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By Danqing Gao, Brijes Mishra

Spatial variance of rock properties is an important characteristic of rock which addresses the heterogeneity of mechanical and physical properties and their effect on underground mining. Assessing spatial variance can be useful for both locating potential difficult grounds and performing reliability analysis in the mining support system. This study shows a microscale numerical model for rock material based on continuum mechanics. To consider the spatial correlation factor of mechanical properties in realistic rock mass, this study introduces a spatial correlation concept into the traditional type III extreme value distribution model. Based on the improved microscale random model, we conducted a series of numerical uniaxial compressive tests and one longwall mine model to investigate the progressive failure of rock. The results show that spatial correlation factor can significantly affect the load-deformation curves and fracture patterns. The spatial variance model was applied to a longwall mine that included several cutting sequences to observe the influence of the spatial variance on roof behavior. The cohesion and friction random fields induced failure that propagated randomly through the immediate roof in different entries. The results showed that the spatial variance provides an accurate prediction of erratic roof falls in coal mines.

Jul 20, 2020

By Danqing Gao, Brijes Mishra

Heterogeneity in rock formation affects both rock behavior and strength. Spatial variance of rock properties is an important characteristic of rock that addresses the heterogeneity of mechanical and physical properties and their effects on underground mining. Assessing spatial variance can be useful for locating potential difficult grounds and for performing reliability analysis in the mining support system. This study presents a spatially correlated, random model to investigate the influence of rock heterogeneity on rock strength and failure propagation. A random field database with specific spatial correlation was created for each physical-mechanical property using laboratory data and the extreme value stochastic model in MATLAB. Based on the improved microscale random model, we considered one three-dimensional numerical model to study a mine operating in the Pittsburgh seam. The influence of random field data on entry roof was investigated. The realistic random field database added two scale-measured parameters from horizontal and vertical directions to control the spatial correlation length. A number of cutting sequences were also considered in order to identify the effect of spatial variance on roof behavior. The results show that spatial variance provides an accurate prediction of erratic roof falls in coal mines.

By Gabriel Walton, Sankhaneel Sinha

"Rib failures are a major hazard in underground mining. When pillars are subjected to loading, extensile cracks are generated parallel to the excavation boundary, which can manifest as rib falls. A common mitigation measure is to install supports, especially bolts, normal to the rib surface. The type and spatial distribution of these supports along the pillar is often based on experience rather than comprehensive analysis. Since conducting field experiments is often impractical and expensive, a convenient alternative is to perform 3D numerical modeling. In this study, FLAC3D has been used to capture the interaction of rib bolts and the failure processes governing the stability of pillars. An associated goal is to determine whether, at all, a continuum software is capable of modeling the effect of supports. The modeling involved two important steps: selection of a proper constitutive model, and, explicit simulation of rock bolts. Based on precursory work in the last decade, an S-shaped strength criterion was chosen that can describe the tensile fracture mechanism of rock at low confinement and shear failure mechanism of rock at high confinement. The built-in pile structural element in FLAC3D is a simplified representation of the complete bolt system. Hence, the different components of a rock bolt (i.e., steel, grout, steel-grout interface, and grout-rock interface) have been explicitly modeled within the rock mass and then tested for its ability to replicate the ground-support interaction behavior. INTRODUCTION Rib failure-related hazards and injuries have plagued the mining industry for decades (Mohamed et al., 2016; Iannacchione and Prosser, 1998). In highly stressed environments, excavation parallel cracks are the primary initiators of skin instability. In absence of any support, this failure can indirectly destabilize the excavation by increasing the exposed span of intersections and roadways. Over the last two decades, there have been numerous injuries (fatal and non-fatal) due to rib failures in underground coal/non-coal mines."

Jan 1, 2017

By Mick Lownds, Ruilin Yang

The potential advantages of electronic detonators with accurate timing have been increasingly recognized by the blasting community. However, in comparative blasts the results with pyrotechnic timing are sometimes comparable to those from electronic timing. Statistical variation in blast results is a plausible cause of these observations.

Jan 1, 2011

By M. G. Lipsett

One challenge in applying information technologies in Mining is building a business case. In Mine Maintenance, there is a complex flow of information that contributes to making informed business decisions. By understanding those information relationships and the cost of wrong decisions, analysts can estimate the value of information flow. Developers can then ensure that systems deliver key information in an accurate and timely way. In this paper, general maintenance decision-making is discussed, with examples of how model-based analysis can improve the information delivered to decision makers.

May 1, 2001

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 Mathias Jern, Ruilin Yang

A blast vibration model has been developed that simulates effects of almost all blast design parameters on the blast vibration peak particle velocity (PPV) from a production blast with multiple blastholes at a given point of interest in the rock. The velocity of detonation (VoD), initiation points, explosive types (density, VoD, energy), charge decoupling, and decking in each blasthole are simulated along with other blast design parameters. The information from signature hole blast vibration and the blast design are the input to the model. The model can be used to assess blast damage in proximity of blastholes as well as far field vibration PPV.

Jan 1, 2019

The environmental impact of solid waste materials is closely linked to their potential to produce a hazardous leachate once deposited in a landfill. This potential is conventionally assessed with simple laboratory batch leach tests, which find more and more frequent application also in the minerals and metals industry. Such tests are intended to help distinguish between high and low risk wastes, but are completely unsuitable to allow quantitative prediction or modelling of the long-term leachate generation potential. In the present approach the leachate generation process is perceived as a combination of bulk convective transport, stagnant zone and inner particle diffusion, as well as reaction kinetic effects. Model equations are formulated accordingly. A modelling frame work, WASTESIM, has been developed at UCT, which allows flexible combination of the model components and simulation of leach scenarios. Quantitative model parameters are obtained from a systematic laboratory study on the waste material in question. The combined assessment and modelling approach is demonstrated with a study on Cr (VI) leaching from a ferro-chromium slag material. Although not straightforward, the approach is particularly useful in determining long-term liabilities in the context of waste disposal sites with considerably more reliability than has previously been possible. Keywords: waste deposits, waste leaching, heap leaching, environmental, risk assessment, Cr (VI), ferro-chromium, slag.

Jan 1, 2000

OBJECTIVES ??REDUCE OPERATING COSTS ??INCREASE LIFE COMPONENTS ??EXTEND LIFE of THE DOZER ??REDUCE MAINTENANCE COST ??REDUCE DOWNTIME ??IMPROVE DURABILITY & RELIABILITY ??IMPROVE BOLD JOINTS PREFORMENCE ??IMPROVE SAFETY

May 1, 2004

By H. P. Kritzinger, T. C. Kingsley

Rotary kilns are used for a variety of mineral processing operations. Hatch makes use of a kiln model developed from first principles to evaluate designs for its clients. This tool has been applied to a variety of pyrometallurgical applications. This paper illustrates the application of numerical optimization techniques in combination with the kiln model in the interrogation of a generic iron-ore reduction process. The fundamental modelling concepts are explained, followed by a description of the optimization approach. The results show how the combination of the two methods, with modern computing power, can generate a large number of viable design and operating candidates.

Jan 1, 2014

By S. Zhang, Z. Hua, D. Feng, X. Tong, X. Xie

The separation and beneficiation of low grade collophanite has long been a technical challenge in phosphorous production. It requires the joint efforts of process design, reagents optimisation and operational control. In this study, the statistical response surface method was applied for determining the optimum reagent dosing in the flocculate flotation of a low grade (18.59%) collophanite ore. The dosage of three reagents, including a pH regulator (Na2CO3), depressant (Na2SiO3) and flocculant (modified starch), were input parameters of the modelling design. Two quadratic mathematical models were derived for prediction of grade and recovery based on the statistical design. Statistical analysis of the experimental results validates the reliability of the models. Through further calculation, the optimum dosage of the three reagents were found to be 3,020g/t Na2CO3, 1,990g/t Na2SiO3 and 880g/t modified starch, with which a maximum recovery of 75.81% and P2O5 grade of 30.08% was obtained from flocculate flotation test. Keywords: Process optimisation, modelling, froth flotation, collophanite ore, response surface methodology

Jan 1, 2020

By Ioannis K. Kapageridis

The lignite deposits of the Kozani-Ptolemais-Amyntaio basin in western Macedonia (North-West Greece) present a difficult modelling problem. Each deposit consists of several thin lignite layers ranging from a few centimetres to a few tens of centimeters in thickness, and thin intercalated sterile layers of marly limestones, marls, clays, and sands. These layers are practically impossible to model individually due to fast lateral transition of lignite layers to humus clay and vice versa and the lack of reliable and detailed stratigraphic correlation, leading to compositing methods being applied prior to any interpolation and modelling. The complexity of the deposit is further increased by the presence of a number of faults. This paper presents the modelling and estimation procedures applied during the most recent study of the South Western Field ? a new deposit that is considered for development and lignite production over the next years and will support the operation of a new power station in the area. Special focus is given to drillhole database structuring, fault modelling, stratigraphic correlation, mineable lignite intervals compositing, and resource estimation. The use of specialised mine planning software in all stages of modelling and estimation is thoroughly explained.

Oct 1, 2009

By G. Ferrara

In process and plant simulation, more reliable prediction of industrial results and evaluation of data for designing purposes may be attained by the combined use of (a) modeling and simulation of ore characteristics and (b) modeling and simulation of integrated plant operations. The systems for modeling and simulation of ore characteristics are discussed as well as the conditions in which their use may be necessary (complex structure of the ore-body and variability of the ore fed to the plant). Two examples, for coal and bauxite run-of-mine (ROM), are reported. The procedure of linking the process unit models and the approaches for the solution of integrated systems are indicated. A general-purpose program for the simulation of integrated plant operations is described, and some examples of its use are reported.

Jan 1, 1984

By E J. Sellers, A Cocker

Movement of the fragmented rock mass is an inevitable consequence of open cut blasting. Uncontrolled, unaccounted movement from blasting commonly causes ore loss and dilution from waste mixing. Therefore, the prediction of the post-blast location of both ore and waste is vital in grade control and of direct interest to mining geologists. Direct measurement techniques have matured significantly over the past decade, but their use remains expensive and labour intensive. Access and safety issues are further disincentives to regular movement monitoring. What is needed is a combination of direct measurement to establish baselines and reliable predictive modelling.The W H Bryan Mining and Geology Centre of the University of Queensland has pioneered 3D blast movement modelling using ‘physics engines’ to handle in-flight collisions and predict the final resting place of blasted material. Open cut metalliferous mines are a demanding environment for this style of modelling as they can involve complex geometries and variable buffering, which leads to inconsistent confinement. A version of the model designed to deal with these complexities is under development. A well-controlled field trial was needed to validate this new version.A validation trial was completed at a gold mine in South-East Asia. The aim was to increase throughput by increasing the blast powder factor without losing grade through dilution and mixing with waste. Four blocks were blasted to identify the effect of bench height and face confinement on ore movement, fragmentation and process throughput. The powder factor and blast timing were kept constant. Movement of the broken rock was measured by placing blast movement monitors at known positions in the block and then locating them after the blast. The majority of sensors were recovered, providing a unique insight into blast movement dynamics and generating a substantial data set for model validation.The model (called ‘MetaMove ‘) was calibrated for one blast and applied to investigate the extent of grade loss and possible mitigation strategies. Conventional mining techniques that involved firing across the strike of the orebody, and no post-blast boundary adjustment of the ore/waste boundaries prior to digging, were found to cause up to 44 per cent loss of high-grade ore, depending on the grade distributions. Post-blast adjustment of the ore/waste boundaries can negate this loss. The model indicates that altering timing and ensuring that the block boundaries are well confined can further constrain the movement of ore/waste boundaries. Thus, the model can be successfully applied to minimise grade dilution and limit misclassification of ore as waste whilst using higher powder factors to increase mill throughput. Application of a calibrated model to move ore/waste boundaries prior to digging will enable the production geology team to add significant value to the mining operation.CITATION:Cocker, A and Sellers, E J, 2014. Modelling blast movement for grade control at an open cut gold mine, in Proceedings Ninth International Mining Geology Conference 2014 , pp 377–386 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 18, 2014

By A Keddie

Standard microeconomic theory suggests that the behaviour of mineral extraction and processing firms with respect to their demand for water can be modelled and a market demand for water subsequently derived. Such a model, although an abstraction of the real world, should be able to predict the responsiveness of quantity of water demanded to change in price, and, change in demand to a range of factors including: expectations about reliability of supply, changed commodity prices for mineral production, and change in water technology and storage at mine site. This paper demonstrates that the price of water is particularly responsive to changes in demand and that although price increases would result in some additional supplies, physical constraints on supply suggest that the industry will be paying considerably higher prices for water in the future. It is recommended that the mining industry undertakes quantification of possible price increases to position itself to minimise the impact on their operating costs as well as to make responsible capital investment decisions to facilitate future expansion or commissioning of new mines. Substantial investment is required to commission a new mining venture with expected rates of return subject to risk and uncertainty due to fluctuations in world commodity markets as well as reliability of secure supplies of inputs. If a reliable supply of water was subject to uncertainty and water was a critical input for production, then the initial mine design would typically consider a range of production decisions contingent on levels of uncertainty with respect to water supply. These states or sets of water supply, will affect production decisions and future water demand. Modelling production decisions contingent on different states of nature, termed the state-contingent approach, provides a number of insights about producer behaviour under uncertainty. This paper investigates the assumptions underlying the derivation of the market demand for water by the mineral resource industry and identifies the drivers of demand and the responsiveness of the industry to change in price and supply, particularly in relation to capital investment in water-use technologies. The usefulness of these models to the mining industry is considered by reference to the increasing demand for water by the industry in Queensland, in a climate of water shortages.

Jan 1, 2006

By T Ma, F T. Suorineni, Q He, J Oh

Directional hydraulic fracturing was invented by Polish experts and was first applied in coal mining to prevent hard roof rock bursts. Based on its successful application in coal mining, directional hydraulic fracturing has the potential to reorientate the hydraulic fracture trajectory. Recently, this technique has been introduced into cave mining for the purpose of lowering breakdown pressure. The hydraulic fracture is much easier to initiate with the assistance of an initial notch. No systematic theoretical or experimental studies have been carried out to investigate the influencing factors in the hydraulic fracture reorientation process. In this paper, the numerical modelling software Realistic Failure Process Analysis3D (RFPA3D) – Flow Version is used to study the influence of the in situ stress condition and rock mass heterogeneity on directional hydraulic fracturing in brittle heterogeneous rock masses. Firstly, the reliability of RFPA3D in simulating hydraulic fracturing is validated by comparing its results with experimental results and the simulation results from the extended finite element method. The hydraulic fracture trajectory is then observed in a three-dimensional stress environment. The results indicate that for the in situ stress condition, when the borehole lies in the ?2–?3 plane, only the difference between ?2 and ?3 has an important influence on hydraulic fracture reorientation. Furthermore, rock mass heterogeneity is a key factor that must be accounted for when fracture reorientation is required.CITATION:He, Q, Suorineni, F T, Ma, T and Oh, J, 2016. Modelling directional hydraulic fractures in heterogeneous rock masses, in Proceedings Seventh International Conference and Exhibition on Mass Mining (MassMin 2016), pp 369–384 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2016

By W Valery, S Morrell

In the mining industry blasts are usually designed to fracture the in situ rock mass and prepare it for excavation and subsequent transport. The run of mine (ROM) fragmentation is considered good when it is fine enough and loose enough to ensure efficient digging and loading operations. Mining optimisation strategy is hence usually focussed on minimising total mining costs and maintaining these ROM fragmentation characteristics. Although this approach ensures an efficient mining operation it ignores the potential impact on crushing and grinding. Investigations by several researchers have shown that designing blasts to produce ROM fragmentation to optimise crushing and grinding performance enhances the overall efficiency and profitability (Eloranta, 1995; Kojovic et al, 1995; Bulow et al, 1998; Kanchibotla et al, 1998; Scott et al, 1998; Simkus and Dance, 1998). Field experimentation in this area is often found to be difficult because of high implementation costs and insufficient understanding about the effect of fragmentation at different stages in a comminution circuit. Modelling and simulation of blasting and comminution processes provide a more economic alternative to explore the impact of blast design changes on the down stream operations (Kanchibotla et al, 1998; Kojovic et al, 1998; Adam and Siddall, 1998; Bulow et al, 1998). However, the reliability of such simulations depends on:the ability of the models to reproduce the physical processes that take place; characterisation of rock mass in terms of its blastability and comminution characteristics; and in the case of blast modelling the ability to predict fines (-10 mm) has been found to be particularly important as this fraction has a significant effect on mill throughput.

Jan 1, 1999

By Harald Ulrik Sverdrup, Anna Hulda Olafsdottir

The long-term supply of nickel to society was assessed with theWORLD7 model for the global nickel cycle, using new estimates of nickel reserves and resources, indicating that the best estimate of the ultimately recoverable resources for nickel is in the range of 650–720 million ton. This is significantly larger than earlier estimates. The extractable amounts were stratified by extraction cost and ore grade in the model, making them extractable only after price increases and cost reductions. The model simulated extraction, supply, ore grades, and market prices. The assessment predicts future scarcity and supply problems after 2100 for nickel. The model reconstructs observed extraction, supply and market prices for the period 1850–2020, and is used to simulate development for the period 2020–2200. The quality of nickel ore has decreased significantly from 1850 to 2020 and will continue to do so in the future according to the simulated predictions from the WORLD7 model. For nickel, extraction rates are suggested to reach their maximum value in 2050, and that most primary nickel resources will have been exhausted by 2130. After 2100, the supply per capita for nickel will decline towards exhaustion if business-as-usual is continuing. This will be manifested as reduced supply and increased prices. The peak year can be delayed by a maximum of 100 years if recycling rates are improved significantly and long before scarcity is visible.

Jan 26, 2021

By M Campbell, A Jeffcoate, J-C Vannay, B Perriaux

Phyllite waste rock at the Simandou Pic de Fon and Oueleba Iron Ore deposits (Guinea, West Africa) variably weather to form clay-rich rocks. This weathering modifies the mineralogical, geochemical and mechanical properties of the phyllites. Final pit walls will largely be formed in phyllite, so it is critical that the slope design takes account of the distribution and variability of weathering within this material. Phyllite intact material strength has been correlated with geochemistry (ie mineralogy) facilitating the establishment of domains of intact rock strength (IRS). In order to calibrate this geochemically-based strength model, core from diamond drilling (DD), comprising a variety of phyllite material types (from soft clay to moderate strength rock), was geotechnically logged to assess intact strength; further validation was achieved by uniaxial compression (UCS) testing and point load tests (PLT). The correlation between geochemistry and strength offers a potentially powerful tool for differentiating basic mechanical properties of the rock mass, especially at Simandou where a significant proportion of the resource drilling is done by reverse circulation (RC). Unlike DD, reliable measurements of material strength from RC samples can prove difficult, especially in clay-rich material. Therefore, gaining information from routine geochemical assay results, independent of the sampleÆs physical integrity, is a valuable and cost-effective source of reliable empirical data. Data acquired using this approach provides an opportunity to develop strength domains, which are integrated into mine planning block models. In combination with other geotechnical characteristics, this can be a valuable input to the development of geotechnical models. This technique has allowed spatially representative rock strength data to be derived and offers the potential for optimising pit slope angles in areas where hitherto conservative design criteria had been assumed.CITATION:Jeffcoate, A, Campbell, M, Vannay, J-C and Perriaux, B, 2013. Modelling intact rock strength of clay-rich rocks with geochemistry at the Simandou iron ore deposit, Guinea, West Africa, in Proceedings Iron Ore 2013 , pp 193-202 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 12, 2013

By P Dowd, A Adeli, C Xu, X Emery

Geometallurgical modelling is increasingly being incorporated into mineral resource modelling and estimation as a means of increasing efficiency, decreasing operating costs and reducing risk in mining operations. Traditional geostatistical workflows for geometallurgical modelling face several difficulties, in particular, related to the non-additivity of process response variables, to highly heterotopic data sets and/or to preferential sampling designs, all of which may explain why most attempts to estimate geometallurgical response variables from assay data and mineralogy are still based on statistics and machine learning. The aim of the work presented here is to demonstrate the applicability of geostatistics to estimate copper recovery from copper sulfide ores at the Prominent Hill Iron Oxide Copper-Gold (IOCG) deposit in Australia. As recovery is non-additive, the preferred workflow is the joint estimation of the masses of metal in the feed and in the concentrate, both of which are additive variables. While the mass of metal in the feed can be estimated from abundant online assay analyses, the mass of metal in the concentrate can only be estimated from a very limited number of laboratory-scale batch flotation tests. Traditional approaches to estimating the masses of metal in the feed and in the concentrate, such as simple and ordinary co-kriging, are described and discussed. A modified version of co-kriging is introduced, which incorporates linear relationships between the mean values of the input variables, in addition to a spatial correlation model. Co-kriging with related means is shown to outperform traditional simple and ordinary co-kriging in terms of precision, accuracy and consistency of the estimates, and offers a practical and efficient tool to deal with highly heterotopic and preferential sampling designs.

May 24, 2023