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By Atta B. Yiadom, A. David Miller, Robert C. Kirby, Sean M. Todaro

"San Pablo Dam is a 170-foot (52-meter)-high earthfill embankment, located approximately 10 miles (16 kilometers) north of downtown Oakland, California, that impounds a 38,600 acre-feet (47.6 million m3) reservoir for customers in the East Bay Municipal Utility District's (EBMUD's) service area. Seismic upgrades were designed and constructed in 2008 through 2010. Work included removal of an existing 140,000 cubic-yard (107,000 m3) downstream buttress, which was replaced with an enlarged 300,000 cubic-yard (230,000 m3) buttress founded on alluvium and colluvium that were improved in-place using Cement Deep Soil Mixing (CDSM) technology. The site characterization for the project, design of CDSM, reuse of CDSM spoils as construction materials, and environmental permitting have been described in five previously published professional papers.This paper provides a brief summary of the design of the seismic upgrades and presents the results of measurements made during and/or after construction including the variation of CDSM strengths with time, piezometric levels within the dam and foundation soils, and seepage flow rates. These measured values are compared to the values estimated during design of the seismic upgrades.INTRODUCTIONSan Pablo Reservoir is located approximately 10 miles (16 kilometers) north of downtown Oakland, California, as shown in Fig 1. As many as 50 million gallons (200,000 m3) per day pass through the reservoir for treatment and distribution to a portion of the 1.3 million customers served by EBMUD. The dam is founded mainly on alluvium and was originally built in 1920 using materials excavated from the left and right abutments consisting of siltstone, claystone, fine-grained sandstone, mudstone, and shale that were excavated and placed using hydraulic fill methods. The dam is located within two miles (three kilometers) of the Hayward Fault which is capable of a moment magnitude 7.25 earthquake.Because of the foundation materials, construction method, and proximity to the Hayward Fault, the dam has undergone a series of seismic improvements, including the placement of a downstream compacted earth buttress in 1967 and an upstream compacted earth buttress in 1979. In 2002, the State of California Division of Safety of Dams (DSOD) requested that EBMUD evaluate the seismic stability of San Pablo Dam, following the results of a study that same year that indicated a 62 percent chance of a greater than 6.7 magnitude earthquake striking the San Francisco Bay region between 2003 and 2032. The dam was evaluated and it was concluded that portions of the underlying foundation soils may liquefy during the maximum credible earthquake which could cause the dam to become unstable."

Jan 1, 2015

By O. A. Bascur

Ores are becoming extremely variable with mineralogy and hardness disturbing the grinding and flotation circuits. The current grinding and flotation sensors provide large amounts of data for process optimisation. Adding the right context and operational events augments operational knowledge for proactive actions to improve the performance of the grinding and flotation circuits. A data-driven strategy is needed to enable operations, maintenance, and business personnel to quickly and easily take corrective action when abnormal conditions occur. A digital plant template transforms data into operational insights in real-time. It uncovers the hidden, idle and downtime losses. By measuring and managing these unproductive times, people find new ways of avoiding them, improving the profitability of the plant. The information created by the real time analytics enables the calculation of recovery in real time and develops predictive analytics models to find the best operating condition based on the type of ore currently mined. The creation of new workflows and collaboration between mining and concentrator plant and the enterprise, including services providers, are enabled. A grade recovery model is used to identify the best operating conditions in real-time. An optimal Gaudin size distribution shape is used to find the grinding operating conditions that optimise the metal recovery in the rougher sections of the mineral processing plant. Sensors in the flotation circuits enable estimation of metal recovery and determine the optimal froth depth and aeration profiles, using an industrial air holdup flotation model. The implementation of a recovery/grind strategy with industrial examples in non-ferrous metal concentrator is presented in the paper. Keywords: Digital transformation, soft sensors, predictive analytics, grinding flotation optimisation, flotation bubbles, particle size, particle size distribution shape, froth aeration profiles, flotation air hold up model, recovery predictive analytics

Jan 1, 2020

By S. Mason

Many organizations are realizing that continual improvement in health and safety relies on addressing the potential for various forms of human error. Of these, violations are often the most frequent form associated with accidents. These occur when an individual, or individuals, deliberately contravenes established and known safety rules. They have been associated with up to 90% of accidents and incidents in some industries and yet rarely receive the systematic attention they deserve in the promotion of safety. This paper presents underlying motives which cause violations. These can vary significantly from mine to mine and from job to job. Managers need some measure of attitudes to determine the underlying motives behind violations if they are to determine effective strategies for promoting safe behaviour. Questionnaires form the starting point to address attitudes and the motives behind rule violations. The choice of the most suitable questionnaire, however, will vary from organization to organization. Guidelines on the choice of questionnaire are offered.

Jan 1, 1998

By Hairong Zeng, Shahram Tafazoli, Edmond Chow

Blast fragmentation is one of the main parameters for optimizing mineral processing, but reliable data is difficult to acquire, resulting in unpredictable performance and efficiency. Crusher and grinder circuits are designed to process specific rock size ranges. Oversized rocks require extra energy to reduce before feeding into the process, and undersized rocks indicate that the process is not used to its full extent. Blast design is the key to controlling the blast fragmentation, so the ability to accurately monitor the particle sizes is imperative.

Jan 1, 2011

By Charles Zdazinsky

Many blasting applications in the mining industry demand that the hard rock being blasted remains structurally competent. For example, pre-splitting is a common technique to reduce fracturing, and operators of dimension stone quarries use this blasting method to eliminate overbreak. When pre-split design parameters are not applied correctly, there will be a redistribution of stresses within the rock, resulting in Blast Induced Rock Damage (BID). Advances in geophysical technology are enabling blast technicians to monitor BID and then use the results to correctly design their blasts.

Jan 1, 2011

By M. J. Farrell

The threat of global warming and its prominent position in public discussion and political debate requires all industry to take stock of its contribution to rising atmospheric concentration of greenhouse gases. For the primary metals industry, the first step must be to identify the pattern and range of emissions at each step in the production chain. Only then can the industry assess the economic consequences of the penalties on emissions that will be imposed by governments and regulators and devise cost-effective plans to avoid or mitigate such penalties. While some work has been done to estimate carbon dioxide (CO2) emissions using Life Cycle Inventory analysis, this approach is less useful than site-by-site emissions estimates. It is the level of specific emissions at each site that will ultimately deter-mine carbon taxation liabilities and participation in emissions trading schemes. Most mining companies have moved with the times to issue sustainability reports for their operations. But in the absence of any standardized reporting format, it is difficult to make useful comparisons between even the best-reported producers on a like-with-like basis. For this reason, Minecost.com modeled the use of fuels and energy used in mining, milling, shipping and metallurgical treatment to cover ?cradle-to-gate? emissions of greenhouse gases resulting from the production of the major base metals copper, zinc, lead and nickel. Greenhouse gas emissions ? overwhelmingly carbon dioxide ? are associated with the consumption of energy at every step in the production chain, from exploration through mining to the production of refined metal. Producers of primary metal employ diverse technologies to mine, mill, smelt and refine several different types of ore. Every orebody has its own special characteristics. In addition, most base metals are produced in concentrate that must be transported to smelters, with con-sequent emissions consequences.

Jan 1, 2009

By G Tranell, E Pastor-Vallés, A Vallejo-Olivares, J B. Pettersen

Metals are essential for the sustainability transition and decarbonisation of society. Yet, it will be paramount to produce them sustainably and minimise the affiliated resource and energy use and the associated emissions. In the circular economy, the metallurgical industry should recycle existing material stocks, and improve its utilisation of wastes, residues and side streams. This increases the complexity of processes, as they become both (often multi-fraction) waste treatment as well as material production processes and brings complexity to the assessment of environmental benefits. Assessing the environmental impact of technological developments frequently is supported by life cycle assessment (LCA). While the method is well documented, its implementation involves several methodological choices that deserve reasoning and analysis, such as how to define the product when former wastes are turned into new products, the selection of impact methodology when converting emissions to environmental indicators, the definition of system boundaries and co-product allocation and the interpretation of sensitivity and uncertainty in final outcomes. In this exploratory study, we investigate how the variation of LCA set-up affects the environmental burden of the system. We consider a metallurgical process where a mix of hard-to-recycle aluminium-containing streams is used to produce aluminium cast alloys in a rotary furnace. Remelting with salt-fluxes allows recovering metals from partly oxidised/contaminated streams, such as dross, bottom ash and industrial shavings, but at the expense of generating significant amounts of salt-slag/salt-cake hazardous waste. The study considers different system alternatives such as landfilling the salt-slag residues versus valourising them into salts, aluminium concentrates, ammonium sulfate and non-metallic-compounds to be used by the metallurgical, construction or chemical industries. Practical recommendations are outlined to facilitate the implementation of LCA in assessing the potential benefits of the circular economy in the metallurgical sector.

Aug 21, 2024

By T. R. Kostecki, K. V. Jessu

"Roof bolts are subjected to axial stresses, shear stresses, or both. Axial and shear stresses were compared between roof bolts machined with two and three slots. Shear stresses perpendicular to and at an angle to the shear planes were evaluated by analyzing a three-slot instrumented roof bolt, performing laboratory tests on two- and three-slot roof bolts, and conducting in-situ test analyses. Threeslot bolts appear to provide a complete bending strain profile, requiring no prior knowledge of the estimated shear-plane orientation. Minimum displacements occur in roof bolts installed perpendicular to rather than at an angle to the shear planes.RÉSUMÉ Les boulons d’ancrage dans le toit d’une mine sont sujets à des contraintes axiales, des contraintes de cisaillement ou les deux. On a comparé les contraintes axiales et de cisaillement de boulons d’ancrage usinés avec deux ou trois fentes. Les contraintes de cisaillement perpendiculaires et à angle aux plans de cisaillement ont été évaluées en analysant un boulon d’ancrage de toit à trois fentes, en effectuant des essais en laboratoire sur des boulons d’ancrage de toit à deux et à trois fentes et en effectuant des analyses de tests in situ. Les boulons à trois fentes semblent fournir un profil complet de résistance aux contraintes de flexion, sans avoir besoin de connaître l’orientation estimée du plan de cisaillement. Des déplacements minimums ont lieu dans les boulons d’ancrage de toit installés perpendiculairement, plutôt qu’à un angle, aux plans de cisaillement."

Jan 1, 2016

By S A. McManus

With the advances in software speed and capability, many of us now are running multiple scenarios on entire models rather than just testing small areas or a few blocks. In the authors experience both the geological and geostatistical academic theory and our rules of thumb, often prove un-useable or incorrect in the real world we work in. The only way to truly validate and tune our models is to complete the entire model and ‘see if it works’. If it lacks some property we were expecting, then we need to find out why and/or run different scenarios to see what changes. This is not always possible with tight project timelines but we find ourselves doing more and more of this sort of thing, and in so doing, understand that every deposit is different and requires its own ‘rules’ to get valid and useful results. For the purposes of this paper, this process is termed Empirical Geostatistics. Take Clayton Deutsch’s ‘all realisations all of the time’ concept a step back. Before you even think of simulating, test the alternate realisations generated by alternate parameters such as different domaining, varying search neighbourhood parameters etc.

Mar 22, 2022

By G Pattenden, R Hargreaves, P Pettit

"Even with the cyclic nature of mining, when it comes down to it, the bottom line is that whatever direction the commodity market is going there is always a desire to improve the economics of an operation in order to deliver a greater return to investors. Adapting to market pressures by introduction of an operational process change can often have a downstream impact. What may be less obvious is that reconciliation can play an important part in measuring the effectiveness of many operational changes. Through the adoption of best practice reconciliation and related comparisons, it is possible to measure the impact of changes across the mine value chain and identify variability that may have been introduced. Using analytical business improvement tools, examining and monitoring planned changes can be crucial in understanding whether the introduced changes have been effective and whether they have provided the expected result. Using several case studies, the authors will highlight the benefits provided by modern business intelligence tools, which can provide data validation and accurately report data trends related to both planned and unplanned change events.Citation:Hargreaves, R, Pattenden, G and Pettit, P, 2016. Measuring the Effectiveness of Change through Best Practice Reconciliation, in Proceedings Ninth AusIMM Open Pit Operators' Conference 2016, pp 71–83 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Nov 15, 2016

By S. Frimpong, E. Siami-Irdemoosa, S. R. Dindarloo

"Electric and hydraulic shovels are the dominant loading machinery in surface mining operations. Despite their critical role in production and their high capital and operating costs, no reliable and comprehensive quantitative performance metric is available. In this paper, a stochastic shovel effectiveness (SSE) measure is proposed for the purpose of quantifying the performance effectiveness of these shovels. The SSE is based on the widely used method of overall equipment effectiveness (OEE) in the manufacturing industry. The OEE measures the performance effectiveness of equipment by multiplying its mechanical availability, utilization and production quality. In manufacturing processes, quality rate is the ratio of the total number of products minus the number of defective products – equivalent to the number of acceptable products – to the total number of products. The SSE similarly uses the mechanical-availability and utilization terms, but instead of quality rate it uses a new parameter named bucket rate.The variability or randomness of the input data, that is, availability, utilization and bucket rate, are further incorporated into the SSE, and a final stochastic SSE distribution is derived in the form of a probability density function. One hydraulic and one electric shovel in a surface mining operation were selected to test the validity of the proposed method. The SSE scores for the two shovels, operating continuously for one year, were derived and compared. As with the OEE, the three-parameter SSE method yielded more representative results for overall performance measurement than a single-parameter approach. Using Monte Carlo simulation, a three-parameter Weibull and a normal distribution were derived for quantifying the overall effectiveness of hydraulic and electric shovels, respectively. As a decision aid, the proposed methodology promises to render a more informative tool than traditional metrics for mine equipment maintenance and management."

Jan 1, 2015

By David I. Verrelli, Boris Albijanic

"Froth flotation is an exceedingly complex physicochemical process. The convenience of distilling much of the complexity of the bubble-particle interactions into a single parameter has led to the continuing popularity of the classical ‘induction time’ to quantify the threshold for bubble-particle attachment to occur. Despite this popularity and the simplicity of the concept, there is no single universal method of evaluating the induction period. In this paper, we begin with a critical review of the available techniques for estimating the induction period. These are: back-calculation from experimental (micro) flotation tests; pushing a particle toward a stationary bubble (or vice versa) using an atomic force microscope (AFM); pushing a bubble toward a stationary bed of particles in the ‘Induction Timer’; pushing a bubble toward a stationary solid surface using the ‘integrated thin film drainage apparatus’ (ITFDA); and dropping particles onto a submerged stationary bubble using the ‘Milli-Timer’ device. Each one of these methods has advantages and disadvantages, and the best choice depends on the application. In the experimental section, we present quantitative comparison of the induction periods estimated using two different techniques, namely the Induction Timer and the Milli-Timer. The same particles were tested in each device, under the same conditions. It was found that by tuning the operation of the particle pick-up device, similar estimates of induction period could be obtained to the estimates made by direct observation with the Milli-Timer. In the former device a bubble is driven toward a particle bed at a controlled rate, whereas in the latter a particle’s motion is governed by the hydrodynamics. The potential to match these presents an intriguing prospect for better understanding the bubble-particle interaction, and the possibility to ‘calibrate’ the simpler Induction Timer against direct observations."

Jan 1, 2014

By P. Mousset-Jones

The USBH Mining Systems and Ground Control Generic Research Center funded a project leading to the improved planning of airflow and refrigeration in underground mines experiencing hot working conditions. The project was broken down into approximately five phases: 1. Visiting some of the known hot mines in the U.S. and sending out a questionnaire to determine other mines which might be experiencing hot working conditions in the future. 2. Choosing two mines in which to conduct measurements to determine the insitu rock thermal conductivity and diffusivity, and comparing these values with laboratory determined values. 3. Investigating computer programs available for mine climate simulation, and testing these programs with case study examples from the two mines where the rock thermal properties were measured. 4. Considering improved ways of estimating the wetness factor and experimenting with the use of heat flux meters to more directly measure the rock heat inflow into the airstream. 5. Applying the results of these investigations to simulating the climate for future mine development and production areas at the two- mines. The project is approximately two thirds completed. At the time of writing, the insitu measurements at one of the mines are still being recorded. This paper will be describing the procedures and results of the insitu rock thermal property measurements, and give a brief description of some of the simulated results obtained for a mechanised cut and fill stope case study from the Homestake Gold Hine in South Dakota.

Jan 1, 1985

By Ralph Johnson, Philippe Gaultier, Loui Fauteux, Andrew Dasys

"This paper outlines the implementation of the Mechanic's Stethoscope from the earliest stages of development to the implementation at Brunswick Mining and Smelting. It details the cooperative efforts of personnel at Noranda Technology Centre (NTC) and Brunswick Mining & Smelting (BMS) during the technology transfer of the Mechanic's Stethoscope. It demonstrates how everyone worked toward a goal of developing a product that is accepted as a useful addition to the work environment.The Mechanic's Stethoscope is an underground vehicle diagnostic system consisting of computer hardware and software intended to assist mechanics in daily tasks. Its tools facilitate quick and easy access to any information required during the maintenance of an underground vehicle. Each tool presents vehicle condition data in a simplified manner. The additional information improves the mechanics understanding of the vehicle condition. The result is a healthier fleet of vehicles and faster diagnosis times.When introducing a computer based system into a traditionally non-computer oriented environment a concern is the acceptance of the system. This concern exists on many levels."

Jan 1, 1995

By A. S. Ratnayake, H. C. S. Subasinghe

In this study, we review the role of mechanical activation in the pyrometallurgical, hydrometallurgical, and electrometallurgical processing of titanium feedstock. Mechanical activation has been shown to decrease the activation energy of chemical reactions, thus enhancing process efficiency and product quality by reducing processing time and energy consumption. Pyrometallurgical processing is energy-intensive and time-consuming. Hydrometallurgy is costly, requires high-grade feed material, and generates toxic waste. Waste generation and process complexity are the major drawbacks of electrometallurgy and solvent extraction. Bioleaching via a mechanically activated pyrometallurgical process can be identified as an alternative method, but the lengthy processing time is the major disadvantage. Mechanically activated titanium concentrate can be used in a finely tuned combined metallurgical process to overcome the challenges and drawbacks in these technologies.

Aug 3, 2023

By McDonough RJ

Mechanical agitation is the preferred system for Carbon-in-Pulp processes. Agitator design requires an understanding of the relationships between energy, shear and flow and the nature of shear rates and shear stress distribution in an agitated tank. Laser techniques are useful when studying these phenomena. The alternatives are open impeller agitation or draft tube circulation. Each has advantages and disadvantages but both require careful choice of impeller and system geometry. Overall the draft tube circulator is the more attractive in many cases. Open impeller agitators are designed in accordance with established procedures for mineral slurries taking due account of shear effects in tanks containing carbon. Preferred tank proportions are 1:1. Circulator design methods were developed in the alumina industry before being applied to CIP processes. Optimum draft tube diameter is critical to power requirements. The overall system must be designed as an axial flow pump operating in a closed circuit. Such a system exhibits quite characteristic behaviour which requires an impeller of varying pitch angle and aerofoil section for best stability and efficiency.' Tank height may be 2 or more times diameter. Resuspension of settled solids can be assisted by a series of slots in the draft tube. These slots have the secondary effect of stabilizing hydraulic behaviour and reducing installed power requirements.

Jan 1, 1982

By J. T. McGrath, R C. A Thruston

The structural changes which take place in polycrystalline copper under the action of alternating cycles of torsion stress were studied, using the optical microscope and the X-ray dif-fraction camera, and an attempt was made to correlate them with changes in the shape of the cyclic stress-strain curve. It was found that the period of work-hardening was less than one per cent of the fatigue life, and that persistent surface marking, which are assumed to be incipient or actual microcracks, occur upon completion of work-hardening. X-ray diffraction patterns revealed considerable grain distortion at the completion of work-hardening in specimens cycled at a high strain amplitude. This distortion became progressively less as the strain amplitude de-creased. Mechanisms for the completion of work-hardening and the formation of microcracks are discussed.

Jan 1, 1962

By J. M. N. P. C. Teles, Venda Oliveira P. J., Correia A. A. S.

"AbstractA laboratory work was performed to study the mechanical behavior of a Portuguese soft soil chemically stabilized with binders and reinforced with metallic fibers when subjected to tensile stresses. To this end and in order to compare the tensile strength results done by two different tests, there were conducted two types of experimental tests: Tensile Split Strength Tests (TS) and Direct Tensile Strength Tests (T). The samples tested had the same binder quantity and different fiber contents, which allowed the characterization of the tensile behavior of the stabilized and reinforced soil, as well as the definition of the best fiber content. Results show that the binder is the main parameter controlling the behavior of the stabilized and reinforced soil until failure, while the influence of the fibers is noticed mainly at the post-failure behavior. The comparison between the tensile strength done by T and TS tests shows that the tensile split test can be used to estimate the tensile strength, although its results are lower than those obtained by the direct tensile tests in general.IntroductionDue to its poor mechanical characteristics, the construction on soft soils presents difficulties that require the use of soil improvement techniques such as chemical stabilization. However, even when mixed with binders, the tensile strength of the stabilized soil is poor, requiring, in certain cases, the use of expensive steel reinforcement or metallic beams, with obvious impact on the final cost of the work. Thus, for the cases where the tensile strength is a design requirement, the soil stabilization should be design with another element, whose primary role is to give tensile strength to the improved soil (Teles 2013).To fill the lack of published studies focused on soft soils both chemically stabilized and reinforced with metallic fibers, the present research aims to analyze the behavior of the improved soil when subjected to tensile stresses. To support the research there were conducted direct tensile tests (T) to directly measure the tensile strength of the samples and tensile split tests (TS) or Brazilian tests to obtain it indirectly. The samples tested had the same binder quantity but five different fiber contents in order to study the influence of the fibers in the improved soil behavior. In addition, a comparison between the results of both tests was made."

Jan 1, 2014

The problem of separating the constituents of a mixed gas has assumed increasing importance to chemical technology during the last several decades. Metallurgical practice, dealing mostly with the application of gases as fuel, such as for the oxidation or reduction of ores, has not often confronted an important need for such separations. If theory occasionally has indicated advantages in the use of purified or separated gases, as for example the "dry" blast for the iron furnace or oxygen-enriched blast for a variety of smelting operations, the economics of the proposals has not often been satisfactory. It has seemed evident that the practice of the chemical plant was too expensive with regard to installation or material costs, or both, for the needs of the basic smelting industries and indeed was applicable commercially to metallurgical purposes only when the metals in question were especially valuable or pure. This bulletin deals with a new mechanical means of attacking the problem of separation. Although it is improbable that any one type of separation could hope to find universal application, the method described is to be regarded as an alternative to conventional means that has attractive possibilities in certain instances. It extends the number of methods previously available by one that has not before been applied commercially and that utilizes a well-known property of gases that never has received effective technologic attention.

Jan 1, 1940

By Inoue T, Takahashi N

To construct the accessing railroad line to the northern portal of Seikan Undersea Tunnel, nine tunnels amounting 7.4km in their total length were excavated through soft mudstones of young- er tertiary era with use of smaller-sized mechanic al excavators. Rocks were classified in four classes to which the tunnel support was designed respectively. Of several combinations of driving equipments stu- died comparatively, the method using the mechani- cal excavators was estimated to be the best choi- ce. The efficiency of the excavator was traced in every construction section and the data colle- cted was reviewed numerically. The result showed that the efficiency of the excavator dropped wh- ere the rocks were as hard as over 200kg/crif for compressive strength. And a few technigues in tunnelling i.e. contr- olling dusts in shotcreting, lattice arch, evaluati- ng measured deformations were tested and review- ed too.

Jan 1, 1987