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By Vincent C. Smith, Agit Singh, Bernard Muller

The control of minerals processing plants is by no means trivial. In order to address some of the difficulties, it was decided to develop and test a model predictive controller (MPC) for a milling circuit. A milling simulator was written to test the MPC controller. Due to the large number of tuning parameters in a controller of this type, an optimising algorithm was written that automatically tunes the controller. Good, robust control was obtained when the controller was tuned using this algorithm. The controller was tested for various scenarios that are often encountered in the minerals processing industry. When problems were encountered, the MPC algorithm was specially adapted to accommodate for these difficulties. Control was further improved by using feedforward control as well as quadratic programming. The movement of the manipulated variables was reduced by using a region of uncertainty that allows the controlled variable to vary within a specified region around the setpoint. Integrators were handled by adapting the algorithm slightly and adding an optional integral error portion in the MPC controller. The performance of the enhanced MPC controller was compared to PI controllers on both the simulator and a commercial plant. The MPC controller showed faster responses with less interaction in both cases.

Jan 1, 2003

By Anuj Narang

Large-scale separation or flotation cells, used in the primary extraction in the oil sands industry, are integral parts of the overall process of bitumen extraction. Good regulation of the interface level between the bitumen froth and the middlings in these cells can result in a significant improvement in bitumen recovery and throughput, and heavily influence process economics. Automatic control of such industrial processes presents challenges such as multi-phase flow dynamics, variable process gain and time delays, poor quality of measurements and significant disturbances. This paper details a case study application of development of multiple models of the dynamics of the interface level and the design of model predictive controllers (MPC) for a separation cell process. A Model predictive controller (MPC) using linear models is designed and implemented in real time on an industrial separation cell. The industrial implementation results show that the MPC scheme provides significant benefits over the current operations which use a PID controller. The benefits include significant reduction in the variance of the interface level resulting in higher bitumen recovery and smoother downstream operation plus energy savings due to reduced underflow pump speed.

Sep 1, 2012

By J W. Edl, F C. Wu

In instrumented model rock blasting experiments in granite blocks, best fragmentation results were obtained when delays between holes were 1 to 2 milliseconds per ft. of burden and when a rectangular shothole pattern was used with spacings larger than the burden. Effective fragmentation in multiple hole blasts seemed to depend primarily on the full development of the crack network around each hole before the charge in the next hole was detonated. The test results showed that simultaneous or almost simultaneous initiation of shotholes in bench blasting resulted in poor fragmentation.

Jan 1, 1975

By D. K. Panda

The behavior of single drops with gas evolution at the interface is of interest because this is one of the important reactions that occur in oxygen steelmaking vessels, where a large amount of iron-carbon drops are dispersed in an oxidizing slag. The carbon dissolved in these drops, reacts with the slag to form CO, which is evolved as a gaseous phase. A room- temperature model was used to study the nature of this type of reaction including the effect of various factors such as viscosity and the presence of surface active impurities. Experiments were done for reacting drops over a wide size range to observe various regimes of behavior. Large single drops were levitated in a counter current flow to produce a sufficiently long residence time to allow the study of the various stages in the reaction. The emphasis of this work was to obtain photographic evidence of a high quality to describe all possible modes of behavior, and so a lot of effort was given to developing and perfecting experimental techniques.

Jan 1, 1994

By S. Kang, D. G. C. Robertson

Slag cleaning furnaces require extensive wall cooling because they involve the use of a superheated slag bath. This is in direct contrast to smelting furnaces, where the wall is usually (but not always) protected by "banks" of solid charge. In order to understand the heat transfer and flow in slag cleaning furnaces a number of model studies have been carried out using molten wax to simulate the slag. Wax is a good model fluid because, like slag, it has a high Prandtl number. Wax models cannot simulate the behavior close to the electrodes (DC arc or AC submerged), but they can and do give a good simulation of the flow and heat transfer at the wall. An understanding of these phenomena is of great importance for the design of cooling panels in the walls of the furnace. Since superheated molten slag will eventually wear away any refractory bricks over time, the wall cooling must be designed to form a frozen layer of slag, referred to as a "freeze lining". The heat flux density (Q/A) required to do this is given by Q/A = h* ?T, where h is the heat transfer coefficient in the slag phase at the wall, and Li T is the superheat (bulk slag temperature - liquidus temperature). Both Q/A and h vary greatly with position and both are usually a maximum at the slag line. In the experimental work, molten wax baths were heated by block heaters to provide similar energy densities to those encountered in commercial slag cleaning furnaces. This procedure was considered to be valid since most of the electrical energy into a furnace bath is dissipated as heat. Gas stirring was used to simulate the gas evolved at the electrode in real furnaces - the quantity of this gas could be estimated from a knowledge of electrode consumption. The similarity criterion was equal gas flow per unit area of surface, in model and prototype. Heat transfer coefficients were measured in the models as a function of power density, gas stirring, superheat, etc., and could be related to the full-scale operations by the use of dimensional analysis.

Jan 1, 1999

The Boliden Aitik concentrator in Sweden processes 2,000 tph of low grade copper ore. The plant consists of five grinding lines feeding four bulk flotation banks with a scavenger concentrate regrind mill, and a column cleaner circuit with a regrind mill. The authors installed a model-based expert, optimizing control system to maximize copper recovery in the bulk flotation circuit while maintaining an appropriate copper grade in the cleaner feed. The optimizing control system uses on-line assays and calculates and implements set points for cell pulp levels, air rates and reagent addition rates. It combines the power of a dynamic population balance model which estimates mineral liberation in each stream, an optimizer which computes appropriate set points and a rule-based module which implements the strategy. The benefits have been evaluated over three months. The model-based expert, optimizing control system generates a measurable increase in copper recovery, around 0.5 per cent and an optimized bulk concentrate grade. The need to maintain the optimizing control system and other practical aspects are discussed.

Jan 1, 1998

By H. Huisa, M. Linn Chong

La Evaluación del Potencial en Recursos Rocas y Minerales Industriales (RMI) a través de los Sistemas de información Geográfica (SIG) es un análisis que utiliza el conocimiento que tiene el sector geológico minero para decidir cuáles son las zonas que proporcionan las mejores alternativas para la exploración y prospección de una actividad minera industrial, basándose en características litológicas, canteras y ocurrencias de RMI, concesiones mineras no metálicas, anomalías espectrales de alteración y accesos; mediante un método de Análisis Multicriterio.

May 1, 2008

By R. K. K. Mbaya

The concept of adsorption or separation of platinum anions from base metal cations in chloride media using native or chemically modified activated carbons has been discussed in various journals within the context of batchwise systems. In our research work, a fixed-bed column, loaded with native and amine-immobilized activated carbon pellets (Norit RO 0.8), was used to study selective adsorption of platinum ions from chloride media at different flow rates, bed depth and initial metal concentrations. The kinetics, mass transfer characteristics, breakthrough data and separation factors (ß(Pt/Fe) and ß(Pt/Cr)) were quantitatively analysed and modeled. The bed-depth service time (BDST) model was used to model the breakthrough curves successfully in fixed-bed columns and also the dispersive diffusion in the radial and axial directions of the bed were evaluated. The inner diameter of the column was 3 cm and the bed depth was between 1.0 cm and 2.5 cm. Concentrated 4 M HCl acid solution was used to elute the fixed-bed column. It was demonstrated that amine-treated activated carbons provides superior separation factors between platinum and base metals (Fe, Cr). Results showed also, that 95% saturation was reached within 10~26 hours depending on the nature of ACs at a flow rate of 11 mL/min and initial concentration of 5 ppm.

Jan 1, 2014

By Lazar Kricak, Vladislav Kecojevic, Dragan Bogunovic

In spite of many advantages explosives have, their usage may cause environmental problem such as seismic vibration. One of the solutions to this particular problem may be application of an artificial screen as a barrier to the seismic wave path. This paper presents the results of experimental research on the artificial screen concept, its characteristics and role in attenuation of seismic effects generated by blasting. More than 1,500 laboratory measurements were conducted with different combinations of screen sizes, positions of the screen to blasting source, and intensities of blasting impulses. The results of the study show a significant reduction of generated vibrations by employment of artificial screens.

Jan 1, 2007

By Harold D. Taylor

Lognormal grade distributions are definitely the rule rather than the, exception in many types of deposits, including precious metals, uranium, and many others. The "normal theory" geostatistical techniques do not work well in these situations because the occasional high grade values, perhaps several orders of magnitude larger than the median, can overwhelm the rest of the data, resulting in variograms and Kriged estimates which are unrealistic or even ridiculous. Robust techniques for variogram modeling have been proposed, and truncation of high sample values can produce more reasonable Kriged estimates, but the technique of working with log transformed data appears to be the best method of handling lognormal data. This paper will discuss primarily the two parameter lognormal case, with some discussion of the three parameter lognormal, but no discussion of other methods of transforming data, such as disjunctive Kriging.

Jan 1, 1982

By Pengfu Tan

In order to understand and control the formation of dioxins and furans in iron ore sinter plants and to possibly avoid expensive end-of-pipe removal stages, thermodynamic calculations on the stability of PCDD/Fs have been combined with sinter process modeling by means of kinetic simulations and computational fluid dynamics. Three thermodynamic databases of PCDD/Fs, derived using the Group Additivity approach and two computational molecular modeling methods, MNDO and PM3, respectively, combined with the SGTE database have been used to model the PCDDIF formation and the PCDD/F isomer distributions in iron ore sintering. The results show very similar conditions for the PCDD/F formation using the different databases. Concerning the isomer distributions of toxic PCDD/Fs, the calculated data derived from the MNDO method showed optimum agreement with measured values from industrial furnaces. The thermodynamic calculations also proved that the isomer distributions found in combustion processes are equilibrium values, while the concentration ratio of PCDDs and PCDFs in the wind boxes does not represent an equilibrium state. A CFD model of iron ore sintering was developed including the kinetics of 15 relevant chemical reactions with the aim of describing the temperature fields and the gas flow patterns in the sintering bed. On the basis of these information and experimental observations reported in the literature possible pathways for the PCDD/F formation in sinter plants have been identified: PCDD/Fs are formed in the critical temperature region of 250 to 450°C below the combustion zone, are then carried downwards with the gas and condensed close to the bottom of the sinter bed. Transported to the discharge end with the solid mixture, they are again released into the gas phase when the flame front approaches the bottom. PCDD/Fs are also formed in the last wind boxes when the hot off-gases cool down and reach the critical temperature range. Consequently, methods to reduce the dioxin formation reactions are proposed including inhibitor addition to the sinter feed and off-gas quenching.

Jan 1, 2003

By Michael L. Free, Shukla. Abhijeet

The short-circuiting tendency of a copper electrowinning cell (EW) based on the roughness of cathode deposits was investigated with varying parameters such as Cu concentration, guar concentration, current density, and temperature. A bench scale EW cell was set up to produce copper under conditions similar to industrial Cu EW. In addition, a statistical analysis and finite element analysis were performed to analyze the deposited thickness, surface roughness and maximum feature height. Interaction data for the cathode deposits suggest that current density and Cu concentration together affect the roughness of deposit more than the combined effect of guar and temperature. Model predictions of roughness were similar to experimental values. The predicted time to short-circuiting was similar to the measured time. This study provides an industrial relevant baseline against which new operating parameters can be compared.

Jan 1, 2014

By MOHAMED WAEL, ANASTASIA GOEVA, ABDULAZIZ TAWFEEQI, IHTISHAM TARIQ, S. M. ZAKIR HOSSAIN, NIAZ ALI KHAN, MUHAMMAD FAISAL IRFAN

Carbon capture and storage (CCS) is an attractive area of research in such fields as CO2 mineral carbonation, global warming and sustainable energy systems. In this study, carbonation efficiency for aqueous mineral carbonation (MC) was achieved through two steps,which include leaching of calciumfrom cement kiln dust (CKD) followed by the reaction of pure CO2 with the calcium hydroxide precipitates formed by the hydroxylation using NaOH. Response surface methodology (RSM) with a Box-Behnken design (BBD) was applied to optimize the calciumleaching yield,while the carbonation efficiency from CKD was assessed using RSMwith central composite design (CCD). Optimization of calcium leaching is highly important, as it is a rate-limiting reaction step in MC and also influences and enhances carbonation efficiency. Different parameters including acid concentration (HNO3), leaching temperature, leaching time, and dose of CKD sample were considered in order to optimize the maximum yield of Ca leaching from the CKD sample. In addition, different CO2 flow rates and temperatures were used as parameters for optimizing carbonation efficiency. Two quadratic regression models were developed for each process, i.e. calciumleaching and carbonation. For calcium leaching, a maximum of 98.55% calcium was extracted under the optimal set of acid concentration 4.13 M, 90 °C, 28 min leaching time, and 13.8 g of CKD sample. For carbonation, the maximum carbonation efficiency of 89.2% was achieved for a CO2 flow rate of 1163 cm3/min at 90 °C. Calcium leaching results indicate that the leaching yield was significantly affected by all the input parameters except leaching time. For carbonation, both factors affected the carbonation efficiency, with the effect temperature shown to be greater than that of the CO2 flow rate. Additionally, the predicted results agreed well with the experimental values for both calcium leaching and carbonation processes, with errors of less than 1% and 5%, respectively.

Jun 5, 2020

By S. K. Sharma, R. Markandeya, G. Venkateswara

"In this study, a three level Box- Behnken factorial design combined with Response surface methodology (RSM) for modeling of process parameters of Multi Gravity Separator (MGS) for recovery Iron values from sub grade iron ore, Deposit No. 5, Bailadila complex has been developed. The three significant operational parameters of MGS, Drum rotational speed (RPM), Drum inclination (degrees) and quantity of wash water (LPM) were considered in the experimental work. Other parameters like feed percent solids, shake frequency and shake amplitude were maintained constant. The ‘as received’ sub grade iron ore sample is admixture of lump and fines and chemically assayed 40.80% Fe, 40.90% SiO2, 0.24% Al2O3 and 0.22% Loss on Ignition (LOI). The obtained results were evaluated with the Box-Behnken factorial design, RSM and also Quadratic programming(QP). Second order response functions were produced for Fe in terms of grade (%) and recovery (%) of the concentrate fraction. Taking advantage of QP, it was observed that maximum grade of 62.21% Fe achieved at an inclination of 4.3degrees, 2.7LPM of wash water and at a drum speed of 198 RPM. Similarly a maximum Fe recovery of 65.37% weight can be achieved at 4.3degrees inclination, 2.6LPM wash water and at a rotational speed of 212 RPM Predicted values of responses obtained using model equations were in good agreement with the experimental values. The influence of the process variables of the multi gravity separator concentrator on grade and recovery of concentrate fraction were presented and discussed."

Jan 1, 2014

Building block cave operations involves significant commitments to capital and time before arriving at completion or full scale production. The focus of the mine planners is habitually to minimize the upfront capital and achieve target development rates and construction dates. However, management of the construction of block cave projects requires understanding of the strategic/tactical decisions that the project planners can take to increase the value of the project and cope with schedule risks. As block cave projects involve development of vertical and lateral access to the underground footprint and ore body, more attention to uncertainties is required as most of those projects need to confront delays leading to a decrease in value. The standard process of development and construction scheduling is often not planned with provisions to realise uncertainties in the construction phase. Uncertainties and risks such as poor ground conditions and equipment breakdowns are the primary reasons for schedule slippage. As a result most of these projects experience delays. In order to mitigate risk to the project schedule, we centre our attention on increasing the value of the project by spending more money upfront and improving the schedule rather than focus on minimizing the upfront capital. Scenario-based simulations along with project appraisal methods hold great promise to address those challenges and enable mine planners to make better decision and enhancing project value. This paper will present a hybrid simulation based approach to model the process of development and construction based on discrete event (DES) and continuous based simulations (CBS). Such simulations will be conducted for scheduling multiple development headings (Apex, undercut, extraction, and haulage levels). Two scenarios are utilized to investigate the impact of risks on schedule and how flexibility in construction can be incorporated to minimize delays: (1) The bench mark scenario is created based on actual data from an existing case study. (2) The flexible scenario is an alternative way to use primary production infrastructure (Ore Handling System) including conveyer drifts, conveyer belt, and a gyratory crusher in the construction process and that requires the system to be in place before starting lateral development in the footprint. As a result, a truck-load system versus a conveying system will be studied to observe the gain in construction speed and to estimate the premium cost for mucking rock from headings and drawbells and transporting it to surface. Such strategic flexibility would be part of the original budget to make the tactical flexibility available during construction. Continuous cash flow models are used to evaluate and compare the scenarios. This study is an example of how new techniques in planning can be used to support decision-making processes in block cave design.

Aug 1, 2013

By Milind Chikhale, Yogesh Reja, Keshav Tyagi

"Using computer models for process design is a well-established practice in the mineral industry. In recent years, there has been emphasis on modeling of processing plant as a whole. This paper covers development of a model for iron ore processing plant. Basic purpose of this model is to use simulation for efficient plant design and help in minimizing risk at the very initial stage of project. Feed to the plant is Hematite iron ore from a deposit located in Eastern India. Major processes in plant include multi-stage crushing, screening, grinding, classification, gravity and magnetic separation. Models for different process equipment were developed using METSIM and Bruno simulation software. Customized black box models and known mathematical models were used for predicting behaviour of processes. Data needed was identified based on the model type. The required data was arranged as per project requirement and processed for development and validation of model. Equipment models were developed and validated on the basis of process design basis, theoretical and empirical data from technical references, and bench scale and pilot scale testwork results. Validated process circuits were assembled to simulate and represent the entire plant process. The result shows expected variation in plant output as a result of variation in the feed. Study concludes by discussing potential applications of the model in plant design."

Jan 1, 2014

By A. Oleynik

The paper presents the modeling and simulation experience in field of research into the mineral row material separation. Features of the subject domain generate a need of different approaches using for modeling and simulation. The general scheme of separation modeling process and some examples of developed simulators are presented. Due to different features and standards of knowledge, different formal models should be used to describe and analyze separation processes in the frame of general scheme. The main types of simulators are modeling tools based on statistical, analytical or expert (logical) methods. Advantages and disadvantages of each method above are mentioned in the paper. Based on the studies in the field considered, an aggregated mathematical model of a separation process has been generated. The aggregated model is presented by two combined equations. The actual apparatus model is formed by substitution of the particular functional expressions of the forces acting in the apparatus into the aggregated model. The developed simulation tools are based on integration of limited experimental data and on ex-pert knowledge available on separation processes. Simulation does not allow producing an optimal, in terms of mathematics, solution. But it gives an opportunity to produce and compare quite adequate solution variants in real time. The results obtained are the theoretical and methodological base for integrated information technologies to support studies in the field of mineral processing.

Jan 1, 2014

By T. Doshi, S. Ennis

The interactions of mineralogy, chemistry and mechanics in an ore concentrator are highly complex, so it can be particularly hard to measure the impact of a specific plant change. This paper describes a method for modeling a baseline metal recovery so that the value of a major process improvement can be measured. This method only considers variables that cannot be optimized, such as mineralogy or equipment availability. Linear regression, random forests, extreme gradient boosting (XGB), and simple two-layer neural network models of process value were tested as candidate baseline model types to assess the impact on throughput and recovery in a copper concentrator. XGB performed the best in terms of accuracy for both throughput and recovery models. Using an XGB model of nonoptimizable process variables provides an accurate, dynamic baseline that can be compared with continuous production data to determine the value added by major concentrator improvements in real time.

Mar 2, 2022

By Cristian Castro, Patricio Gomez, Jason Furtney, Augusto Lucarelli

Understanding the effect of blast-induced damage on wall stability is critical to safe and economical operation of a large open pit mine. In this paper, a numerical modeling methodology is used to investigate damage to rock at distances of greater than 10 m (30 ft) from a blast. Two applications of the model are demonstrated. First, the method is applied at a zinc mine to investigate the effects of pit blasting on underground stopes. The model predictions are compared with the scaled distance formula. Next, the model is used to investigate a common problem in which unfavorable jointing creates a rock wedge on the bench above a blast. The numerical predictions of wedge stability are compared to the wedge energy model described by Wong & Pang (1992).

By Cristian Castro, Patricio Gomez, Jason Furtney, Augusto Lucarelli

Understanding the effect of blast-induced damage on wall stability is critical to safe and economical operation of a large open pit mine. In this paper, a numerical modeling methodology is used to investigate damage to rock at distances of greater than 10 m (30 ft) from a blast. Two applications of the model are demonstrated. First, the method is applied at a zinc mine to investigate the effects of pit blasting on underground stopes. The model predictions are compared with the scaled distance formula. Next, the model is used to investigate a common problem in which unfavorable jointing creates a rock wedge on the bench above a blast. The numerical predictions of wedge stability are compared to the wedge energy model described by Wong & Pang (1992).

Feb 1, 2020