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By T. Eisele, T. Weldum, G. Rajala, H. Walqu, S. Kawatra

The throughput and energy efficiency of comminution circuits is reduced when ore characteristics change, causing bottlenecks in some portions of the circuit while leaving excess capacity in others. The results of analysis of three years of daily grinding circuit operating data for a full-scale plant has shown that the location of bottle-necks in the circuit will change depending on the nature of the feed ore. The circuit tends to be limited by the primary mill capacity when the ore hardness increases, and limited by the secondary mill capacity with softer ores. Two methods are considered for shifting load in the circuit to relieve bottlenecks by taking advantage of excess capacity in other parts of the circuit: 1) Addition of supplemental comminution operations, such as high-pressure grinding rolls, to process specific size fractions that are not handled efficiently by the primary mill; and 2) Use of screens to shift grinding load upstream from the secondary mills back to the primary mills. In the case of the plant examined in this study, it was found that 58% of the time there was sufficient excess capacity in the primary mills that the throughput of the circuit could have been increased by using screens to shift the grinding load from the secondary mills to the primary mills.

Jan 1, 2004

By Y. Q. Zhang, S. S. Peng

Numerical modeling was used to design the pillars and bolting plan for a mine with weak roof and multi-seam stress condition. Previous mining experience, pillar/roof yielding and in-situ horizontal stress were considered in the models. By modeling the upper seam yielding and vertical stress transfer, a multi-seam influence zone was obtained. Appropriate pillar sizes were designed for conditions with and without upper seam stress influences. Roof support for the track and belt entries, using fully-grouted resin bolts and cable bolts, was proposed and implemented in the model. The bolting plan was evaluated under the weak roof condition.

Jan 1, 2004

By R. Corriveaau

This paper is about a horizontally curved conveyor, which carries 6,050 stph of limestone over land from a new quarry to the owner's plant. The conveyor is 5,012 ft long with a horizontal curve radius of5,OOOft Site conditions made a curved conveyor design the most optimal and economic solution. Using our unique custom conveyor calculation program, TKRI was able to accurately model and design the conveyor to properly track the belt and prevent any spillage through the horizontal curve radius. A data monitoring system was installed that allows monitoring of the conveyor both locally and remotely. The remote monitoring allows TKRI to contact the owner for preventive maintenance. Preventive maintenance can reduce the conveyor downtime during normal operating hours.

Jan 1, 2004

By R. Milici

Current federal and State coal assessments estimate resources in the ground, resources available for mining, and economically recoverable resources. None of these assessments predict the amount of coal that may be produced from an assessed area in the near future (~20 years). Predictive assessments of coal production would be based on an understanding of the regional coal geology (coal systems), potential demand, and knowledge of the mining history of the region. The output of the predictive assessment would be a supply curve – a probability distribution of the amount of coal expected to be produced from current and new mines during the assessment period. I

Jan 1, 2004

By S. Vogely, J. Trescot, D. Connor, F. Beloy

In 2001, the Minntac Division of US-Steel retrofitted one of their Grate-Kiln Iron Ore Pelletizng lines with a Ported-Kiln Air Injection System (PKAIS) the first of it’s kind in the world for oxide pellets. The Ported Kiln System injects air under the bed of pellets in the rotary kiln, causing rapid oxidation of the magnetite pellets. This rapid oxidation allows for lower kiln temperatures, reducing fuel demand; less heat load on the annular cooler; and higher pellet quality. Both the process and the equipment are patented developments by Metso Minerals. This paper discusses the process, the key equipment, and the benefits to the pellet plant and the downstream blast furnace operations.

Jan 1, 2004

By Steve Kral

In the United States, the U.S. Environmental Protection Agency (EPA) is set to implement its Tier 2 air quality standards governing high-horsepower, off-road diesel engines. The regulations take effect in January2006. In Europe, similar standards, called Stages, are due to take effect about the same time. And other markets, such as Japan and Australia, have their own standards on tap. Tier 2 standards will further reduce the amount of nitrogen oxide (NOX), sulfur dioxide (SO2), diesel particulate matter (DPM), carbon monoxide (CO) and hydrocarbons off-highway diesel engines are allowed to emit. And even more restrictive Tier 4 standards are due in 2011. The upshot is that operators of high-horsepower engines, particularly in mining, will begin using in their new off-road haul trucks, excavators, shovels and other mining machines diesel engines that are designed to meet these more stringent standards.

Jan 1, 2004

By S. G. Hardcastle, C. K. Kocsis

Ventilation is an expensive prerequisite for underground mining. Current mining trends, including increasing depth and mechanization and more stringent health regulations would generally dictate that more air volume is required in order to provide good working conditions underground. However, any increase in the mine’s intake airflow can produce a disproportionate increase in power consumption and hence operating costs due to the cubic relationship between the sup-plied air power and the airflow (Power a Flow3). Furthermore, forecasts of significant increase in energy prices and new commitments with regard to reductions of greenhouse gas(GHG) emissions, determined the mining industry to look into developing new concepts, design tools and incorporate the latest mining technologies in order to lower capital and operating costs while meeting commitments regarding GHG emissions. The advances in computing power and modelling software now make it possible to design, model and schedule a mine from opening to closure. A developing trend is to design and plan the mine by means of orebody modelling software, followed by using discrete-event simulation techniques to predict production rates and evaluate various operating scenarios throughout the life of the mine. The authors are currently evaluating how such process simulators could be adapted in order to forecast the need for materials or a specific resource, and one of these would be the mine’s “life-cycle” airflow demand as a function of scheduled production rates and mine operating characteristics. Further to this, based upon the mine’s life-cycle airflow demand schedule, the ventilation system could then be designed using a mine ventilation simulator. This new design approach would integrate in parallel the development of the ventilation system with the current mining conditions, therefore, heading towards “develop-as-you-go” as opposed to developing the system for final requirements with high upfront costs. This new ventilation system design criteria would also incorporate the use of the “ventilation-on-demand” technology, which will further lower development and production costs and implicitly, the mines’ GHG emissions.

Jan 1, 2004

By Marcus A. Wiley, Gregory Abramov

Borehole mining (BHM) is a remotely operated method of extracting rock material through boreholes by high-pressure water jets. Figure 1 illustrates a BHM tool and fluids circulation. The tool consists of at least two pipes, one for pumping down high-pressure water, the second for delivering slurry to the surface. This article reviews the BHM process. It discusses current and new applications for borehole mining and help the readers determine if BHM is applicable in their situations. Previous articles in ME about BHM explained either a particular project (ME, April 2001, pp. 33-36) or a newest patent in this area (ME, March 1991, pp. 313-318). However, neither one provided an overview on the modern BHM technology.

Jan 1, 2004

By P. Harris, G. Groenmeyer, L. Parolis

The effect of molecular weight, charge and the presence of the cations Ca2+, Mg2+and K+ on the adsorption of carboxymethyl cellulose on pure talc obtained from Balmat, New York have been investigated. Higher adsorption densities were obtained in the presence ofCa2+ and Mg2+ ions than with K+ ions and higher ionic strength solutions resulted in higher adsorption densities. Changing the molecular weight did not influence the adsorption however increasing the charge (DS) of the polymers resulted in lower adsorption densities.

Jan 1, 2004

By R. Abel, T. Wildeman, N. Heflin

A study was conducted to assess environmental effects of waste rock piles on water in the Russell Gulch area. Each pile was rated on physical characteristics of proximity to an ephemeral gulch, extensiveness of erosion features, size, presence of vegetation, and presence of a kill zone. Chemical assessments focused on three leachate tests performed on waste rock samples. Ratings were based on pH, conductivity, acidity, and analysis for 31 metals using inductively coupled plasma emission spectroscopy. The chemical and physical assessment of each site is used to make a rating of each pile on its overall potential to deliver contaminants.

Jan 1, 2004

By R. Gehauf

Magnetic separation using rare earth rolls (RER) and rare earth drums (RED) have seem tremendous development and use in recent years. While the process of magnetic separation is understood, the principles affecting the separation, the specific application and the optimization of RERs and REDs are less well known. This paper offers practical insight into the basic operation, selection and optimization of RERs and REDs. It is a guide for the engineer who must design a test series and select the proper equipment for that application. It provides the engineers and line operators who control the daily operation of the equipment a basic understanding of the dynamics of operation and the principles that govern the optimization of RERs and REDs.

Jan 1, 2004

By W. G. Pariseau

Regression analysis of calculated on measured displacements were used to assess the influence of fill and fold plunge on shaft pillar mining at the Homestake Mine. These effects were neglected in the original three-dimensional finite element analysis undertaken in 1991. An average fold plunge of 15? and a 24K fill (Young’ modulus of 24,000 psi or 165 Mpa) were used in the reanalysis. Measured displacements were obtained from an array of 36 m (120 ft) multiple-position borehole extensometers installed in June 1994 and read to March 2003. Results indicate the effects of both on calculated displacements and thus on regression parameters are noticeable. However, these neglected effects would not have changed the original inference of Ross Shaft stability during pillar mining.

Jan 1, 2004

By M. T. Worley

Joint Development Associates International, Inc. (JDA) began humanitarian relief and community development in Central Asia in1992, following the collapse of the former Soviet Union. Appropriate technology has played an important role in their efforts to assist those segments of society that are most vulnerable to poverty and disease. Three case histories are described to illustrate the successful implementation of simple, but effective technology in community development.

Jan 1, 2004

By M. Kockler, S. J. Jung

Underground operations at the Rain Mine averaged 360 tonne/day (400 ton/day) utilizing underhand drift-and-fill and longhole stoping with delayed fill between 1993 and 2002. Mining from four ore zones produced over 803 800 ore tonnes (886 000 tons) at a grade of 9.32 gm/tonne (0.270 oz/ton). Even though openings in the ore could be as large as at 9 m (30 ft) wide, 30 m (100 ft) high, and over 60 m (200 ft) long, the weak rock surrounding the ore zones restricted development size to 3 m (10 ft) wide by 3.7 m (12 ft) high.

Jan 1, 2004

By C. H. Bucknam

Principles of Green Chemistry provide useful guidance for sustainable mineral process development. Laboratory bench scale testing was carried out using pregnant cyanide leach solutions, and a number of commercially available mercury precipitation reagents were compared using jar testing to determine the most efficient and selective reagents for mercury precipitation. The most efficient reagent identified was sodium polymeric thiocarbonate (NaPTC).Coagulation experiments with fine diatomaceous earth resulted in a stable precipitate, with good settling properties. On line monitoring of the mercury in solution is recommended for process implementation to conserve reagent removing approximately 90-95% of the mercury with minimal silver and negligible gold losses.

Jan 1, 2004

By Nigel Fung, J. D. Humphrey, R. H. Oats, J. H. Ingle

Production dozing of cast material is a cost effective method of improving dragline or mobile equipment overburden removal. Yet dozer productivity is reduced during the part of the process that requires the dozers to cut material away from the highwall. One solution is to use a hydraulic excavator to remove this material and throw it into a windrow for the dozers. By freeing up the dozers for more productive work the overall system productivity increases 25% and cost per yard is reduced by up to 10%. Dozer fleet sizing can be determined to match a specific production schedule or can be sized to balance with an excavator’s production.

Jan 1, 2004

By J. E. Warm

Florida’s ancient beach ridge sand deposits, mined for construction aggregate, are highly variable. Rinker Materials utilizes a small reverse-circulation drill rig to prospect and profile unconsolidated fine aggregate deposits more effectively and inexpensively than other drilling methods. Sample data is stored in a spreadsheet that calculates yield and volume. Rinker also uses a Trimble ProXR backpack GPS to locate boreholes in the field, track mine progression on a monthly basis, and to map restrictive features such as wetlands. Autodesk Land software is used to create detailed deposit maps and mine plans. Rinker believes that these practices have led to improved awareness of deposit characteristics and deposit utilization.

Jan 1, 2004

By K. A. Larsen, J. L. Ariail, C. M. LaRosa

This article discusses the evolution of U.S. laws and policies towards environmental remediation at mine lands over the last 20years, the opportunities that these changes present for reuse, and the remaining challenges associated with community capacity for effective reuse planning and implementation. Emerging initiatives by the U.S. Environmental Protection Agency and Department of Interior for addressing these challenges are discussed.

Jan 1, 2004

By K. M. Atencio, T. Pike, S. Forrest

We will introduce the Small Business Liability Relief and Brownfields Revitalization Act, which is an amendment to CERCLA and the types of sites it includes and excludes, especially as related to mine-scarred land. We will also describe the types of available funds, whether they are competitive or not, what entities are eligible to receive them, and how to access them. We will introduce the legislation’s liability provisions; for example, the recently issued interim guidance clarifying some of the conditions that contiguous property owners, bona fide prospective purchasers, or innocent landowners must meet to qualify for the liability limitations provided in the Brownfields Law.

Jan 1, 2004

By E. J. Berentsen, R. F. Nanna, D. Dell’ Elce, R. Lougheed

Apollo Gold’s Black Fox project is located 10 km (6.2 miles) east of Matheson, Ontario, Canada, on Hwy 101 East It is located within the prolific Destor Porcupine Fault Zone, which is also the host for the Dome and Hollmger mines to the west and the Holt and Holloway mines to the east. The local host rocks are intensely deformed and carbonized ultramafic volcanics, pillow basalts, syenitic felsic intrusives and argillaceous sediments. Gold occurs with pyrite and as spectacular specimens in native form. Past production accounted for a total of 195,337 oz (6,075,606 g) of gold. Apollo Gold Exploration, Inc. is conducting an intense drilling program aimed at expanding the reserve base.

Jan 1, 2004