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By William J. McDonough

Advanced materials are polymers, metals, and ceramics fabricated as intermaterial compounds, alloys, or composites. The resultant components have higher strength-to-density ratios, greater hardness and wear resistance, and one or more superior thermal, electrical, or optical properties when compared with traditional materials. Advanced materials, the basis for many of today's emerging technologies, offer savings in total energy consumption, improved performance at reasonable cost, and less dependence on imports of strategic and critical mineral resources.

Jan 1, 1992

By F. B. Henderson III

Since the "end" of the Cold War, revolutionary new research and commercial remote sensing capabilities are being developed that will dramatically change the way we map the earth and address its environmental problems. The technology challenge is not the growth of new environmental remote sensing technologies themselves. It is, rather, how these new innovative observing systems can be accepted and used to the benefit of both the regulatory and the mining communities in the light of present concerns about unknown risks of discovery and liability. The basis for this paper is an unpublished technology primer prepared for the industry-government Workshop on Advanced Measurement and Site Characterization for Mining Impacts held at Colorado School of Mines, Golden, Colorado, July 14-17, 1997

Jan 1, 1999

By David Tisdale, Phillip Mackey, Nagendra Tripathi, Matthew Kreuh, Pascal Coursol

Xstrata Nickel’s Sudbury smelter operation is based on fluid bed roasting of Ni-Cu sulphide concentrate, followed by electric furnace reductive smelting and Peirce-Smith converting to produce a Bessemer matte for electro refining, along with sulphuric acid produced from smelter gas. While the site dates back to the 1930s, the present smelter configuration has been operational since 1978, and currently has a nominal capacity of about 67,000 tpy of contained nickel and is investigating options to expand in future up to 85,000 tpy. As part of a review of plant capacity options, a new metallurgical model of the plant was developed in order to examine a number of processing alternatives. Based on the METSIM™ platform, the present model includes the ability to examine the impact of a number of plant parameters on potential plant performance including; for example, the following: percent of sulphur elimination in roasting, matte grade, degree of matte metallization, temperature, coke requirements, sulphuric acid production, CO2 emissions and overall energy requirements. The process model also includes a number of special features adopted; for example, approaches to effectively model the complex Ni-Cu-Co-Fe-S-O matte system. This paper provides a description of the model and gives an overview of the results. As well as presenting the results of the present study, the applicability of this modeling approach to pyrometallurgical systems in general is also briefly discussed in the paper.

Jan 1, 2009

RME has a vision for a new grinding plant operational paradigm made possible by RMEÆs fast, safe Mill Relining System. Some new liner designs can degrade SAG mill performance because of mill volume loss, ball strike (rotational speed limitations) and other issues often brought about by modifying liner design for maximum life and without a backward glance at metallurgical consequences. Freshly relined mills can initially produce as little as 80 per cent of their maximum throughput, that maximum occurring toward the end of the linersÆ wear life. RMEÆs proposition is to see new liners designed for maximum commercial performance. This may mean more frequent mill relines but with liners designed to yield optimum grinding, metallurgical and profitability performance, not maximum life. In other words, mill liner profiles and mill relining speed become key operational controls and not simply æmust doÆ maintenance functions. Taken to the extreme, liner profiles may prove capable of ætuningÆ a grinding plant for maximum profitability in any metal price environment. Following the introduction, the first section of this paper provides an update describing recent and significant developments within RMEÆs range of Mill Relining Systems, the enabling technologies which permit more frequent liner exchange without incurring additional downtime imposts. The second section outlines RMEÆs vision of a æliner profile versus profitabilityÆ commercial model, developed either intuitively or by using a combination of new measurement and modelling technologies. These new measurement and modelling tools provide the opportunity to predict the optimum commercial outcome, off-line in the virtual world, before committing to an expensive liner experiment.

Jan 1, 2007

By J Young, S Yu, P Moyo, M Powell, A Musunuri, B Bonfils, S Kanchibotla, P Yaroshak, V Jokovic

The appropriate design of liners continues to be an issue on many mills worldwide. Loss of milling capacity especially at liner change, uneven wear lives along the mill, substantial scrap on worn liners, excess mill down-time, undesirably short and unreliable wear lives are all common issues. This paper presents a designed approach to liner optimisation that follows a logical path of initial design and step-wise improvements based on liner wear monitoring. The target is to have a good liner design from start-up, then tune the profiles, heights and thicknesses based on wear monitoring. This is conducted as a team of liner specialist, site personnel and liner supplier. The application to the Pustynnoye SAG mill of JSC Altynalmas in Kazakhstan is presented. The increase in liner life by around 50% along with increased mill throughput of over 20% illustrate the huge benefit of the cooperative triumvirate approach through the gains that can be made in productivity and reduced liner costs.CITATION:Powell, M, Kanchibotla, S, Jokovic, V, Hilden, M, Bonfils, B, Musunuri, A, Moyo, P, Yu, S, Young, J, Yaroshak, P, Yalcin, E and Gorain, B, 2018. Advanced mine to mill application at the Barrick Cortez mine, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 177–196 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

By III Feeley

The U.S. Department of Energy is supporting the engineering development of three advanced physical coal cleaning technologies--selective agglomeration, advanced flotation, and advanced cycloning--capable of significantly reducing the pyritic-sulfur content of U. S. coals. The objective of this activity is to provide the coal production and electric-utility industries with a cost-effective option for addressing the SO2 emission reductions required by the 1990 Clean Air Act Amendments. A secondary objective is to evaluate the potential of advanced coal cleaning for removing trace elements that are precursors to the formation of hazardous air pollutants. This paper will summarize the status of the three advanced physical coal cleaning engineering development projects.

Jan 1, 1993

By Andreas Hucke

For the roadway design in the German hard coal mining industry, an advanced combined planning system has been applied during the past 20 years. The German mining industry is working with single entry roadways system. After first longwall passage the roadways will be stabilised with side wall building material packages. Later this roadway will be used again for the second retreating longwall. The intention of the implementation of several different design methods for the planning of the roadways is to enhance the reliability of the results. On one hand the planning system uses numerical simulation and physical modelling in addition to analytical and empirical methods. On the other hand in-situ monitoring and analysis during the roadway development will be used to verify and calibrate the numerical and physical models. Especially before the implementation of new support elements in underground, this system is suitable and reasonable because the new support elements will be tested in the physical and numerical simulation prior to cost intensive underground tests. The interaction between the numerical and physical modelling in comparison with underground monitoring and analysis during development and the later use of roadways will be shown with some examples. The first example shows a rock bolted rectangular roadway which will be mined at both sides of the roadway. Different support and roadway building material package systems are investigated under various stress conditions. The results are utilised to optimise the roadway support and the roadway side package systems. The influence of different points in time of the installation of several support elements in a combined arch and bolted roadway is shown as another example. Two different types of support systems are compared within the physical models. These models are used as a base for ongoing numerical analysis and simulation to find out the ideal point of time to assemble the different support elements. The last example handles the influence of slickensides in the roof of arch shaped roadway on their stability. Different slickenside positions and densities are investigated and classified.

Jan 1, 2006

By Tim A. Beattie, John R. Grant, David L. Kennedy

After many years of research, ICI staff have developed a numerical modelling system for the study of detonator/primer/explosive configurations. Results from this work clearly identified that current primer designs were not as effective in delivering their energy potential as needed. Alternative designs were evaluated and several prototypes, all essentially spherical in shape, were built for testing. Results have shown a significant improvement in various aspects of primer performance, including omni-directional pressure transferral and increased energy release rates. Reliable, high performance priming of explosives is now achievable for a much wider application range.

Jan 1, 1991

By I. James, R. J. Durrheim, M. S. D. Manzi, O. Valeshin, J. Lepine, L. V. Socco, C. Colombero, A. Malehmir, M. K. Rapetsoa, M. Sihoyiya

The FUTURE project aims to enhance seismic surveying in South African mining by integrating advanced acquisition technologies. In this paper, we detail surface and underground seismic surveys at the South Deep gold mine as part of the project. Surface seismic acquisition used co-located broadband micro-electromechanical sensors, one and three component recorders connected to geophones, distributed acoustic sensing using a straight fibre optic cable, along with a 6 ton broadband seismic vibrator operating with 4–180 Hz linear sweeps. In addition, underground surveys employed a combination of straight, and helically wound fibre optic cables, cabled-based and nodal sensors, along with a 500 kg drophammer mounted on a skid steer bobcat. The surface and underground seismic arrays were time synchronised using a GPS-time transmitter to allow for accurate seismic data recording in a GPS-denied environment. Results show the efficacy of these techniques in acquiring high-resolution seismic data, revealing detailed subsurface geological structures and mineralisation down to 3500 m below ground surface. Surface data revealed clear seismic reflections corresponding to the Black Reef and Ventersdorp Contact Reef. An underground P-wave velocity model exhibits low velocity anomalies that are associated with fracturing, while a P-wave reflection stack section shows significant reflections and a degree of faulting below the tunnel floor that was not observed on the surface reflection seismic data. We highlight the potential of these technologies to enhance safety, efficiency, and sustainability in mining. This study sets a benchmark for future reflection seismic surveys, paving the way for safer, more efficient, deep mineral exploration and extraction practices.

Jan 12, 2025

By Reinhard Gnilsen

Soil Nail walls, like any other structure, must meet high standards of design to be acceptable to the public and owners. On the other hand, the concept of soil nailing trails behind other structures in terms of defined design criteria that are commonly acknowledged. This is not to say that soil nail walls need to be less safe or less conservative than alternative more conventional concepts. Instead, the lack of established design criteria and design methodology entails that rules of thumb from past experience, overly simplified calculation assumptions, and the engineers' common sense judgement must substitute for a complex analysis of true stability and wall performance. Those "design approaches" must be conservative to ensure an adequate structure. Also, soil nailing may not be perceived prudent where site conditions are considered beyond past experience. For instance, site conditions may be perceived out-side the scope of soil nailing applicability where walls are very high, soil parameters variable or low, or nearby buildings close to the wall edge. The latter relates in particular to deep

Jan 1, 1988

By G. Cavanough, A. Torrance

Emulsions have been developed for over forty years to become the most common water-resistant explosives used in the mining industry. An emulsion is a common commodity, with many examples in our day to day lives of one immiscible liquid dispersed in another. They have varying degrees of stability from a few seconds to years. What makes their application in explosives unique is twofold. They contain a high concentration of salts in the dispersed phase and also have a far larger volume of dispersed phase than continuous phase. The continuous phase contains at least 75% by weight of an oxidizer such as ammonium nitrate dissolved in water. The crystallization point of these solutions is often >60oC which means that the formation of the emulsion has to occur at an elevated temperature. Once the emulsion is cooled, its structure helps to prevent the formation of crystals in an otherwise unstable system. At room temperature there is a considerable potential for the small oxidizer droplets to crystallize which is countered by the strength of the oil layer and also the size of the emulsion droplet. If the emulsion droplet is too large then crystals can form which may lead to rapid deterioration of the emulsion and overall crystallization, accompanied by a temperature rise as the heat of crystallization is released from the emulsion. The size of the emulsion droplet is critical in preventing crystal growth and subsequent droplet coalescence and emulsion break down. One method of examining emulsions and understanding their structure is to use optical microscopy to measure droplet size and also emulsion deterioration from shearing, temperature cycling and when contaminants are introduced, such as detergents, different oil types, coating agents and dust particles. This paper reports on advanced techniques to quickly assess emulsion quality and stability

Jan 1, 2024

Productivity and efficiency of diesel-powered underground trucks and LHDs can be enhanced through the application of a range of advanced technologies. In addition, these machines are subject to ever more stringent emissions control requirements. This paper will review how various technologies can improve usability, maintainability, and performance of LHDs, through a number of examples. The use of instrumentation and monitoring to understand the role of operator practice on mucking efficiency, as well as the use of finite-element analysis to evaluate structural design, and the use of control techniques to modify operator inputs and hence decrease power consumption, will be presented.

May 1, 2002

By Vince Newberry

Alcan Rolled Products at Oswego, New York, commissioned Recycle II during May of 1995. Recycle II is an advanced technology UBC recycling facility designed to meet the most stringent environmental standards enforced to date in the United States, particularly with respect to NO, and particulate emissions. This paper addresses the exacting requirements and strategies of Alcan's Recycle II project andThorpe Technologies' design considerations and solutions for the supply of environmentally favorable melting furnace and delacquering systems. The furnaces are equipped with low NOx regenerative burners and furnace pressure and hearth gas flow controls designed specifically for processing the hearth gases through baghouses. The delacquering system is a new generation Apros concurrent flow unit designed for low NOx emissions.

Jan 1, 1995

By D Xiong, G Xu, L Yao, F Wang, Y Duan

The goal of this project has been to digitise and use drill parameter data from rotary drilling (measurement while drilling; MWD) for a more effective planning of the blasting process in surface mines. A more accurate and reliable digital drilling and automatic hardness identification technology was developed, which includes both a hardware and software system. In the aspect of hardware, we designed a positioning, navigation and hardness perception terminal system which consists of a global positioning system original equipment manufacturer board, programmable logic controller and sensors of measuring major parameters, and a wireless data transmission system which combines digital blasting platform and wireless transmission facilities. In the aspect of software, we developed the navigation software of locating blastholes using LabVIEW and C++, and the blasthole design software using AutoCAD ActiveX (C#) technologies. This new technology is applied at Jiangxi Dexing Copper Mine, and initially realising the digitisation of drilling and hardness identification in blasting zone.CITATION:Duan, Y, Xiong, D, Yao, L, Wang, F and Xu, G, 2015. Advanced technology for setting out of blastholes and measurement while drilling, in Proceedings 11th International Symposium on Rock Fragmentation by Blasting, pp 593–598 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 24, 2015

By C. Pichler, S. Luidold, C. Wagner, C. Sagadin, D. Kreuzer

Engineers and scientists have been combating the attack upon refractory materials of molten metals/matte and slags for hundreds of years. The details in many cases are still questionable or at least debatable. The corrosion is a major concern for furnace operators as refractory wear or failures inevitably results in reduced production efficiency and furnace reliability. Also the cost to industry is considerable and only a thorough understanding of all the complexities of the process will help to minimize that cost. One of the critical questions to overcome is the correct selection of refractories for the individual process steps to provide long and predictable refractory life together with high furnace availability. To understand the nature of the reactions involved in refractory corrosion, it is crucial to determine the complex thermo- chemical equilibria of the reactions occurring between the refractory materials and the process phases. A simulation model coupled with commercial software like FactSageTM is demonstrated aiming to understand the corrosion mechanisms between refractories and the molten process phases and draw implications for improving the performance of refractories and refractory lifetime. INTRODUCTION The extraction or recycling of valuable materials, e.g. metals, can be done by two main routes, pyro- and/or hydrometallurgical processing, depending on the chemical behavior of the used ore, scrap or pre-treated concentrate. Sometimes it is also necessary to use both process routes for the extraction or the recycling of valuable materials. In the case of a pyrometallurgical treatment, the usage of refractory materials is inevitable. This is mainly caused by high temperatures, prevailing during processing. The interaction between refractory material and slag, metal or matte leads to different reactions and interactions. As a main result corrosion of the furnace lining (refractory material) takes place. Hence, recurring furnace shutdowns occur for renewing the refractories. This leads to reduced production efficiency. Such refractory lifetimes are between some hours and decades, depending on the processes.

Jan 1, 2019

By C Xu, B Li

Multi-sensor fusion visual perception technology significantly enhances visual perception capabilities in complex and harsh environments by combining visual data from different sensors. This technology is especially useful for scenarios where traditional single visible light sensors, such as standard cameras, struggle due to poor lighting, adverse visual conditions, or other visual obstructions. In environments with low light, smoke, or dust, the performance of conventional visible light sensors degrades, limiting their application. By integrating data from various sensors like radar, infrared thermal imaging, and others, multi-sensor fusion technology provides a more comprehensive and complementary visual solution. This fusion not only enhances the robustness of visual systems but also greatly expands their potential applications in fields like visual surveillance. In recent years, deep learning methods have become the mainstream technology for addressing multi-sensor fusion issues, demonstrating significant advantages in adaptive feature selection compared to traditional machine learning methods. However, deep learning-based multi-sensor fusion algorithms still face several challenges. The design of network structures is often redundant, lacking effective screening of useful components within multimodal information. Mainstream fusion algorithms focus excessively on improving display effects without adequately considering the needs of downstream applications and tasks. Existing fusion perception algorithms are generally designed for open visual scenes and lack targeted design for complex visual degradation factors present in tunnel environments of mines. Current deep learning methods for designing multi-sensor fusion networks heavily rely on manual experience to create fusion modules. This reliance increases the complexity of network design and can lead to redundancy. Redundant network modules are difficult to identify in end-to-end learning tasks at this stage, significantly slowing down network inference and potentially interfering with the output of fusion perception. Additionally, training these fusion modules typically requires large amounts of well-annotated multimodal data, further increasing implementation difficulty and cost. For instance, the fusion network design proposed by Li and Wu (2018) focuses on extracting multimodal fusion features, while Zhao et al (2020) introduced a feature decomposition mechanism in the feature fusion and extraction modules. Researchers like Zhang and Ma (2021), Xu et al (2020), and Liu et al (2017) have attempted to improve network structures through dense cascades and the introduction of residual connections. Although these methods have improved the handling of multimodal information to some extent, they still face limitations in distinguishing between useful and redundant information, with redundancy persisting in network designs. Ideally, the design of fusion networks should be more intelligent, guiding network structure design heuristically based on the importance of different modal information for the current task. This would reduce information redundancy and network weights, requiring the development of new algorithms or frameworks capable of automatically identifying and optimising fusion strategies, thereby reducing dependence on manual experience while improving fusion efficiency and network performance. Current deep learning designs for multi-sensor fusion algorithms often overlook the

Sep 1, 2024

By D. McCarthy

This paper discusses the process involved in developing an optimum method of treating and removing heavy metals from water that have leached out from the native rock -prior to discharge back into the environment. Also designed into the system is a manner to stabilize the metals removed as a precipitate, so that they can be disposed of as a non-hazardous waste.

Jan 1, 1992

By E Jak, M Shevchenko, D Shishin

One of the key aspects to develop sustainable metallurgical production is to ensure that the predictive power of thermodynamic tools is brought up to a new level of accuracy and reliability. Exploring new polymetallic processes, integrating primary and recycled materials, means utilising the uncharted areas within the Cu-Pb-Zn-Fe-Ca-Al-Mg-Si-O (major) – Cr-Na (slagging) – As-Sn-Sb- Bi-Ag-Au-Ni-Co (minor) slag-solids-metal-matte-speiss-sulfate system. This requires extensive integrated experimental and thermodynamic modelling study, which is underway at PyroSearch at the University of Queensland (UQ).

Aug 21, 2024

By Shani Engelbrecht, Belinda McFadzean, Avuyile Wali, Natalie Shackleton, Vratislav Malysiak

Frothers play a crucial role in sulphide and PGM ore flotation recovery, and AECI Mining Chemicals studies on PGM ores have shown significant flotation kinetic increases with the optimal frother-collector combinations. Using Senfroth 200 as the industry baseline, remarkable kinetic increases were observed with AECI Mining Chemicals developed frothers in the first concentrate. Even in the worst-case scenarios, 4E PGM recovery increased by 5% at a slightly higher concentrate grade. It is important not to limit frother dosage to a fixed value. Instead, enough frother should be added to maintain a stable bench float, measuring the dosages by frother volume before and after tests. Frothers can be specialized blends and their importance should not be underestimated. The results produced by formulating and innovating frothers to address specific industry challenges have been encouraging. Testing a frother on a plant scale does not have to be as daunting as with collectors, enabling the identification of the best frother-collector combinations at an industrial scale. AECI Mining Chemicals bench scale testwork has motivated plant-scale trials that have successfully transitioned to commercialization. This paper compares the results from metallurgical and froth stability tests and shows that occasionally frothers that have a less stable froth can have improved valuable mineral recoveries, while still exhibiting better drainage for reduced entrainment and mass pull. It was shown that caution should be used when relying only on simplified froth stability tests in the evaluation of new frothers.

Feb 1, 2025

By Trevor Riters

Advancements in Emerson’s instrumentation technology have brought value and efficiencies to the mining industry. Some think of instrumentation as basic sensors and valves, but with our solutions, we equip operators with real time, accurate, and reliable data that they can use to operate more effectively. Working with Caltrol, an Emerson Impact Partner, we successfully engineered wireless skids for a leach pad to provide precise measurement and control of raffinate solution to many of the large mine sites in Arizona.

Feb 1, 2025