Search Documents

By J. D. Noll, J. A. Organiscak, A. B. Cecala

Significant strides have been made in optimizing the design of filtration and pressurization systems used on the enclosed cabs of mobile mining equipment to reduce respirable dust and provide the best air quality to the equipment operators. Considering all of the advances made in this area, one aspect that still needed to be evaluated was a comparison of the efficiencies of the different filters used in these systems. As high-efficiency particulate arrestance (HEPA) filters provide the highest filtering efficiency, the general assumption would be that they would also provide the greatest level of protection to workers. Researchers for the U.S. National Institute for Occupational Safety and Health (NIOSH) speculated, based upon a previous laboratory study, that filters with minimum efficiency reporting value, or MERV rating, of 16 may be a more appropriate choice than HEPA filters in most cases for the mining industry. A study was therefore performed comparing HEPA and MERV 16 filters on two kinds of underground limestone mining equipment, a roof bolter and a face drill, to evaluate this theory. Testing showed that, at the 95-percent confidence level, there was no statistical difference between the efficiencies of the two types of filters on the two kinds of mining equipment. As the MERV 16 filters were less restrictive, provided greater airflow and cab pressurization, cost less and required less-frequent replacement than the HEPA filters, the MERV 16 filters were concluded to be the optimal choice for both the roof bolter and the face drill in this comparative analysis case study. Another key finding of this study is the substantial improvement in the effectiveness of filtration and pressurization systems when using a final filter design.

Aug 1, 2016

By H. Y. Sohn

Considering the two most important issues the ironmaking industry faces today, i.e., energy consumption and greenhouse gas emissions, it would be advantageous to utilize the concentrate-size raw materials directly without pelletizing or sintering, especially without the use of coke. This plenary lecture describes two such processes developed at the University of Utah. One is the Flash Ironmaking Technology (FIT) and the other is a moving-bed process for continuous ironmaking with gaseous reduction of iron ore concentrate (MBIT). These technologies are designed to produce iron directly from iron concentrate without requiring pelletization/sintering and cokemaking in two significantly different temperature ranges. They take advantage of the high reactivity of the concentrate particles and will considerably reduce energy consumption and carbon dioxide emissions compared with the current processes. The process of the development from the conception of the idea, to kinetic feasibility establishment, to laboratory flash furnace, and finally to the operation of a prototype facility for the development of the FIT is discussed. The development of the MBIT also started with the formulation of the process concept, followed by kinetics feasibility establishment, and the design of a potential industrial reactor. The results of economic analyses on the FIT are briefly described.

May 12, 2023

By A. J. Kwitowski

Teleoperation is a technology that can provide significant health and safety improvements in mining, by relocating machine operators hundreds of meters away from the face area. The U. S. Bureau of Mines (USBM) has recently developed a teleoperation system for continuous mining and haulage equipment. This system features near-real-time closed-loop control. A prototype system was developed and demonstrated on the surface. This system could be used in thin-seam applications down to 914 mm. Details are provided on the developed teleoperation system, results of testing, and expected, future applications of this technology for improved safety.

Jan 1, 1994

By S. Tuylu, D. Adiguzel, A. Bascetin

"Optimization techniques are successfully used in many different fields such as engineering, physics, economy, and politics in order to enhance the performance of the systems. In concrete technology, Aggregates are prepared by mixing the water and cement in proportional quantities. In order to obtain desired quality control parameters, the determination of the ingredients ratios is one of the important problems for the optimization. Additionally, in the quarries where the aggregate quality constantly changes, blending optimization must be made to obtain a sustainable aggregate quality. This study showed that linear programming, which is easy and which includes many aggregate properties, cannot be used in terms of some aggregate properties. Therefore techniques such as nonlinear programming or genetic algorithm must be used. INTRODUCTION Concrete is a used construction material and made by mixing the aggregate, cement, and water. The concrete properties are directly related to the properties of these materials in blending. The quantity of aggregates in concrete is approximately 70 percent of the concrete’s volume. Therefore, the most important material is aggregates. The extraction of aggregate materials in quarries is more problematic because of variable bedrock properties. Therefore, the quality of the materials changes and the characteristics of the concrete are also influenced directly. In terms of sustainable use of natural resources, produced aggregate materials which have different qualities should be used optimally (Adiguzel et al., 2014). Nowadays, in the solution of the blending optimization, various optimization techniques are being used such as linear programming, nonlinear programming, and genetic algorithm. In this study, blending optimization techniques especially used for concrete aggregates blending have been summarized, and the advantages and disadvantages of these techniques have been introduced. BLENDING PROBLEMS Blending is a frequently encountered problem in process-type manufacturing such as mining, refinery, food industry, chemical industry and metal industry (Sakalli 2010). Blending is a commonly used method in lots of practical solutions (Sarker and Newton 2008). Several optimization techniques are available for blending problems (Furman and Pardalos 2009). The most important issue is to blend with minimum cost. The blending problem is a special linear model which was developed to solve this problem. In blending optimization research, linear programming is a widely used method (Adiguzel et al. 2011; Bascetin and Adiguzel 2011)."

Jan 1, 2016

By Konstantinos Komnitsas, Evangelos Petrakis, Emmanouil Varouchakis

During the modeling of grinding systems, population balance modeling (PBM) which considers a constant breakage rate has been widely used over the past years. However, in some cases, PBM exhibited some limitations, and time-dependent approaches have been developed. Recently, a non-linear framework which considers the traditional linear theory of the PBM as a partial case was introduced, thus allowing the estimation of product particle size distribution in relation to grinding time or the specific energy input to the mill. In the proposed model the simplified form of the fundamental batch grinding equation was transformed into the well-known Rosin–Rammler (RR) distribution. Besides, the adaptability and reliability of the prediction model are among others dependent upon the operating conditions of the mill and the adjustment of the RR distribution to the experimental data. In this study, a series of grinding tests were performed using marble as test material, and the adaptability of the non-linear model was investigated using three loads of single size media, i.e., 40, 25.4, and 12.7 mm. The results indicate that the proposed model enables a more accurate analysis of grinding, compared to PBM, for different operating conditions.

Jun 24, 2023

By A. Bascetin

Materials produced in quarries have been used for different intentions such as concrete and cement raw material, asphalt and embankment aggregates, railway ballast. Especially in cement manufacturing, the chemical composition and the uniformity of the raw materials play a strategic role in the economy and quality of the cement process. Therefore, it is necessary to achieve uniformity and desired chemical composition and maintain these at all production stages according to the type of cement produced. To achieve this goal the production planning and pit design play an essential role. This paper briefly outlines the production optimization of cement raw materials in a quarry in Istanbul western part of Turkey. For the purpose it was used the 3D ore body modeling and the geostatistical techniques. The variation of chemical components (%CaO, %Al2O3, %Fe2O3 etc.) and quality control parametres (LSF, SR, AR and etc.) obtained from the quarry were determined. Then the values of unknown chemical components and quality control parameters in the ore body were estimated using Kriging which is one of the geostatistical interpolation methods. The open pit design was also created by specifying wall slopes and taking into consideration of the grade distributions of the benches. The most important revolution in the paper is investigating the effects of the block dimensions in block modelling which is important for reserve estimation. The other important point in the study is using the different range values in variogram analysis for determination optimal reserve estimation. n this study, the effects of two parametres on reserve and waste amount estimation were determined according to CaO% distribution. The study was pointed out that the changing of the two parameters are very important for the optimal mine planning and environmental considerations.

Jan 1, 2010

By Soner Top

In this study, a process to separate manganese and iron from manganiferous iron ores by reductive acid leaching followed by magnetic separation was conceived and experimentally tested. In the leaching process, sulfuric acid was used as lixiviant and oxalic acid was used as reductant. The experimental results showed that the manganese and iron separation was optimal when the concentrations of the sulfuric acid and oxalic acid were 0.75 M and 30 g/L, respectively, at a temperature of 80 °C, a solid/liquid ratio of 67 g/L, stirring speed of 400 rpm and leaching duration of 60 min. Under these conditions, 90.49 percent and 6.78 percent of Mn and Fe were dissolved, respectively, from the ore sample in a size fraction of smaller than 106 µm. It was determined that the leaching of manganese from the ores was a second-order reaction with activation energy, Ea, of 53.38 kJ/mol. The leaching residues obtained under the optimal conditions were subjected to wet high-intensity magnetic separation tests to recover the remaining iron content. This separation process produced a concentrate containing 56.20 percent Fe and 1.79 percent Mn with iron and manganese recoveries of 56.83 and 66.73 percent, respectively. To the best of our knowledge, this is the first time that a magnetic separation process was used on a residue obtained from the reductive acid leaching of manganiferous iron ores to recover iron.

By S. Angioletti

This paper addresses strategic investment decisions when they are nested in a project development format where each project is implemented in phases and each phase is approved to move on to the next phase only if certain technical and economic requirements are met. This configuration is sometimes referred to as a ?Project Portfolio?. Mining companies maintain project portfolios in their exploration investment plan. This study proposes a procedure to best manage an exploration project portfolio including technical and economic uncertainties. The procedure may support decision makers in a simple and intuitive way, while maintaining the rigor and precision required by the rather large amount of financial resources typically called for by mining projects. The procedure was tested in a real case study of a gold mining company and its exploration projects portfolio. The procedure uses the following approaches: i) investment valuation methods under technical and market uncertainties based on Option Pricing Model, Real Option Theory and Option Space; ii) portfolio management and Stage Gate®1 method; iii) Monte Carlo simulation.

Jan 1, 2010

The impact of smoothing on the definition of ore and waste boundaries using linear estimation and conditional simulation methods is discussed. The nature of transfer functions is examined including their ability to incorporate categorical data (e.g. a dominant lithology code). An Ore Block Optimization (OBO) transfer function is presented that provides a clear guide for the mining geologist. Advantages are seen in defining stockpile cut-off grades and meeting production targets such as maximizing head grade, maximizing ore tonnes or minimizing ore loss or dilution. Each of these scenarios impacts on mine profitability and grade control.

Jan 1, 1999

By S. P. Winkelmann

The expansion in gold production in the Carlin 'Trend over the last few years has been one of staggering proportion. To increase gold production while minimizing capital requirements and providing for the safe and efficient mining and processing of ores has required a tremendous effort by the Mine Engineering group at Newmont Gold. This paper discusses the organizational changes implemented to effectively deal with a full range of engineering problems and how the Newmont Gold Mine Engineering group dealt with these problems. Specially developed computer software and their applications will be explained. Improvements in the techniques used in converting geologic resources into reserves, and in scheduling the mining of multiple pits to feed multiple processing facilities, as well as ore control procedures are presented. Current mine engineering practices are discussed.

Jan 1, 1990

By Andrea Brickey, RICHARD AMOAKO, Akshay Chowdu

Production forecasts derived from the medium-term schedule represent the best path forward for underground mining operations to achieve corporate and operational goals. Unforeseen circumstances, such as equipment breakdown, can cause significant deviations from established production forecasts in the short term. Such situations require timely mitigation of the effects of the deviations in order to stay as close as possible to the medium-term plan. This paper presents a deterministic mathematical formulation for short-term scheduling that addresses this challenge. The formulation is able to make up for deficits resulting from operational disruptions by minimizing deviations from medium-term production goals and medium-term activity start dates. We demonstrate this in a case study by simulating disruptions involving reduction in ore extraction capacity and development advance rate. Aside from the rescheduling capability, this formulation can help mine planners conduct analysis on the impact of various disruptions on the schedule. The formulation can help identify those conditions or disruptions that are more detrimental to the achievement of forecast targets, or otherwise. The formulation also affords mine planners the flexibility to prioritize one production goal over the other, depending on operational conditions at the mine. In the future, we seek to incorporate in the formulation respirable dust, diesel particulate matter and ventilation constraints in order to create more realistic schedules, and enhance miners’ health and safety.

Jan 1, 2024

By R. Frenette, A. W. Mo, H. A. Hamza

Fine particles present major technical and economic problems to those who deal with solid/liquid separation processes. In the coal industry the problem is compounded by the large amounts of produced fines such as those present in Western Canadian coals. Flocculants in the form of high molecular weight water soluble polymers are commonly considered an effective solution for the enhancement of the separation process. These reagents are relatively expensive especially when considering a low-price commodity such as coal. Optimization of the use of these reagents is therefore an operational necessity. Six polymers were evaluated as to their effectiveness in flocculating a fine coal tailing. Results were compared with those for a reference flocculant, in-use at that time in the washery. It was shown that, in general, flocculants significantly improve the solid/liquid separation process. The ranking of the flocculants as to their effectiveness in settling and filtration indicated that the best flocculants for settling were not necessarily the most effective for filtration. Flocculants that showed the best filtration improvement were generally cationic and those best for settling were anionic.

Jan 1, 1988

By A. Noble

"Froth flotation circuits are widely used throughout the mineral processing industry for the concentration of fine particles. It had been estimated that nearly 2 Gt (2.2 billion st) of ores are treated globally each year using this versatile separation process (Fuerstenau, 1999). Due to the high feed tonnage, a large economic incentive exists for flotation plant operators to optimize the performance of this critical processing circuit. Prior to the 1950s, the optimization of flotation circuits primarily involved the manual adjustment of operating variables based on visual observation and sporadic sampling (Lynch, Harbort and Nelson, 2010). During the next several decades, however, the advent of improved on-line instrumentation coupled with the rapid development of high-speed microprocessors allowed the industry to develop more advanced control systems that could quickly adjust operational parameters in response to disturbances in ore characteristics and plant flows. These early online controls typically involved feedback loops designed to stabilize cell performance through the automatic manipulation of process variables such as pulp levels, gas rates and chemical dosages. The set-points for these controllers were often set by plant operators based on one or more operator objectives, such as maximizing throughput, recovery or grade. More recently, these regulatory controllers have been interfaced with high-level data display and management systems that provide operators with the ability to better optimize flotation plant performance based on mathematical models and rule-based algorithms (Greet, 2010).While tremendous strides have been made during the past several decades, even the most modern flotation plants are still faced with the long-standing question: “What are we trying to optimize?” From an operator perspective, some common responses include “Maximize tonnage of saleable concentrate” or “Maximize metals recovery at a customer-specified market grade.” These replies may or may not reflect those of management, who often focus on economic goals such as “Maximize profits for each operational unit” or “Maximize rate of return for all corporate assets.” Unfortunately, these high-level objective statements do not always translate well into practice due to the disconnect between plant operating protocols and product value. Attempts have been made by industry to overcome this issue using various types of optimization routines such as linear programming or other optimization engines. While this approach does have some merit, these blind routines require considerable input data and interpretational expertise and provide little or no fundamental insight that can be used to drive improvements in concentrator performance."

Feb 1, 2017

By A. Hajati

The main purpose of this study was to find the optimum values for factors affecting the Zn recovery rate using oxine or dithizone as a chelating agent collector during flotation in a Hallimond tube. Eight control factors, including four levels of pH, oxine/dithizone, corn starch, sodium thiosulfate, sodium citrate, sodium silicate, conditioning and floating durations were considered in a Taguchi experimental design technique. An L32 orthogonal array was applied to determine the signal-to-noise (S/N) ratio. Analysis of variance (ANOVA) was used to determine the optimum conditions and the most significant parameters affecting the reaction rate. Analysis of the experiments using the Taguchi approach indicated that pH had the highest contribution to the recovery rate of zinc oxide particles. The results showed that the recovery rate of zinc increased by 43.4 ± 3.0% and 24.9 ± 3.2% using oxine and dithizone, respectively, under optimum conditions with a confidence level of 90%.

Jan 1, 2010

By H. T. McAdams

The logic of regression analysis as an operations research tool is critically examined, and a formal basis for its application to mining problems is developed. The traditional view of regression analysis as a statistical discipline does not provide an adequate basis for evaluating a regression model in a specific area such as ore reserve calculation or process control. In particular, the validity of the residual-sum-of-squares criterion is questioned, and the need for a criterion based on interpolative features of the model is emphasized. Strictly speaking, a regression model is statistically supported only at points at which observations are available, yet inferences are drawn with regard to a continuum. When considered as a mathematical function, therefore, the model is observationally defined only on a domain consisting of a finite number of points. Extension of this domain to an interval of the real line must be based on physical rather than statistical argument. Vector space and function theory concepts useful as a logical framework for a physically oriented problem analysis are discussed and their usefulness demonstrated in a practical problem.

Jan 1, 1966

By Timothy J. Orr, Robin J. Burgess-Limerick, Jennica L. Bellanca, MARGARET E. RYAN

Powered haulage continues to be a large safety concern for the mining industry, accounting for approximately 50%of the mining fatal accidents every year. Among these fatal accidents, haul-truck-related accidents are the most common, with 6 of 28 and 6 of 27 fatal accidents occurring in 2017 and 2018, respectively. To better understand why these accidents continue to occur and what can be done to prevent them, researchers reviewed the 91 haul-truck-related fatal accidents that occurred in the USA from 2005 to 2018 and performed bow-tie analyses using the final reports published by the Mine Safety and Health Administration. The analyses explore the context of the accidents with a focus on the initiating event, event outcome, hazards present, and possible preventative and mitigative controls. Overall, the vast majority of the accidents resulted in a haul truck colliding with the environment, and the majority of these events were initiated by loss of situational awareness or loss of control. The majority of the hazards were related to design and organizational controls. The results of this study suggest a need to investigate operator decision-making and organizational controls and to focus on improving design and operation controls such as mine design and operational procedures.

Feb 22, 2021

By D. R. Willmer

An understanding of how health and safety management systems (HSMS) reduce worksite injuries, illnesses and fatalities may be gained in studying the behaviors of health and safety leaders. These leaders bear the accountability for identifying, understanding and managing the risks of a mining operation. More importantly, they have to transfer this knowledge of perception, recognition and response to risks in the mining environment to their workers. The leaders’ efforts to build and maintain a mining operation’s workforce that consistently executes safe work practices may be captured through more than just lagging indicators of health and safety performance. This exploratory study interviewed six leaders in occupations such as site-level safety supervisors, mine superintendents and/or general managers at surface and underground stone, sand and gravel and metal/nonmetal mine sites throughout the United States, with employee populations ranging from 40 to 175. In exploring leaders’ perspectives on how they systematically manage health and safety, examples such as approaches to task training, handling near-miss incidents, identifying future leaders and providing workers with feedback offer insights into how leaders translate their knowledge and management of site-level risks to others.

Jan 1, 2018

By D. R. Willmer

An understanding of how health and safety management systems (HSMS) reduce worksite injuries, illnesses and fatalities may be gained in studying the behaviors of health and safety leaders. These leaders bear the accountability for identifying, understanding and managing the risks of a mining operation. More importantly, they have to transfer this knowledge of perception, recognition and response to risks in the mining environment to their workers. The leaders’ efforts to build and maintain a mining operation’s workforce that consistently executes safe work practices may be captured through more than just lagging indicators of health and safety performance. This exploratory study interviewed six leaders in occupations such as site-level safety supervisors, mine superintendents and/or general managers at surface and underground stone, sand and gravel and metal/nonmetal mine sites throughout the United States, with employee populations ranging from 40 to 175. In exploring leaders’ perspectives on how they systematically manage health and safety, examples such as approaches to task training, handling near-miss incidents, identifying future leaders and providing workers with feedback offer insights into how leaders translate their knowledge and management of site-level risks to others.

Jan 1, 2017

By Ronald W. May

The Lower Cretaceous McMurray Formation in northern Alberta contains bituminous sands interbedded with other sediments which form the reject encountered during mining operations. Grade prediction is based on a combination of geological interpretation, computer modelling and past mining experience. In addition to estimates for ore, an accurate estimate of "waste" or "reject," are required for Mine Planning. This study investigates the ability of point-kriging using geostatistics, to augment the existing data base of drill-holes in a study area on Syncrude's leases. This approach enables the assessment of potential "worst" case - "best" case scenarios within the context of Mine Planning.

Jan 1, 1985

By Todd Kilduff, Ryan O’Connell

Pipe canopies continue to gain momentum as a reliable methodology for construction of excavations below critical facilities with minimal surface settlement tolerances, such as railroads or roadways. Two tunnel projects designed by Kilduff Underground Engineering in the Salt Lake City, UT area, each at varying stages of completion, had project design criteria for selection of a tunneling methodology to minimize surface settlement. Both projects consist of a pedestrian tunnel, one crossing beneath a major roadway in downtown Salt Lake City and the second beneath UPRR tracks. Both projects were in difficult, coarse alluvium/fan ground conditions with project criteria that resulted in minimal cover above the tunnel. For each project, a pre-support pipe canopy was designed, requiring the placement of steel, canopy pipes driven the extent of the tunnel length. The pipe canopy is installed using a trenchless technology and then excavated with SEM tunneling and shoring provided by traditional support of excavation methods. The pipe canopy pre-support method offers a low-impact method to install an underpass beneath critical structures by adding significant stiffness to the subgrade to mitigate surface settlement during the main tunnel excavation sequence. These case studies seek to communicate the challenges associated with pipe canopy installation in site-specific ground conditions and explains how these challenges were overcome. This paper aims to define the project risks and describes the pipe canopy methodology as a viable solution to mitigate surface settlement in low cover tunneling scenarios.

Jun 13, 2023