

By P. Mayer

"Determining the correct mechanism of a boiler tube failure is important for the prevention of future tube failures. Proper corrective measures can be undertaken to alleviate the root cause or causes for a failure only when the correct mechanism is known. A mechanism of boiler tube failure is defined as the process which degrades the tube and produces a failure.An expert system package was developed for use by electric utility power plant personnel during investigation into the cause of a boiler tube failure. It is intended to assist their efforts to recognize and identify a basic failure mechanism that can produce the type of boiler tube failure under investigation. The program guides the user to the most likely failure mechanism by asking simple questions, answers which can be obtained by determining the failure location, type of fuel, and from visual inspection of the failed tube. Expert systems are a form of artificial intelligence which imitate the decision-making process of experts.IntroductionBoiler tube failures (BTFs) continue to be the single largest source of forced outages in fossil fired electricity generating stations. Because of this a concentrated effort is being made to minimize boiler tube failure occurrences. Eliminating boiler tube failures could be worth $5 billion a year to the electric power industry(1).The aggressive service environment of fossil-fired boilers is largely the reason for these failures because the combined effects of stress, temperature, corrosion, erosion and vibration cause deterioration of boiler tube material properties and reduction in wall thickness.Determination of the boiler tube failure mechanism is important for the prevention of future problems. The root cause for a failure can be established and proper ameliorative measures taken only when the failure mechanism is identified correctly. The correct identification of failure mechanism is a complex process which may include many individuals and institutions. Technical specialists in metallurgy, chemistry, combustion, and boiler design frequently cooperate with the station staff in a failure investigation . These individuals rely on personal experience and numerous reports , theories, studies, private communications and investigations concerning the different failure modes and mechanisms."

Jan 1, 1990

By J. C. O'Rourke

"Gibraltar Mines Ltd. has been operating its open pit copper mine for fifteen years. In that time, over 140 million tons of waste and low-grade material has been placed on the mine waste dumps. Laboratory and in situ testing indicated that enough leachable copper was recoverable from the dumps to justify a leaching operation which would include the construction of a solvent extraction-electro winning plant. The plant, which was commissioned in October 1986, was designed to process 3000 USGPM of dilute copper solution to produce 5000 tons per year of high-quality cathode copper.This paper deals with the start-up and initial year of operation of this plant. The three areas: leaching, solvent extraction, and electrowinning are presented with emphasis on the innovations which were made to help overcome the problems unique to the Gibraltar operation.The Leaching CircuitThe mine waste dumps are leached to produce a pregnant copper solution as feed to the SX-EW plant. To achieve this the dumps are sprinkled with a mildly acidic solution which percolates through the dumps. In travelling through the dumps the solution contacts the surfaces of the liberated copper minerals and dissolves the soluble copper into the form of copper sulphate. The leaching reaction is achieved by a combination of bacterial action to oxidize the sulphides and solubilization of the copper into the acid solution.For the bacterial action to occur the dumps must be near the ideal pH of 1.9 to 2.1 and the necessary elements of the reaction must be present. Because a bacterial reaction is involved there is a lag time between the time when the conditions for bacterial growth are achieved and when the bacteria are in their active growth phase. Laboratory leaching tests with Gibraltar ore indicated that bacterial action takes two to three months to reach its maximum rate (Fig. I).The expected lag time for the planned rate of bacterial leaching prompted Gibraltar to start irrigating the dumps in late June 1986 for a plant start in early fall. The lag time proved to be longer than expected and the dumps took until November to start producing copper at the expected rate (Fig. 2)."

Jan 1, 1988

By M. M. Hajdasinski

"Any study in the field of theoretical investment analysis, or practical project evaluation, must be based on the assumption of one of the commonly applied models of time and value representation, and the corresponding interest convention. The lack of clear assumptions in this regard may easily confuse both the author of the study and the reader, and sometimes even lead to inaccurate results.In the first part of this paper formal definitions of the continuous and discrete models of time and value representation are introduced; in the second part, the importance of transparent assumptions is shown using a concrete example of inflation calculation in project evaluation.IntroductionIn his recent paper, L.D. Smith(10) discusses an important aspect of mine investment analysis: inflation in project evaluation. His interesting presentation of current practices of handling inflation by Canadian and international mining companies in their feasibility studies ends, in the conclusions, with a call for clear assumptions made when evaluating mining projects.With this call, an important issue has been addressed. The lack of clearly stated assumptions, or their incompleteness, are relatively frequent with regard to the interest convention or the model of time and value representation assumed when evaluating mining projects. It is, for example, fairly common that the quantitative evaluation of a project is performed according to the discrete model of time and value representation and the discrete interest convention, and the graphical presentation, supporting this evaluation, reflects the continuous model.Sometimes such an ambivalency means nothing more than just a formal inconsistency; there are cases , however, that may well lead to a serious confusion and /or to inaccurate results . Before this can be demonstrated on a specific example, a concise description of the models of time and value representation used in the evaluation of industrial projects seems to be in order. Although these models (especially the discrete one) have been in common use in the research and practice of financial analysis for considerable period of time, they have been applied rather intuitively, and their forma] definitions are difficult to find even in the standard textbooks on Engineering Economy."

Jan 1, 1990

By R. E. Stewart

"Using the concept of economic life and marginal analysis, it can be shown that proper equipment replacement timing can save a mining company many thousands of dollars. To assist management with determining the economic life of mining equipment, a new computer package has been developed. The package, called ERG (equipment replacement guide), incorporates all important economic factors related to equipment usage, such as operating costs, maintenance costs, salvage values, depreciation, volume of work, tax credits, inflation rates, ROJ, etc. The information is used in a series of equations which balance the costs of new equipment against the total cost of old equipment. The solution of the equations determines economic life and the point in time when the old equipment should be replaced. IntroductionIn an operating mine, equipment must eventually be replaced or downgraded for a variety of reasons. Fleets of haul trucks, dozers and other major pieces of equipment deteriorate over time until the mounting costs of maintenance and repair force either a major overhaul or the ir replacement by new and more efficient pieces of equipment.The question of determining the best time to replace old equipment has been approached in many different ways. Various methods, ranging from operating experience, intuition and physical necessity to sophisticated computer models have been devised to help cope with equipment replacement decisions . The best of the se will incorporate the most important economic factors related to equipment usage, such as operating and maintenance costs, salvage values, depreciation, work delivered, the cost of capital, tax credits and, of course, the effects of inflation.Economic TheoryThe fundamentals of equipment replacement theory grew out of the interaction between economics, engineering and finance. The use of annual cost comparisons and rate-of return calculations were helpful in handling situations in which assets with different finite lives were being compared. Later developments bringing together the concept of economic life and marginal analysis helped provide additional refinements to the theory. Taylorui showed that the displacement of an aging asset with a similar, but newer, asset can be justified economically when the marginal cost of keeping the asset one more year exceeds the minimum uniform annual cost equivalent of the proposed replacement."

Jan 1, 1980

By D. Eastick, S. Hardcastle

"Over the last few years, a multi-faceted feasibility study has been evaluating the introduction of hydrogen fuel cell-powered equipment into underground mines to replaced diesel engine-powered equipment. The analysis has shown that under normal operating conditions fuel cells could at the very least be an environmental and health benefit by eliminating combustion engines and their unwanted by-products. However, they could also generate significant reductions in the amount of ventilation a mine needs to supply when compared to dieselized operations; this would further decrease a mine’s energy consumption, its associated greenhouse gas impact, and also reduce a mine’s significant ventilation-associated costs. Fuel cell-powered equipment also has the advantage of lower noise and heat production compared to its equivalent diesel-powered counterpart.The degree to which fuel cells can generate ventilation benefits in underground mines depends upon a number of operational parameters and mine specific qualifiers such as current ventilation control or management, mine depth, inherent dust conditions, and minimum velocity requirements.However, another major consideration in the introduction of fuel cells in underground mines will be the safety requirements associated with diluting and removing the potentially explosive hydrogen in the event of a gas leak. In outside surface applications, it is possible to use dispersion, buoyancy, time, and lack of ignition sources as mitigating factors in deriving a low risk of an explosion. However, in underground operations, these factors change, and dispersion and buoyancy are limited; time may not be available and, in non-coal mines, ignition sources are not typically controlled. When a hydrogen leak occurs, the availability of sufficient ventilation to dilute and effectively remove the gas will be critical. Consequently, ventilation may be the prime risk controlling factor. In this paper, the authors evaluate the potential benefits of replacing diesel engines with fuel cells in powered production equipment, discuss the mitigating qualifiers that could limit ventilation savings, and evaluate solutions to retain and maintain an additional ventilation capacity in the event of an emergency situation, such as a hydrogen leak from the fuel cell stack or its distribution system."

Jan 1, 2007

By Karl Hoover, Cassandra Spence, Brent Bachewich, Jaakko Levanaho

"Since year 2000 the gold recovery into copper concentrate at Hudson Bay Mining and Smelting has reduced considerably during the summer months. This initiated a testwork program in the fall 2003 to find reasons and solutions for such change. During the testwork mineralogical factors, water quality effects and different reagents were evaluated. The reason for the lower recovery appeared to be the sensitivity of some collectors to pulp temperature. As a result of the work different collectors are being used in the mill in the summer than in the winter. A modification to the water system was also made to provide cooler water to the mill in the summer months.INTRODUCTIONHudson Bay Mining and Smelting (HBMS) is located in Northern Manitoba, just on the border of Manitoba and Saskatchewan. The complex consist of four different mines, Callinan, Trout Lake, Konuto Lake and 777 mine including copper smelter and zinc hydrometallurgical plants producing metallic copper and zinc. Gold is a very important byproduct providing about 30% of the mine revenue. In early 1990s when the company was facing declining ore reserves and was starting to gradually close down the operations, the 777’th exploration drill hole discovered a new orebody, which initiated a $0.5 billion expansion program. The main projects were a new 777 hoist with underground development and a new zinc cell house. About $30 million was used to increase the mill throughput to the present 2.27 million tonnes or 2.5 million short tons per year. The expansion programs were finished by the end of the year 2003.Historically the gold recovery at HBMS has varied between 60 and 70%. The recovery has been somewhat lower during the summer months. Gold recovery improvement projects were conducted throughout the 1990s, but were not focused on the seasonal gold recovery variance. However, since 2000, when the water system modifications to meet the increased water demand were completed, the gold recovery during the summer has been much lower than in the past. In August 2003 gold recovery fell below 30%, which initiated a metallurgical research program to discover the reasons behind the low gold recovery in the summer."

Jan 1, 2005

By Charles Kocsis

Over the last few years a multi-faceted feasibility study has been evaluating the introduction of hydrogen fuel cell powered equipment into underground mines to replaced diesel engine powered equipment. The analysis has shown that under normal operating conditions fuel cells could at the very least be an environmental and health benefit by eliminating combustion engines and their unwanted by-products. However, they could also generate significant reductions in the amount of ventilation a mine needs to supply when compared to dieselized operations; this would further decrease a mine?s energy consumption, its associated greenhouse gas impact and also reduce a mine?s significant ventilation associated costs. Fuel cell powered equipment also has the advantage of lower noise and heat production compared to their equivalent diesel powered counterpart. The degree to which fuel cells can generate ventilation benefits in underground mines depends upon a number of operational parameters and mine specific qualifiers such as current ventilation control or management, mine depth, inherent dust conditions and minimum velocity requirements. However another major consideration in the introduction of fuel cells in underground mines will be the safety requirements associated with diluting and removing the potentially explosive hydrogen in the event of a gas leak. In outside surface applications, it is possible to use dispersion, buoyancy, time, and lack of ignition sources as mitigating factors in deriving a low risk of an explosion. However, in underground operations these factors change, dispersion and buoyancy are limited; time may not be available and in non-coal mines ignition sources are not typically controlled. When a hydrogen leak occurs, the availability of sufficient ventilation to dilute and effectively remove the gas will be critical, consequently ventilation may be the prime risk controlling factor. In this paper, the authors evaluate the potential benefits of replacing diesel engines with fuel cells in powered production equipment, discuss the mitigating qualifiers that could limit ventilation savings and evaluate solutions to retain and maintain an additional ventilation capacity in the event of an emergency situation such as a hydrogen leak from the fuel cell stack or its distribution system.

May 1, 2007

By C. A. Rowland Jr

"I. INTRODUCTIONFred C. Bond's ""Third Theory of Comminution"" (1) was published in 1952. The mathematical statement of the Third Theory is the well-known Bond Formula:where W - Kw H per short tonWl - Work IndexP - Product size in microns which 80% passesF .. Product size in microns which 80% passesWork Index, as defined by Fred Bond, "" ... is the comminution parameter which expresses the resistance of the material to crushing and grinding. Numerically, the Work Index is the KwHrs per short ton required to reduce the material from theoretically infinite feed size to 80% passing 100 microns."" (2)Work indices for grinding can be obtained tram Bond grindability tests and can be calculated from plant grinding mill operating data when power consumed per ton of ore ground, the feed size analysis and the product size analysis are known.Work indices obtained tram Bond grindability tests, having been obtained from standard and controlled laboratory procedures, are reproducible and for the sample tested are accurate. The degree of accuracy relative to plant mill operation depends upon how representative the sample is of the total mill feed.The results of the Bond closed circuit rod and ball mill grindability tests (3) are given in grams of product sized material produced per revolution of the test mill. In developing a method to evaluate plant operating data and results from his grindability test, Fred Bond developed the ""Third Theory of Comminution."" In the process formulae were developed for converting grams per revolutionobtained from grindability tests to work index.The standard feed sizes for the Bond grindability tests are:Rod Mill Test ore crushed to minus 1ll inchBall Mill Test ore crushed to minus 6 mesh (Tyler)The formulae for converting grams per revolution to work index incorporate the 80% passing sizes for the feed to and the product produced in the specific test. Therefore, accurate work indices can be obtained from Bond grindability tests when the feed size is finer than standard. To obtain accurate test results, the ratio of reduction should be greater than 6 to 1."

Jan 1, 1972

By M. N. Brodie

"The ability to adjust the speed of a SAG mill offers benefits to the process and to equipment maintenance. It can be provided with some slight effect on availability ranging from somewhat enhanced to somewhat reduced, depending on the particular equipment that is used. Several techniques have been developed for monitoring the magnitude of the contained charge, and several algorithms have been used to control mill feed rate and mill speed. The various benefits and the means by which they can be realized are examined and compared. Reasons for Variable SpeedProcess RequirementsThe recovery of minerals from ore is dependent on particle size and residence time in process. Separation in a given plant is most efficient at a particular rate and a particular size (e.g., 80% minus 200 mesh). If the particle size increases, less mineral will be liberated. If the particle size is significantly reduced, the process of choice may not be able to effect separation, and power, media, and maintenance costs would be increased.If a SAG mill-ball mill combination delivers the desired throughput at the correct size for efficient separation when processing ore of the design hardness, some adjustment must be made to maintain this condition when the ore changes. The processing of ore softer than design will result in overgrinding, unless:• the throughput is increased inversely to the change in hardness which lowers recovery by overloading the separation facilities;• or the SAG mill feed rate remains constant, but the speed is reduced to feed coarser material to the ball mill for finish grinding to the desired size.There is also the effect of changing milldiameter to consider. A nominal 36 ft diameter SAG mill will have an effective diameter of 35 ft with new liners and 35 ft 6 in. with worn liners. A mill designed to operate at 0.76 p.u. (per unit) of critical speed with new liners (9.84 rpm) will be changed to 0.765 p.u. with worn liners. If 0.76 p.u. is the desired value, the mill speed should be reduced to 9.77 rpm."

Jan 1, 2003

By G. Warren

"In the past, smelting and refining of the precious metals recovered from ore has been generally looked upon as a small and relatively minor component of the business of gold mining. This is not surprising when one considers that the manpower, space and capital components of a gold refinery at an operating mine can be several orders of magnitude smaller than other unit operations at the same location. This philosophy is changing however, as economic and environmental pressure are forcing a re-evaluation of all aspects of gold mining and milling.This paper describes and evaluates three furnace technologies available and used by precious metal operators. The operation of arc, induction, and reverberatory furnaces are discussed and their strengths and weaknesses with respect to capital cost, impurity removal, slag quality, and environmental concerns highlighted.INTRODUCTIONIn the past, smelting and refining of precious metals recovered from ore has been generally looked upon as a small and relatively minor component of the business of gold mining. This is not surprising when one considers that the manpower, space, and capital components of a gold refinery at an operating mine can be several orders of magnitude smaller than other unit operations at the same location. Generally, gold producers will spend a great deal of effort to squeeze the last drop of efficiency out of a leach or grinding circuit via simulation or testwork but will design and build the refinery based upon past practices or industry standards. That past practices or industry standards will provide a functional refinery is undisputed; that this philosophy achieves the efficiencies that are possible or demanded in other plant operations is debatable.Environmental and worker hygiene requirements are considerations as well. Pollution control equipment can become a substantial contributor to both the capital and operating costs of a refinery and furnace selection has a marked influence upon the type and cost of this equipment. Slag characteristics and subsequent processing options available also play a role in furnace selection as precious metal slag losses and the recovery effort can greatly influence the cost / benefit analysis of a particular technology."

Jan 1, 2001

By Phillip Cancilla, Daniel Roy, Frank Rosenblum

"The manual moisture determination methods employed today by mineral processing plants falls short in providing timely information required for automation control. The costs associated with transporting and handling concentrates still represent a major portion of the overall treatment price. When considering the cash flow of a mining operation, that is governed by both the smelter contract, with moisture penalties and the quantity and quality of the concentrates shipped, an efficient method of on-line moisture content would be a welcome tool.A novel on-line determination system for ore concentrate moisture content would replace the normally tedious classic manual procedure. Since the introduction of microelectronic-based control systems, operators have strived to reduce the treatment costs to the minimum therefore a representative and timely determination of on-line moisture content becomes vital for control set points and timely feedback. Reliable sensors have long been on the “wish list” of mineral processors since the problem has always been that you can only control what you can measure. Today, the task of moisture determination is still done in the classical technique of loss in weight by uncontrolled procedures. These same methods were introduced in the earliest base metal concentrators. Generally, it is acceptable to have ore concentrate moisture content vary within a range of 7 to 9%. Many times, delays in manually achieving reliable feedback on the moisture content results in the moisture varying from 5 to 12% before corrective actions can be made.This paper first reviews the traditional and widely available methods for determining moisture content in granular materials by applying physical principals and properties to measure moisture content. All methods are in some form affected when employed on mineral ore concentrates. This paper describes a unique and promising on-line moisture sensor in two mineral processing applications, which not only automates the tedious tasks but also results in reliable moisture feedback that can be used in the optimization of the de-watering process equipment such as pressure or vacuum filters and fuel-fired driers. Finally, two measurement applications will be presented to indicate the usefulness and to summarize the measurement requirements for the proposed method of employing drag force and mechanical properties of the material itself to determine the moisture content."

Jan 1, 2001

By E. Fried

Cemented paste backfill (CPB) is an innovative tailings management method that consists in returning considerable amounts of mine tailings into the underground mine openings. The filled stopes thus participate to the ground support that allows maximizing orebody extraction and a safer environment for the mine workers. There are also significant environmental advantages of using CPB. Indeed, up to 50% of the concentrator tailings can be backfilled, leading to a smaller volume of problematic waste materials to be managed at the surface. Once the CPB is placed, or when the mine is flooded at its end-life, the backfill is subjected to underground water flows that may leach and spread the pollutants (mainly metals, sulphates, and acidity) which can contaminate the underground waters. The aim of this study is to characterize the leaching properties of CPB material and to identify the cement phases that ensure the metal fixation. A laboratory procedure was implemented consisting in the preparation of various paste backfill mixtures using sulphide-rich and sulphide-free materials, different types of binder, and mixing waters having various sulphates, copper and zinc concentrations. After 90-days curing time, the samples were submitted to column leaching tests. The CPB materials were flushed each day with 100 ml of deionised water during 100 days. The collected leachates were then analyzed for pH, Eh, electric conductivity and chemical composition. For some samples, a differential acid neutralisation test was carried out. The objective of this experiment is to dissolve selectively the hydrated phases by adding incremental acid concentrations. By analyzing punctually the equilibrated solutions, the composition of the dissolved phases and their metal content can be estimated. The leaching test results showed that the pH of the leachates remains alkaline during the test period. When the pH decreases under 10 (after 30 days), different behaviours in terms of chemical element release (especially for zinc) were observed. During the test, the oxidation of pyrite seems to slow down, probably due to passivating phenomena. Moreover, the differential acid neutralisation test results allowed a better understanding of the CPB mineralogy and the Zn-bearing cement phases. Zinc and the other metals seem to be fixed within a calcium-magnesium silicate.

May 1, 2007