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By S. T. Johansen, B. T. Løvfall, T. Rodriguez Duran

In this paper we develop a physics-based model for lining erosion in steel ladles. The model predicts the temperature evolution in the liquid slag, steel, refractory bricks, and outer steel shell of the ladle. The flow of slag and steel is due to forced convection induced by inert gas injection, vacuum treatment (extreme bubble expansion), natural convection, and waves caused by the gas stirring. The lining erosion takes place by dissolution of refractory elements into the steel or slag. The mass and heat transfer coefficients inside the ladle during gas stirring are modelled based on wall functions which take the distribution of wall shear velocities as a critical input. The wall shear velocities are obtained from computational fluid dynamics (CFD) simulations for a sample of scenarios, spanning out the operational space, and a model is developed using curve fitting. The model is capable of reproducing both thermal and erosion evolution well. Deviations between model predictions and industrial data are discussed. The model is fast and has been tested successfully in a ‘semi-online’ application. The model source code is available to the public at [https://github.com/SINTEF/refractorywear].

Apr 16, 2024

By R L. Langak, R A. Heins

The use of differences in specific gravity between minerals to separate them has long been utilized in the extractive industries. The environmental and cost benefits of the commercialized forms of these processes are well understood and widely used. Gravity concentration is used inter alia in the primary beneficiation of gold, diamonds, coal, tin, ferrous metal ores and andalusite. The potential for economic loss due to poor performance of these gravity processes is significant, but diverse in manifestation and regular process monitoring can prevent or at least reduce these losses. The measurement of performance of gravity processes has always presented a challenge, due primarily to the masses of material involved and the physical nature of the processes, generally typified by long reporting time, and hazardous materials (such as Tetrabromoethane) for float and sink type tests. The development of density tracers has improved this situation, however recovery of these tracers from the process streams created the next set of challenges, requiring significant manpower to physically remove tracers from product dewatering screens. Additions to these tracers (magnetic or x-ray fluorescent) eased the recovery mechanism issues but made them much more expensive to produce, hence operators became concerned about losses during process testing. In addition, magnetic recovery of smaller size tracers by a magnet suspended above a loaded screen panel is still problematic. The development of new low cost magnetic tracers has improved statistical significance of tracer tests, as the tracers themselves can be bought and used in much larger quantities, whilst still remaining economically viable. Coupled with the development of effective magnetic recovery technology, such as the Gekko MagScreen, for even fine sized tracers, on-line, continuous tracer testing is now becoming a reality. Whilst the development of high technology radio frequency detection tracer systems continues, enabling the real time measurement of the process and interpretation of results, miniaturization and recovery of these tracers, which is critical given their costs at present, remains an issue. Keywords: Gravity, process measurement, tracers, magnetic recovery

Jan 1, 2006

By J. L. Fuentes-Cantillana, J. B. Solar Menéndez, A. O. Cámara

The Principality of Asturias is a region situated in Northern Spain with two centuries of tradition in underground coal mining. In addition, its uneven relief has obliged the construction of a great number of tunnels both for railways and roads. Basing on this experience and an ever increasing need to improve on safety, the Barredo Foundation dependent on the Regional Government and the University, provides and manages a Centre for Research of Fires and Ventilation in Tunnels. The Centre has as its most important infrastructure, a tunnel 540 m long, 9,5 m wide and 8,0 m high at centre. This section coupled with ventilation equipment allows the simulation of risk conditions at real scale, which is achieved by modifying the geometry of the section and through two powerful stations situated one at either en of the tunnel. In addition, the Centre houses two test benches for fans and electrical motors at high temperatures. One bench with a re-circulation conduit is the most appropriate for tests in Transversal and Semi-transversal type of installations. The other, is for the testing of electrical motors or fans which operate in zones where the surrounding temperature is high. In this Centre, training has also been developed for Fire Fighters and Civilian Protection Personnel who have to work in fire and smoke rescue conditions in underground structures. Testing conducted at real scale enables this formation and also to improve different computer programmes in the field of Fires and Ventilation.

Jan 1, 2003

By G. M. J. van Heerden, R. C. W. Webber-Youngman

"This article describes the re-engineering principles applied in the design of a personnel transportation system for the Bafokeng Rasimone Platinum Mine in the Rustenburg area of South Africa. It incorporates conveyor belt travelling, chairlift operation, and also includes consideration of proposed changes/modifications to the existing conveyor belt infrastructure.The purpose of the project was to identify, through a process of evaluation, the appropriate option and/or combination of transportation options that would be safe in terms of personnel transportation as well as cost-effective. Alternative measures for transporting personnel (not using belt riding) would have a significant positive spin-off, increasing the availability of the belt and thereby increasing production. This paper explores the feasibility of interventions that would improve safety through eliminating risk associated with personnel transportation as well as contributing towards improving the mine’s position on the cost curve.The design in consideration at the Bafokeng Rasimone Platinum Mine consists of two shaft systems, namely the North Shaft and South Shaft, each comprising twin decline shafts. One of the decline shafts is equipped with a conveyor belt for rock and personnel transportation, and the other with a winder for trackbound material transport. The conveyor belt has been used for personnel transportation since the commissioning of the shafts. The conveyor belt is equipped with platforms for personnel getting off and on the belt and a number of safety devices designed to ensure safety while travelling on the belt. Intensive training in the practical aspects of belt riding is given to every person, and unsupervised riding on the belt is permitted only once belt riding competence is demonstrated. Despite this, the safety results were poor, with 106 injuries between 2006 and May 2013. Fortunately, no fatalities were reported during this period.An investigation of alternative means for personnel transportation or engineered solutions to the current conveyor belt infrastructure in the safest, most effective, and most economical way was therefore needed. There was a major risk of safety-related stoppages being imposed following another belt accident/incident. This would prevent the mine from transporting personnel underground by belt and result in major production losses. From the commissioning of the Phase 2 shaft deepening project on both shafts, dedicated chairlifts have been used for personnel transportation as opposed to the conveyor belt installed in the Phase 1 area. The chairlifts have been in operation since 2004 and no chairlift-related incidents have been recorded thus far. According to safety statistics, it is clear that the chairlift is the safer method for the transportation of people in the shaft.To fulfil the objectives/scope of this study, it was recommended that both primary (new chairlift decline with infrastructure) and secondary options (modifications to the current conveyor belt infrastructure) be considered for implementation on both the North Shaft and South Shaft to reduce or eliminate accidents/incidents as a result of belt transportation. The associated capital expenditure would be approximately R200 million. Considering the future impact on the business as a whole, this would definitely be capital well spent."

Jan 1, 2016

By P V. Savage, T Glück, RCA Minnitt, C Bothma

Manganese Metal Operations ?Manganese Metal Company (MMC), a subsidiary of Samancor BHP Billiton, has two production facilities for electrolytic manganese metal in South Africa and produces a range of about 44 Mn metal products. ?The company is accredited with ISO 9000 and uses Six SigmaTM for continuous improvement. ?The control of the process relies on the effective functioning of approximately 250 different control loops at 50% automation.. ?Approximately 50000 samples are analysed every month. ?There are pyro, hydro and physical unit operations for the production of electrolytic manganese metal flake and value added products ? [ ]

Jan 1, 2005

By C. Tokoro, T. Kato

The objective of this study is to improve the shrinking core model for particles with a particle size distribution and clarify the activation mechanism of rare earth elements dissolution by mechanochemical activation. To achieve this objective, the method, called the doubly integrated micromodel, was applied for a shrinking core model in this study. This method consists of integrating the batch leaching rate of a single particle over the distribution of both feed particle size and reactor residence time to arrive at the fraction unleached. The usefulness of the shrinking core model improved by doubly integrated micromodel was confirmed by comparing it with a shrinking core model. To apply the shrinking core model improved by doubly integrated micromodel to rare earth elements dissolution from weathered residual rare earth ores by mechanochemical activation, leaching experiments were performed for grinding samples by planetary ball milling. The reaction equation of mechanochemical reaction by planetary ball milling for weathered residual rare earth ores was investigated by x-ray absorption fine structure analysis. As a result of a kinetics study, the rate-determining process of leaching changed from reaction to diffusion reaction control by planetary ball milling. Based on these results, it was revealed that the main mechanism of activated rare earth elements dissolution from weathered residual rare earth ores was a mechanochemical reaction by planetary ball milling. Keywords: Mechanochemical reaction, particle size distribution, shrinking core model

Jan 1, 2020

By J. M. Ortiz

This paper shows the usefulness of geostatistical conditional simulation combined with the quantification of sampling errors obtained from the analyses of fundamental errors ? validated from duplicate data ? to assess the relevance of the quality and quantity of the information, for short-term mine planning purposes. Traditional blast-hole drilling equipment has been designed for efficient drilling, but not for obtaining high-quality samples. Furthermore, blast-hole sampling interferes with production, and thus usually produces poor-quality results. These results are the basis of short-term plans, where the grades of selective mining units are estimated and used for distinguishing between ore and waste. Under these conditions, misclassification (ore blocks sent to the waste dump and waste blocks processed at the plant) is inevitable, leading to significant hidden losses that can amount to millions of dollars per annum. Reverse circulation drilling with the latest automated sampling technology improves significantly the quality of the information used for short-term planning, and thus reduces misclassification, improving the financial returns of the operation. In this paper, we present the general methodology for assessing the effect of poor blast-hole sampling, as compared to advanced reverse circulation drilling grids at several spacings, in order to arrive at the most appropriate grid for short-term planning. This plan can be prepared well in advance using several additional variables that are usually not available when the plan is based on blast-hole samples. Furthermore, blending options can be analysed in order to optimize plant recovery, minimize the use of sulphuric acid, etc. Three case studies are presented, namely a typical porphyry copper deposit, an exotic oxide copper deposit, and a complex gold deposit, where mineralization is controlled by structures and lithology. This paper shows that in all cases, advanced reverse circulation drilling grids provide good-quality information that, coupled with the use of geostatistics for short-term mine planning, significantly improve the financial returns of the operation.

Jan 1, 2014

A mineralogical study was conducted on the feed (3.51 g/t Au and ~90 g/t Ag) and four leach residue samples (assaying 0.09 to 0.19 g/t Au and 30.0 to 61.5 g/t Ag) from the Pinos Altos silver-gold deposit in Mexico to determine the cause for gold and silver losses. A comprehensive mineralogical and analytical approach including fire assay, gravity pre-concentration, ore microscopy, mineral liberation analyser (MLA) and electron microprobe was used for the current study. Results showed that gold and silver lost in the leach residues occurred mainly as inclusions in quartz and silicates (accounting for over 80% for Au and 92% for Ag of the head assays, respectively), with a minor amount in iron oxide and other minerals. The amount of liberated gold and silver is negligible. Results also showed that gold and silver particles in leach residues are mainly ranged from 1 µm to 5 µm in size, which implies that ultrafine grinding is required to improve the recoveries of these two metals. Keywords: mineralogy, gold deportment, silver deportment, silver-gold ore, leach residue, recovery improvement.

Jan 1, 2009

By B. Strohmeier

The role of large, ultra-high-powered arc furnaces in a fully integrated steelworks for the production of flat products is outlined, and an account is given of the technological improvements that have been implemented over the past few years to enable the arc furnace to remain competitive against the conventional route using blast furnaces and top-blown-oxygen steelmaking (LD). Modern secondary refining facilities have been installed, enabling the arc furnace to operate at high production rates in the manufacture of high-quality flat products.

Jan 1, 1985

By Ö. Erdem

The investment decision making process in the insurance and finance industries is affected by new advances such as simulation techniques. These advances have improved the discounted cash flow method (DCF). In DCF, a dynamic and flexible model construction is not possible because it does not consider uncertain conditions. Each project should be evaluated taking into account the related uncertainties because the related uncertainties determine the characterization of the project. Related uncertainties can be processed in dynamic DCF, which is applicable to both financial and non-financial industries with different kind of uncertainties, such as power generation and petroleum projects. The dynamic DCF method can estimate net present value (NPV) while managing related project uncertainties with a simulation method like Monte Carlo Simulation. The simulation method is preferred because its output is unbiased. Therefore, a more realistic financial evaluation of the project can be concluded. In spite of the improvement of dynamic DCF, this project evaluation method is not used frequently in mining industry. However, the mining industry is ideally suited to this concept because it is highly dependent on estimations such as orebody size and ore grade. During the project evaluation stage, these uncertainties can be included with the dynamic DCF method. This study aims to contribute to increasing the usage of this method in mining projects. A copper reserve in Turkey is selected as a case study to apply uncertainty assessment for the evaluation of NPV.

Jan 1, 2012

By H. J. Glass

Collection, preparation, and analysis of blasthole chippings is expensive. Frequently, interpolation of grades at unsampled locations is considered using techniques like kriging. A pre-requisite for kriging is that an experimental variogram is established. In order to assess the quality of the experimental variogram, a measure is developed in this paper. The measure is derived from analysis of the time-honoured expression relating the variance, semivariance, and covariance. It reflects the weighted average deviation of the summed semivariance and covariance from the biased variance. The proposed measure allows assessment of the influence of key variables on the quality of the variogram. Using simulated data, it follows that the quality improves with an increasing number of samples, increasing density of the sampled locations, increasing regularity of the sampling pattern, and increasing uniformity of grades in the absence of correlation. Application to real data shows that the minimum number of samples could coincide with a marked decrease in the value of the measure. Establishing a threshold value is subject to further research. Keywords: variogram, variance, covariance, semivariance, minimization, sampling.

Jan 1, 2003

By M. M. Oosterveld

"In South West Africa diamonds are mined from ancient beach deposits by the Consolidated Diamond Mines of South West Africa, Limited.To improve the control of mining production, a computer is used for the calculation of statistically more accurate and homogeneous ore blocks. Geological and sampling information has been digitized and stored on magnetic files.The figures derived for each block entail the calculation of the diamond size frequency distribution, the diamond density distribution and the ore reserve by using the density distribution.The diamond size frequency distribution is used for estimating the revenue in an ore block.A description is given of how a linear programming system can be used for production planning."

Jan 1, 2014

By Z. Jin, Q. Yun, C. Lu

This paper presents a quantitative assessment model for the assessment of environmental load in gold production, which is based on environmental ecology, Life-Cycle Assessment and technical conditions of gold production in China. This model can make environmental assessment in terms of a set of indexes and quantitative approach by means of artificial neural network, which also improves the theory of Life-Cycle Assessment. Keywords: Artificial neural networks, Environmental load, Assessment, Utility function, Gold production

Jan 1, 2003

This paper presents recent advancements in the MillMapper software technology, developed and used for thickness gauging of liners of cylindrical grinding mills used for mineral comminution. MillMapper uses calibrated laser scanner data captured inside a mill to determine thickness at several million points on all liner surfaces with millimetre accuracy. The paper is structured as follows. First, a review of the technology and its numerous advantages over existing techniques and the value it adds to operations are presented. These are followed by discussion of recently-implemented innovations, including improved visualisation and inspection tools, automatic ball charge volume measurement and automatic mill liner volume/weight measurement. Results from its application at several sites in Australia are presented throughout.

Jan 1, 2007

By A. S. Macfarlane

Mineral resource management (MRM) practice has developed in South Africa over the course of the last ten years, with the purpose of integrating previously isolated technical functions into a value chain aligned, process organization, responsible for mine planning and optimization. The implementation of MRM within various companies has met with varying degrees of success, often resulting in incremental improvements in the planning process and, conversely, often becoming the scapegoat for poor delivery on plans and projects. The reason for this has been, amongst others, a lack of a suitable metric to define the success rate of MRM in the business at hand, in terms of its contribution to the bottom line. This paper is the result of extensive research by the author into this subject, which has resulted in the conclusion that economic value added is an appropriate measure that will lead to real optimization and value creation in mining companies, if applied within a new, holistic model

Jan 1, 2006

By B. S. Xakalashe, I. J. Geldenhuys, B. Bowman, M. W. Erwee, G. A. Venter, J. Zietsman, C. Sandrock, Q. G. Reynolds

Understanding the behaviour of plasma arcs is an important part of the design and operation of direct current electric arc furnace smelting processes, which are used in the industrial production of many metallurgical commodities. In recent years numerical and computational modelling techniques have begun to illuminate the complexity of arc behaviour and how it is deeply connected to the thermodynamic and physical properties of the arc plasma. Plasma properties may be estimated from first principles using statistical mechanics methods, but this requires as input some knowledge of the composition of the gas phase that occurs over the process during smelting. In this paper the authors describe a workflow using thermochemistry software to predict the expected gas phase composition through a given process, followed by plasma property calculations using an open-source software tool that has been in development for several years. This tool, 'minplascalc' has been in development for several years and is also described in detail here. The workflow is then applied to the calculation of plasma properties of interest for a variety of historical and current pyrometallurgical processes, and the results are compared. The plasma property data are published in an open-access database for general use.

Mar 4, 2025

By E. Lutz, M. Momayez, K. W. Brown Requist

As real-time air quality monitoring becomes more prevalent in US underground mines, it is important to provide the highest data reliability with the fewest possible sensors. Real-time sensors remain costly, and these costs are not exclusively financial; the time required to install, calibrate, and maintain real-time sensors poses a large barrier to widespread implementation. Current atmospheric monitoring systems typically rely on displaying point-specific values. This requires operators to infer real-time airborne contamination distributions. Monitoring and control software utilizing mine ventilation network (MVN) solvers has been implemented in limited cases because of their ability to simulate ventilation systems quickly, but these solvers use a one-dimensional representation of the mine, limiting spatial resolution of estimated distributions. Computational fluid dynamics (CFD) has likewise been considered as a means to improve spatial resolution, but processing times prevent its use as a basis for monitoring and control. For the real-time monitoring of airborne contamination distributions, we propose a spatial interpolation method that can estimate the distribution of airborne contaminants in near-real time. This method provides a middle ground between fast processing times and increased spatial resolution. With the use of a pathfinding algorithm and optimization through absolute percentage error minimization, this method outperforms spatial interpolation with a Euclidean distance. By providing contamination distribution information to operators, this method and its derivatives stand to outperform current atmospheric monitoring systems.

Apr 16, 2024

By M. Louarrat, G. Enaime, A. Yaacoubi, A. Baçaoui, J. Blin

"The purpose of this study is to prepare a new activated carbon from olive stones for use in gold recovery by carbon-in-leach (CIL) and carbon-inpulp (CIP). The preparation method chosen was physical activation using steam. The effect of four process parameters: the residence time for carbonization, the activation temperature, the residence time for activation, and steam flow, were studied by the mean of response surface method (RSM) in order to optimize the yield, iodine index, and attrition characteristics. These two last responses were used as primary indicators of gold recovery capacity and mechanical strength. The results obtained show that optimal activated carbon can be prepared under the following conditions: a carbonization time of 157 minutes, activation at 921°C for 53 minutes, and a water vapour flow of 0.18 mL/min. This optimum carbon has an iodine value greater than 1100 mg/g and an attrition index in the order of 0.74%. These values reflect the quality of the precursor (olive stones) as a raw material for the development of an effective new activated carbon for the gold mining industry. IntroductionActivated carbon is an effective adsorbent widely used in industry due to its high surface area, well-developed reproducible microporous structure, and high degree of surface reactivity and adsorption capacity. World consumption of activated carbon is steadily increasing. It is primarily used in industrial wastewater and gas treatment and also for silver and gold recovery from cyanide solutions (Syna and Valix, 2003; Soleimani and Kaghazchi, 2008; Buah and Williams, 2010; Eddy et al., 2011). However, activated carbon is expensive and it needs to be regenerated after each adsorption cycle. In order to decrease the cost of manufacturing activated carbon, low-cost forest and agricultural wastes are considered promising new materials. In recent years considerable research has been reported on activated carbon from agricultural wastes, such as olive stones (Yavu et al., 2010), acorn shells (Sahin and Saka, 2013), peanut shells (Wu, Guo, and Fu, 2013), grape seeds (Jimenez-Cordero, 2014), coconut shells (Yalcin and Arol, 2002; Gratuito, 2008), palm shells (Sumathi, 2009), cherry stones (Jaramilloa, Gomez-Serrano, and A´lvareza, 2009), macadamia nut shells (Eddy, 2011), apricot stones (Soleimani and Kaghazchi, 2008), and bagass (Syna and Valix, 2003)."

Mar 1, 2019

By B. Maybee, J. Venter, J. Wesseloo

The selection of open-pit slope angles involves high-value decisions with small changes in slope angle, often representing significant changes in net present value. The existing methods used to define design acceptance criteria have evolved from factor of safety to probability of failure (P[F]) to risk consequence to risk frontiers, which represents current state of the art. Current design acceptance measures are based on references to published tables representing the experience and judgement of their authors, who did not specify the purpose of the measures contained therein. As the purpose of the published design acceptance criteria is not specified (i.e., definite stability, marginal stability, optimization, etc.), such tables cannot be used to achieve optimum slope angles that maximize profitability. This paper develops a design acceptance criterion that maximizes profitability by defining a formulation for optimum risk that balances expected risk and reward. The model developed is titled the Mining Risk Model (MRM), and is applied to open-pit slope angle selection through an equation for optimum probability of downside (P[D]O) that balances the upside or opportunity, the P[F], and the downside impact. This formulation for optimum risk is unique, as many authors have presented objective functions for their risk models that can be optimized, but none of the sources reviewed contained a formulation for optimum risk. The MRM is sufficiently flexible to allow the design performance measure that drives P[F], and hence P[D]O, to be selected based on the intended goal. Furthermore, the essential information that must be known to quantify optimum risk is defined. This allows users to determine what information to collect for optimum risk decisions. A further benefit of the MRM is that slope angle decisions and pit shells can be ranked to select the best option, and a threshold is provided that separates acceptable from unacceptable decisions. Finally, the workflow and information required to determine optimum risk are presented.

Sep 9, 2024

By D. G. Krige

Recent publications have demonstrated the important role that can be played by a priori information of the grade levels, variability, and spatial patterns in adjacent or nearby areas in improving the quality of grade estimates for virgin or sparsely drilled areas. A research project was therefore conducted involving the collection and analysis of extensive sampling and borehole data from 7 reefs on some 30 Witwatersrand mines. This paper shows that the 'equivalent' log variance for the two-parameter lognormal model provides a good basis for the study and comparison of the levels and behaviour of relative variances. The trends of these against the corresponding log areas were found to form distinctive patterns, which are useful for these purposes. The patterns for the Basal, Vaal, Carbon Leader, and Main Reef Series form a reasonably close group, whereas those for the V.C.R.(particularly where the facies are mixed), B Reef, and Kimberley-Elsburg Reefs (particularly for narrow channel widths) do not always conform. The patterns shown by underground chip samples are also compared with those obtained from borehole cores. It is shown how this information can be used to improve the borehole valuation of new mines and of virgin areas in existing mines.

Jan 1, 1993