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By S. Acar

"In recent years the gold mining industry has been challenged by declining metal prices as well as having to treat ores that have low grades and are refractory in nature. Many factors must be considered when metallurgical studies are designed to develop process design criteria for these type of ores. These factors are mostly related to the mineralogical and chemical compositions of the ores, the geological setting of the deposit and how the ore/waste will be mined, such as whether openpit or underground, the mine schedule, and the mine fleet type and capacity. The purpose of this paper is to provide an experience-based practical approach to how to select and characterize test samples as well as devise process development metallurgical studies for both oxide and refractory gold ores, and to provide insight into some of the matters that might go wrong during the course of the studies. This paper is intended as both a guide for someone new to the field and also as a reminder for those familiar with the field. IntroductionThe recent decline in ore grades and metal prices have challenged mining companies to reduce capital and operating costs associated with developing new mineral resources. In some cases, metallurgical studies have been sacrificed to prevent cost overruns resulting in inadequate mineralogical, chemical and metallurgical characterization. Consequences have included longer construction schedules, higher initial and working capital, higher operating costs and less than desirable plant performance (Whincup, 2010; Torres, Chaves and Meech, 1999).Mineralogy, geology, mining type and sequence, and the metallurgy of an orebody will determine the process development metallurgical study requirements and eventual process plant design. Therefore, once the geologist has an early indication of a prospective orebody, geologists, metallurgists, mining engineers, and social and environmental responsibility scientists should convene and devise a plan on how to exploit the orebody economically (Lunt, Ritchie and Fleay, 1997).Geologists may find a prospective orebody solely based on grade. However, if the orebody cannot be mined and processed economically, then it is deemed not to be a deposit. An example of this could be a refractory gold deposit, either sulfidic, carbonaceous or siliceous refractory or any combination of those, that may not be mined and processed economically due to reasons such as the physical location of the deposit, depth of the ore lode, or social and environmental concerns. Therefore, an early collaboration between all disciplines must be established.Each orebody may have its own unique mineralogical, geological and chemical characteristics (Guresin et al., 2012). These unique characteristics should be effectively sampled to reduce risks associated with process design and engineering efforts for the process development metallurgical studies. If the sample or samples are not representative of these unique characteristics, then the studies performed will be pointless. The project metallurgist in charge of conducting metallurgical studies should also possess general geology, mineralogy and mine engineering knowledge. Recommended readings are a book on understanding mineral deposits by Misra (2000) and articles on heap leach development by Scheffel (2014a and 2014b)."

Jan 1, 2016

By W. C. Morgan

The Federal Surface Mining Law enacted in 1978 is now being translated into regulations which must be followed in future coal mining. Substantial change to mining procedures is required to maintain stricter air and water control while mining and to return the mined out land to equal or better use than before. These changes do not come easy; and in most cases, they create a substantial additional cost. Based on field observations and mining studies, Caterpillar has been making suggestions on the use of their types of equipment to conform to the new standards at the least cost. This paper will be a brief review of some of the overburden stripping and reclamation methods suggested by Caterpillar. A production and cost comparison of dragline, scraper/dozer and truck, loader systems in 20 to 150 ft. Overburden conditions illustrates potential cost savings using mobile equipment.

Jan 1, 1980

By Gordon R. Haworth

During the past ten years we have experienced a period of rapidly-changing ground rules for the mining industry. Domestically we have had to contend with numerous new regulations controlling the impact of mining-related activities on the environment. However, for the purposes of this presentation we will assume that in the United States, after a certain amount of compromise on all sides, the industry will be able to work within the framework of the new regulations, and therefore we will concentrate on offshore developments. Due to the limitations in time and scope, this paper will be directed primarily toward the metal mining industry. We contend that the U.S.-headquartered mining company should remain active, and even expand its interests in foreign countries in the future. This is our feeling in spite of recent setbacks and the low return on investment experienced in recent years by some of the metal mining companies in their foreign operations.

Jan 1, 1975

By Yves C. Lizotte

Although blasting remains the most inexpensive method of fragmentation in hardrock mining, the significance of the costs of blast-induced rockmass damage in terms of mining efficiency and safety is becoming increasingly recognized. There is no straightforward and systematic method of adequately measuring blast damage in on-going mining operations. This paper considers various techniques available to measure blast damage, making particular reference to recent underground hardrock mine studies. It concludes by proposing a damage audit procedure for integration into routine mine production control.

Jan 1, 1996

By James P. Bowersox

Modem mineral processing plants handle large amounts of ore and produce large tailing streams. Plant performance can be optimized when the water is quickly recovered with a thickener. The caisson thickener was developed to overcome process and mechanical problems with the conventional traction and center column units. The caisson is a hollow center column that serves as a pump house. The rake arm structure is supported by a hydrostatic bearing which sits on top of the caisson. The caisson thickener with a hydrostatic bearing has operated for many years in several mineral processing applications.

Jan 1, 1981

By Jay R. Schafler, Jacob L. Brinkman, Catherine E. Johnson

"The United States coal mining industry is currently experiencing a decline in both demand and commodity price while facing implementation of more stringent air and water pollution regulations. Company profits have decreased significantly, forcing several major companies to declare bankruptcy. The industry was required to adapt to survive. Many of these companies have adjusted by abandoning mines; the last two decades have seen a drastic decrease in the number of mines. To discover the primary causes of this downturn, three major aspects must be studied: properties of abandoned mines, commodity history and regulatory impact. Trends since 1994Each year, U.S. coal mines are required to submit data on a variety of categories to the U.S. Mine Safety and Health Administration (MSHA) and the U.S. Energy Information Administration (EIA). This data include administrative records, production values and information regarding the attributes of the mined material and the mine itself. Each year since 1996, EIA has released a report summarizing the data from two years prior. Additionally, MSHA maintains a database containing a collection of all the most current data. These resources are the primary sources for the figures included in this article. There are several items to note regarding this data:1. The EIA reports from 2016 and 2017 were not released at the time of writing this report.2. The MSHA data set is actively maintained as information is provided. This means the data for 2016 is from June 27, 2016 and data for 2017 is from Aug 24, 2017. All other points represent the end of-year values.3. Each of the figures only includes data pertaining to active mines. EIA defines active mines as both active and temporarily idled mines, and inactive mines as nonproducing and abandoned mines. MSHA separates all four into separate categories, though this paper combines the MSHA values according to the EIA definition for the purpose of comparison."

Jan 10, 2017

By MARK J. VANARELLI

Estimating groundwater inflows in rock deep tunnels is critical to the safety of personnel constructing the tunnel and the cost of construction. This paper presents two case studies for estimating steady-state groundwater inflows into deep rock tunnels. The case studies included the Chattahoochee and Nancy Creek tunnels. In this paper, statistical methods were applied to packer test data obtained from exploratory borings during geotechnical site investigations. A semi-empirical procedure was utilized for estimating groundwater inflows into these deep rock tunnels. It is the most widely used method/procedure in the tunnel industry. The Chattahoochee and Nancy Creek tunnels are deep rock tunnels which exhibit radial flow conditions. For the radial flow condition, a statistical analysis presented in this paper indicates that the semi-empirical procedure works well; however, variations in the procedure and/or an insufficient amount of testing could lead to underestimations of the inflow quantities. Packer test data plotted in histograms were observed in all cases to be log-normally distributed for the radial flow condition. Modeling using Monte Carlo simulations was observed to be an effective tool for removing irregularities in the distribution of the data and incorporating high-end permeability data to derive reasonable groundwater inflow estimates. This paper is based on the PhD thesis entitled “Improvements to the Current State of the Practice in Steady-State, Groundwater Inflow Estimates into Rock Tunnels based on the Application of Statistical Analysis Methods of Packer Test Data obtained from Exploratory Borings During Geotechnical Site Investigations.”

Oct 9, 2020

By Jürgen F. Brune, SAMUEL A. LOLON, ADITYA JUGANDA, Gregory E. Bogin Jr

Historically, there have been many occurrences ofmine fires and explosions recorded in the United States and other countries that have demonstrated the existence of explosivemethane–airmixtures, herein referred to as explosive gas zones (EGZs). The risk of mine explosions can increase if the EGZs migrate out from the gob into the surrounding mine entries. Fluctuating barometric pressure is the common cause for EGZs outflowing or outgassing from the gob. Numerical analysis using a 3D computational fluid dynamics method was developed to fully understand the outgassing phenomenon. A number of simulations using various magnitudes and periods of barometric pressure changes indicated that the EGZ outgassing potentially occurs due to lags in pressure, which are strongly influenced by mine conditions and ventilation systems. An early warning system with a real-time pressure monitoring and the application of gob ventilation boreholes are recommended to detect and mitigate explosion hazards from gob outgassing.

Aug 24, 2020

By Christopher B. Kapes

To reduce concentrate dewatering and drying costs, the Concentrator Division at Phelps Dodge Morenci, Inc. investigated available filtration technologies. Numerous methods were explored, including: drum, disk, belt, pressure, hyperbaric, and ceramic media filtration. An economic evaluation of the individual filtration technologies indicated the advantages of ceramic media filtration for Morenci concentrates. This paper discusses the technological development culminating in the first full scale application of ceramic media disk filters in North America. Low moisture contents are obtained at high production rates and greatly reduced operating costs.

Jan 1, 1994

By JESSICA W. A. AZURE, Samuel Frimpong, AZUPURI G. A. KABA, FORSYTH A. KADINGDI, PROSPER E. A. AYAWAH

This study developed machine learning (ML) models for predicting rock formation reactive forces experienced by a hydraulic shovel bucket during excavation. To do this, rock formation in the form of muckpile was modeled as granular ball elements in three-dimensional particle flow code (PFC) using linear bonding logic. A typical field-size hydraulic shovel bucket modelled in AutoCAD was used to excavate the rock formation and the three-dimensional shovel bucket resistive forces required to cut through the rock formation were measured and recorded. The experiments involved different muckpile height, bulk densities, repose angles, and average fragment size. Six ML algorithms, artificial neural network (ANN), K-nearest neighbor (KNN), linear, random forest (RF), regression tree (RT), and support vector machine (SVM), were evaluated on their ability to predict the shovel bucket resistive forces. The input variables used for the prediction of the resistive forces were the muckpile bulk density, angle of repose, height, and fragment size. The results showed that the ML techniques are useful and reliable methods of predicting rock formation resistive forces based on the rock formation properties. This research is a preliminary step towards developing reliable models for accurate prediction of excavation forces/torques which could potentially enhance hydraulic shovel process automation.

Sep 27, 2021

By Hugo E. Camargo, Amanda S. Azman, Brian Kim

Repeated noise exposure and occupational hearing loss are common health problems across industries and especially within the mining industry. Large mechanized processes, blasting, grinding, drilling, and work that is often in close quarters put many miners at an increased risk of noise overexposure. In stone, sand, and gravel mining, noise is generated from a variety of sources, depending on the type of ore being mined as well as the final consumer product provided by that mine. Depending on the source of noise generation, different strategies to reduce and avoid that noise should be implemented. The National Institute for Occupational Safety and Health (NIOSH) has evaluated the noise profile at three operational surface stone, sand, and gravel mines. A-weighted sound level meter data as well as phase array beamforming data were collected throughout the mines in areas with high noise exposure or high personnel foot or vehicle traffic. Sound level meter data collected on a grid pattern was used to develop sound profiles of the working areas. These sound contour maps as well as phase array beamforming plots were provided to the mines as well as guidance to modify work areas or personnel traffic to reduce noise exposure.

Jan 6, 2022

By J. Stawovy, A. Fourie, J. D. Quaranta

Coal refuse impoundments are disposal facilities specifically designed for the coal mining industry. Re-purposing refuse impoundments for co-disposal with natural gas flowback water and waste rock overburden has been investigated. The aims of this study were to investigate properties of coal refuse classification under the influence of co-disposed wastes as geochemical material exposure pathways from hydraulically exposed sodium and calcium ( Na+, Ca2+) cation loading from disposal of flowback water produced during the development of horizontal drilled natural shale gas frack wells, and waste rock having limestone characteristics. The geotechnical index classification of saturated cohesionless refuse is required to evaluate the liquefaction potential for strain or strength loss contributing to ground movements. This study is relevant to identifying changes in the coal refuse geotechnical index classification as sand-like, clay-like, or a borderline transitional material from the effects of ion and waste exposure in the impoundment’s reservoir porewater. Laboratory geotechnical tests were performed on fine coal refuse blended with different cations to classify the altered plastic behavior and index classification. Following determination of the index classification, the specimen’s stress–strain responses were investigated through isotropically consolidated undrained (ICU) triaxial compression tests. This experimental study culminated with two salient findings: the first is that introduction of ions alone into the refuse tailings or impoundment porewater resulted in significant material changes in property index classification, and the second finding was that the difference in refuse index classification did not correlate into noticeable effects of the monotonic undrained triaxial strength parameters.

Jul 5, 2022

By A. E. Halim, J. F. Brune

The 2006 Sago, Darby, and Aracoma mine disasters in the United States (US) forced the US government to implement the 2006 MINER Act and additional regulations that require all US underground coal mines to install and maintain refuge chambers to manage entrapment emergencies, in particular, fires and explosions. However, there is a debate on whether barricading in refuge chambers is a good strategy to survive such emergencies. Australian coal mines are not required to use refuge chambers and, instead, have adopted a strategy that focuses on instructing and training miners to self-escape to the surface. This paper analyzes merits and problems of using refuge chambers and self-escape to the surface to manage emergencies in fires or explosions in an underground coal mine. The authors found that the use of refuge chambers may not be the best strategy during extensive fires or when multiple explosions happen. In these situations, mine rescuers are unlikely able to extract miners who are sheltered in chambers and conversely, self-escape may save more lives than sheltering. Chances for successful self-escape are further improved by regular, externally assessed training such as Level 1 Emergency Exercises required in the Australian State of Queensland. These exercises put pressure on mine operators to ensure and maintain the effectiveness of their emergency management system.

By Raj K. Rajamani, Samira Rashidi

High pressure grinding rolls have been utilized in various operations during the past four decades, simply due to their inherent mode of breakage that offers metallurgical benefits with pronounced energy reduction. For every new application, wear and in particular roll surface wear protection has always been the focal point of HPGR trade-off studies. Wear remains an important issue throughout a mine’s life given inevitable variations in the ore deposits properties. Hence, the capability of continuous scanning of rolls provides ample information about any deviations in the design values as well as their effect on the wear pattern. In part I of this manuscript, we present the feasibility of in-line scanning of roll surface in a 200 × 100 mm lab-scale HPGR. First, the in-line scanning was developed in a mock-up roll and then the scanner was moved to the laboratory-scale HPGR. We present the choice of scanners and the methods adopted to achieve high-level accuracy of determining wear. Even though we planned for micron-level precision of scanning, the inherent variability in shaft rotation was higher than the variability in the roll diameter due to wear. The hundred-kilogram mass processed in the HPGR was not sufficient to create enough wear that is discernible to the in-line scanner. Yet, the method tested is a promising avenue for inline scanning of HPGR rolls.

By M. Mustafa Kahraman, Sean Dessureault, W. Pratt Rogers

Most contemporary mines have considerable amounts of data. Structured and unstructured large data sets are colloquially named big data. Much of the data in mining operations come from a variety of systems, each with different databases and reporting environments. Standard technology deployments create a Bsilo-ification^ of data leading to poor system benefit. Through modern server monitoring and systematic approach, data utilization and value can quantifiably be measured. The Data Utilization and Value Index (DUVI) can quantify business intelligence best practices and user interaction. This study seeks to provide a data management tool to measure data utilization across the process of converting data into action.

By H. Askari-Nasab, B. Osei, K. Awuah-Offei

The U.S. coal mining industry consumes approximately 142 billion kWh/a of energy. The U.S. Department of Energy estimates that the industry’s annual energy consumption could be reduced by 49%. This constitutes nearly $3.7 billion of potential savings on coal production costs at 5.3¢/kWh of energy. Additionally, with climate change regulation on the horizon, any benefits from energy savings in the near future are compounded by associated reductions in CO2 emissions. Research indicates that operating conditions significantly affect energy efficiency. Modeling and simulation have been shown to be a cheap and reliable means of evaluating the effects of process interactions and operating conditions. The goal of this work was to apply stochastic process simulation to model the energy efficiency of a typical truck-and-shovel mining system and use the model to evaluate production strategies to improve energy efficiency. The research team conducted energy audits of truck-and-shovel overburden removal and used the results to develop regression models describing truck and shovel fuel consumption. The team then built a stochastic simulation model of the truck-and-shovel overburden removal operation and used it to assess a variety of improvement measures by simulation experimentation. Valid fuel consumption models for shovel loading and truck haulage have been formulated, based on the energy audit results. Valid stochastic process models of truck-and-shovel operations have been formulated to study energy efficiency. The following strategies, in decreasing order of impact, provide the most energy savings for truck-and-shovel overburden removal at the mine: (1) shorten haul roads, (2) increase shovel capacity and (3) increase shovel utilization through optimal truck matching. Additional data will be required to adequately describe operator effects on energy efficiency.

Jan 1, 2011

By V. T. McLemore

New Mexico Bureau of Geology and Mineral Resources (NMBGMR) has been collecting data on uranium mining districts, mines and mills since it was created in 1927 and has converted years of historical data into a relational database that can be imported in ArcMap. The database includes information on mining districts, mines, mills and geochemistry, as well as photographs and bibliographic resources. The available data includes location, production, reserves, geologic, geochemical, resource potential and other data. The National Uranium Resource Evaluation (NURE) stream-sediment data provides geochemical analyses for >27,000 samples collected in New Mexico during the 1970s. The NURE hydrogeochemical data provides analyses of water samples. ArcMap includes the location of individual ore bodies as polygons and incorporates the mines and NURE data as individual site locations. The purposes of these databases are to provide computerized data that will aid in identifying and evaluating resource potential, resource development and management, production and possible environmental concerns, such as physical hazards (i.e., hazardous mine openings), indoor radon, regional exposure to radiation from the mines, background geochemical data and point sources of possible pollution in areas of known mineral deposits.

Jan 1, 2010

By P. H. S. W. Kulatilake, T. Hudaverdi, C. Kuzu

Prediction of blast fragmentation plays a key role for overall productivity of mines. In this study, a new multivariate analysis procedure for prediction of blast fragmentation is presented. Several blasts performed in various mines and rock formations worldwide were brought together and evaluated. An extensive blast database was created. Blast design parameters, the modulus of elasticity and in-situ block size were considered to perform multivariate analysis. A complete multivariate analysis procedure was applied in three steps. First, a hierarchical cluster analysis was used to separate the blast data into different groups of similarity. Two different groups were formed based on the elasticity modulus values. In the second step, group memberships were checked by discriminant analysis. The dominant parameters of the occurrence of the groups were determined. Also, discriminant analysis was used to determine the group membership of the respective blasts. As the last step, the multivariate regression analysis was applied to develop prediction equations for estimation of the mean particle size of muckpiles. Two different prediction equations were developed based on the rock stiffness. Validation of the proposed equations on various mines was performed. Prediction capability of the proposed models was found to be strong. The models are not complex and are suitable for practical use at mines.

Jan 1, 2011

By B. Simser, T. Butler

Glencore’s Nickel Rim South Mine, located in Sudbury, Ontario, Canada, is a primary/secondary blasthole operation with ore zones lying between 1,100 and 1,700 m below surface. One of the main benefits of the primary/secondary mining method in high stress ground is that up to 50% of the mining will take place in secondary stopes that should be in a yielded rock mass state. Every future secondary mining stope begins as a primary stope abutment pillar. As with many mines, the stress loading history and rock mass conditions can vary considerably in space and time. Safe mining practices cannot allow for an assumption that the planned secondary stopes are indeed yielded. An incorrect assumption can result in mining development and stoping taking place in high stress ground rather than the expected yielded rock mass conditions. This can result in higher levels of seismicity than expected and incorrect ground support recommendations in areas where workers could be exposed. Seismic monitoring is the mines’ premier tool to track the actual rock mass response to mining. Yielded zones have a reasonably clear seismic signature/pattern over time that is visible in the collected data. The ability to accurately locate small magnitude seismic events can help define and delineate different stages of rock mass failure. The vast majority of the seismic data recorded by the microseismic monitoring system is below moment magnitude (Mw) 0.0. Examples are provided showing how small seismic events (Mw < -1.5) can help provide feedback from the rock mass deformation that allows the ground control engineer to gain a better understanding of how the rock mass is responding to mining processes.

Apr 26, 2022

By Junnan Chen, Hongwei Zhang, Wei Wang, Feng Xie

Thiosulfate is a green gold leaching agent that shows great potential to replace the highly toxic cyanide. Ammonia is traditionally used as the copper ligand in thiosulfate solutions to reduce the reactivity of copper ions towards thiosulfate, but it is a toxic reagent. As a result, efforts to replace ammonia with another complexing agent have received increasing attention. In this study, a novel alternative to ammonia is proposed to explore the potential use of the copper-malic acid-thiosulfate system. Experimental parameters include temperature, initial pH, copper, malic acid, and thiosulfate concentration. The feasibility of the copper-malic acid-thiosulfate system was discussed using Eh–pH and species distribution diagrams. Themodynamics analysis indicates that the mechanism of gold leaching in copper-malic acid-thiosulfate solution is mainly catalyzed by the Cu2( Mal)2H-2 2−/Cu(S2O3)3 5− redox couple. The capability of gold leaching in this system for processing the refractory gold concentrate is comparable to that of cyanidation and the traditional copper-ammonia-thiosulfate leaching processes. Thiosulfate consumption is greatly reduced in the presence of malate due to its strong chelating effect on the copper ions. Moreover, the copper-malic acid-thiosulfate system demonstrates a significant enhancement in leaching kinetics, making it a viable option for processing refractory gold concentrates.

Aug 1, 2023