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By Kam KM, Tran B

Statistical techniques of Box and Jenkins (1976) have been used to assess the existing control schemes and determine the dynamics of flash smelting furnace at the Kalgoorlie Nickel Smelter. Pertinent process variables, such as, oxygen flow, flux flow, matte grade and iron to silica ratio in slag, were considered in the analysis using routine operating data collected over two periods of operation. Results indicate inadequate control of some of the important variables. Dynamic characteristic parameters (dead time and response time) between a set of input and output variables were identified to improve optimisation of the existing thermodynamic model used for flash furnace control.

Jan 1, 1996

By S Wilkinson, S Black, L van den Berg

"The mine ventilation system plays an important role in mitigating human exposure to diesel particulate emissions (DPM), exhaust gases and heat in underground mines. The mine’s secondary ventilation systems are critical for diluting contaminants when working at the face of a heading. To improve these systems it is important to understand and visualise the localised air flow profiles. We have considered an approach that includes both tracer gas measurement–modelling to analyse this complex flow behaviour in a heading. The use of tracer gas enables reliable measurements of flow behaviour and differentiation between the contributions of various contaminant sources including DPM. A pilot study was conducted to demonstrate how tracer gas can be used to directly measure the effectiveness of ventilation dilution in a heading during shotcrete activity. This activity is considered to be one of the more challenging areas for diesel exhaust exposure management. Exposure sources include the diesel engine of the spraying equipment (Spraymech) and concrete agitator truck (Agi) that supplies the shotcrete. During operation both the Spraymech and Agi operators are located outside the equipment’s air-conditioned cabins and both are exposed to diesel exhaust. In the pilot study tracer gas was injected directly into the Spraymech exhaust stream. This allowed thorough mixing, ensuring the tracer gas was able to track exhaust gases and particulates released to the heading. The release was repeated at three different headings with varying degrees of secondary ventilation controls. The study showed that small changes to the secondary ventilation system can significantly impact the contaminant concentration. It also demonstrated that tracer gas can be used to isolate different contaminant sources. The intent is to use this technique in a more comprehensive study to develop best practice guidelines for secondary ventilation installations. This paper presents the technique used and the preliminary results from the pilot study. CITATION: Wilkinson, S, van den Berg, L and Black, S, 2015. Application of tracer gas flow profiling to improve secondary ventilation practice – a pilot study, in Proceedings The Australian Mine Ventilation Conference, pp 345–352 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Aug 31, 2015

By Preston C. Holloway

Transformational roasting involves the heating of a material along with specific additives to induce mineralogical changes in the starting material. By controlling the chemical composition, roasting atmosphere, temperature and time of reaction, the mineral transformations induced during roasting can be engineered to control the distribution of valuable, or harmful, metals and to produce new mineral assemblages that are more amenable to conventional methods of metals recovery or to environmentally safe disposal. To date, this type of process has only been applied to the recovery of a limited number of metals, but current research is looking to expand the application of these techniques to the recovery of metals from a wider range of materials. An introduction to these techniques is presented along with preliminary results from their application to metals recovery from zinc bearing wastes, such as zinc ferrite leach residues and carbon steel electric arc furnace dust.

Jan 1, 2006

By Kazuyoshi Kamimura, Masaya Kawata

"It has been 30 years since the cement deep mixing (CDM) method developed in Japan. CDM method has been applied to many structures. While various technical improvements have been implemented in the meantime, the single-axial and double-axial technologies used at the time of its initial development are still prevalent.In response to the recent trend of reducing construction costs, we developed a triple-axial CDM method called the “Lemni 2/3 Method.” This method uses two lemniscate motions caused by newly developed auxiliary stirring devices and employs a double-axial injection method in which the cement slurry injection takes place only from the outer two axes. In this way, it is possible to create a stabilized body around the three axes. Moreover, this method does not require substantial equipment investment as conventional construction machine and facilities can be used without modification and large volume work is possible.With these technologies, this method can achieve a substantial reduction in the construction period and cost, while ensuring the same level of improvement quality as conventional methods. As a result, this method is being applied to ground improvement work in a variety of places.Lemni 2/3 Method was first put to practical use in 2004. Since then, the method has been used for ten projects. In this paper, we show some application examples of this method.OUTLINE OF TRIPLE-AXIAL CDM METHOD (LEMNI 2/3 METHOD)In the newly developed CDM method (Lemni 2/3 Method), work efficiency is improved by employing triple-axial stirring blades instead of the conventional single- or double-axial type. Existing conventional construction facilities for double-axial type can be used with only minor equipment additions, because the cement slurry injection takes place only from the outer two axes.Construction Machine and Construction MethodThe combination of major construction machines of the Lemni 2/3 Method differs little from the standard specifications of the double-axial type as shown in Fig. 1. Existing work control equipment can be used without modification, which is further evidence of the simplicity, convenience, and economy of the new method. The Fig. 2 photo shows a full view of the construction machine, and the Fig. 3 photo shows the stirring blades and the auxiliary stirring devices. The work procedure for the Lemni 2/3 Method is shown in Fig. 4."

Jan 1, 2015

By B. Haneman, J. A. Gorst, W. Slabbert

"The Bayer process involves the digestion of bauxite in caustic liquors at high temperature and pressure. Typically the digestion section of the plant involves the heating of liquors up to the digestion temperature followed by flashing of the digestion product to atmospheric pressure with the flashed steam used to pre-heat the incoming cold slurry. Despite the heat recovery, the digestion process is a high consumer of energy. The application of tube digestion technology in such plants has resulted in significant improvements in refinery energy efficiency with associated benefits of process simplification and refinery flow sheet capital cost reduction. This paper reviews the potential application of this technology to other metals within the non-ferrous industry.THE BAYER PROCESSA typical Bayer flow sheet is shown in Figure 1. The raw feed material bauxite (containing aluminium hydroxide as gibbsite Al(OH)3 and boehmite AlO(OH)) is digested in caustic liquors (caustic soda is the solvent) at high temperature and pressure. This process extracts the alumina and silica and any carbon present on the ore. The slurry is then flashed down to atmospheric condition allowing for heat recovery from the flashed vapour and producing slurry supersaturated in alumina.Following the digestion process the mud is removed via thickening and then pressure filtration to remove fine particulate and produce a clarified liquor with dissolved alumina in solution. The resulting pregnant liquor is then cooled allowing the alumina in solution to precipitate as aluminium trihydrate Al(OH)3. The precipitated hydrate is then filtered and washed and classified into fine and coarse fractions. The fine material is returned to the precipitation process as seed while the coarse fraction is calcined at high temperature to produce alumina. The filtrate from the filtration process (spent liquor) is then heated by the incoming pregnant liquor before being fed to an evaporation process which produced the strong caustic liquor required in the digestion process. Finally, the mud from the thickening process is washed to recover caustic and then fed to tailings ponds. The washer overflow is then mixed with the digester product to increase super-saturation."

Jan 1, 2012

By D. Bessinger, J. Rabe, J. Zietsman, C. Coetzee, P. H. Lamont, J. Muller

The UCAR® CHILL-KOTE? freeze lining concept combines wall cooling with carbon and graphite refractories of higher thermal conductivities to ?chill? the refractory lining by transferring heat from the refractory lining. Effective sidewall water cooling, together with the efficiency of the heat dissipating conductive refractories, lowers the temperature of the lining to below that of the molten process materials. This causes a layer of slag and process metal to solidify or ?freeze? and form a protective ?skull? which completely coats the refractory hot face. Once formed, the slag skull insulates the refractories, reducing heat loss and protect the lining from erosion, chemical attack, thermal shock, and other stresses. The result: extended life and greatly improved refractory performance. The Ilmenite smelting process depends on the presence of a solidified slag skull to protect sidewall refractory material from chemical attach by molten slag. No known refractory material is able to withstand this corrosive material. To date, UCAR has not applied their Chill Kote ? technology in the ilmenite smelting industry. This paper revolves around the results obtained from conducting an ilmenite smelting campaign on a 500kW DC open-arc furnace with a UCAR designed refractory system. The purpose of this test was to establish the effects such a lining has on refractory wear and the reduction-smelting process. Proper thermo-couple management enabled the authors to monitor lining wear for the duration of the campaign. Prior to the pilot-scale campaign, modeling work was completed to evaluate the feasibility of applying UCAR® CHILL-KOTE? technology to ilmenite smelting furnaces. The successful operation of a pilot-scale furnace equipped with the UCAR® CHILL-KOTE? lining as well as concise modeling suggest that it should be a viable option to consider for an industrial-scale furnace.

Jan 1, 2007

By J. Zou

Open-cut method is most widely used for shallow utility lines installation. In urban areas, unexpected utility lines buried underground potentially turn open-cut construction into a highly risky operation, increasing the construction cost while presenting additional safety hazards. Examples include: breaking existing water main leads to flooding the downtown area; hitting an unexpected gas line causes an explosion. To prevent those accidents, the current practice is to stake out the underground utility lines before the open-cut construction based on the as-built information collected from various utility companies and government agencies. However, the as-built information is not always complete and accurate. To verify the locations of some important utility lines and protect them against damages caused by open-cut construction, new techniques and technologies are used but have their limitations in revealing underground utility lines, such as hydro vacuum method and ground penetration radars (GPR). The emerging technology of ultra-wide band (UWB) radar holds the potential to provide a cost-effective, non-destructive detection method. In this paper, a critical review of current practices and established methodologies is given. The functionality and working mechanism of UWB radar technologies are described. Application potential in open-cut construction is demonstrated by conducting lab experiments. Testing set-ups for detecting unexpected utility lines in soil along with preliminary results are presented. The effects of soil moisture content on the detection range are discussed. Research findings are summarized and constraints are discussed in conclusions.

Aug 1, 2013

By Jena Moshen

Underground Bulk Systems (UBS) technology has gained widespread application in tunneling and underground mining owing to its safety, reliability, increased Velocity of Detonation (VOD) and excellent results. However, its application in perimeter blasting is still limited and researchers are looking at ways of harnessing this technology for perimeter control. This simplifies the charging process by using one cost efficient product for charging both the perimeter and grid holes. This paper presents a case study on the application of underground bulk emulsion explosives for perimeter control blasting in underground room and pillar platinum mines. In order to achieve the required coupling ratios in the perimeter holes, the emulsion is loaded into specially formulated smaller diameter polyethylene (poly) pipes. The effectiveness of this method was evaluated using information obtained during routine blast audits and data supplied by the mines on half cast factors, over break and under break as well as analysis of data from Ground Penetrating Radar (GPR) Scans over a period of four years. This method of perimeter control, has given the platinum miners in Zimbabwe a competitive edge in cost effective perimeter charging and blasting by simplifying the previously costly deployment of traditional barrels and other decoupled cartridges. The method has been adopted by all the platinum mines in Zimbabwe as it has proven to be a cost effective alternative of controlling the perimeter walls, along with other key benefits that relate to safety, productivity and effectiveness.

Jan 1, 2018

By C OÆKeefe, A Thomas

Boom time in the mining industry has presented mill operators with several unique challenges including the need for increased throughput while being constrained by a shortage of skilled labour and aging capital equipment. New instrumentation technology that provides reduced installation costs; no process down time for installation; and reduced maintenance costs and labour requirements; has been introduced to address the labour situation while maintaining production. This new tech- nology also enabled more accurate and reliable process measurements thus providing the capability for operators to maximise throughput with their existing capital equipment. This passive SONAR based technology can accurately measure the volumetric flow rate of single phase and multiphase fluids as well as the amount of air entrained within slurries. This is accomplished in a non-invasive manner. This paper will describe the principle of operation as well as the application of the technology to critical minerals processing applications. Included will be operational examples comparing the SONAR measurement performance to traditional measurement techniques. These examples will include hydrocylone feed flow, flotation concentrate flow, and slurry streams containing magnetic ores. Actual plant data will be presented as well as a discussion on the operational advantages such a measurement capability.Also described will be the power of the technology platform to provide novel process monitoring and control capabilities such as pipeline sand-out prevention and pipeline acoustic monitoring.

Jan 1, 2009

By Jamal Rostami, Asok Ray, Samer S. Saab Jr., Wenpeng Liu

Ground instability, such as roof or rib failures, is one of the most serious and frequent safety hazards that occur in underground mining, tunneling, and underground construction. The ground-related parameters and features of interest, in assessing roof or rib failures, are location, frequency, and orientation of the joints, voids, as well as rock-strength. These parameters are the main components of rock mass characterization that offers effective strategies for ground support, which, in turn, allow one to mitigate the risks related to ground instability. The main objective of this study is to determine the location of joints and classify rock-strengths by analyzing the drilling data recorded from an instrumented roof bolter while drilling for rock bolt installation during the operational cycle. For this purpose, computer programs based on updated pattern recognition algorithms were developed for joint-detection and classification of rock types to offer an estimated strength. This paper briefly introduces ongoing research on joint detection, especially for joints with an aperture less than 0.125in (3.175mm), by employing an instrumented roof bolter in controlled environments. To improve the capability and precision of joint detection programs in detecting the joints from the drilling data and reducing the number of false alarms, many laboratory tests with various simulated joints and rock-strengths were carried out at a J.H. Fletcher & Co. facility. This paper reviews testing procedures, data analysis, updated algorithms used for joint detection, and discusses the latest round of testing in samples with simulated joints at various angles along the borehole.

Jan 1, 2017

By D. J. Wang

Based on the thermodynamic arid kinectic aspects, the vaccum distillation processes for the separation and recovery of metals from wastes are analyzed. As to the separation criteria, The separation coefficient and equilibrium composition relation between vapor phase and liquid phase are the bases of recovery of metals by vacuum distillation, The vaporization rates and condensation mechanisms are also discussed. Some experimental results which deal with metals-containing wastes are described and the performances of a new kind of horizontal vacuum furnace are introduced, which demonstrate that , vacuum distillation may be a prospective technique for circulation and regeneration of some non-ferrous metals from industrial wastes.

Jan 1, 1996

By Ali Naeimipour

Availability of accurate geological information about the rock mass surrounding a tunnel or mine working is the key to enhance and optimize the required ground support measures. Various approaches have been used to obtain data on ground conditions, including the possibility of characterizing the ground while drilling for roof bolts, by the Measurement While Drilling (MWD) system, via optical, sonic and acoustic televiewers, and using various types of gamma probes. While there are many different systems for characterizing the ground in longer, larger-diameter holes drilled downward, the options for using probes and logging systems in short, small-diameter holes drilled in horizontal or an upward direction are very limited. This paper will present the results of recent field tests using optical televiewer (OPTV) to analyze the joints and voids in boreholes drilled in different directions. The studies show that OPTV is a promising tool; however, getting a good quality image from the upward drill holes still need to be studied. Meanwhile, estimated in-situ strength of the intact rock is needed to complement the jointing pattern for rock mass classification. For this purpose, preliminary steps for the development of a borehole scratcher to estimate rock strength will be discussed in this paper.

Jan 1, 2014

In sizing of wet coal by the horizontal vibrating screen, screen openings to be used is much restricted, because coal is sticky and its bulk density is little. The electrically heated screen and other various types of screen had been tried to screen raw coal and coal as raw materials at a few mm. However, they failed to realize satisfactory results. On the other hand, fine sizing of coal is requested by many fields. For example, raw coal is desired to be screened at the fine rate, before being fed to the coal preparation control system in order to transport undersizes as unprepared coal particles and to reduce load in coal preparation waste water treatment system.1) Coals fed to the fluidized bed boiler also should be sized at a few mm. Regardless of many requests on fine sizing of coal, it seems that there are many cases to omit the basic screening process, because the screening is very difficult on a industrial scale. Size control as pretreatment of coal as raw materials is presented as one of the basic screening processes. In 1979, Kinki Industrial Co., Ltd. and Nippon Steel Corporation jointly succeeded in developing the vertical centrifugal screen. Closed -circuit crushing system by the use of this screen has operated actually at N.S.C, Hirbhata .Works, and realized the anticipated result. Consequently, this system has established the position as the most basic technology in the coal preparation. 2), 3), 4) This system has been also introduced to Nakayama Steel Works, Ltd. in 1982. This system termed the CPC (Coal Preparation Control) Process has been operated smoothly in both N.S.C. and Nakayama. Reported herein is the practical application of the vertical centrifugal screen termed V3-Separator. (V3 means vertical, versatile and vibration.)

Jan 1, 1984

By E. Kuzeci, R. Kammel

"Lately various voltametric methods have gained increased attention as an analytic tool in hydrometallurgy. Voltammograms with mercury drop electrodes or glassy carbon electrodes provide information about the electrocrystallization of cathodic deposits and allow calculation of kinetic data by means of characteristic parameters like the peak potential and peak current and their variation with the voltage scanning rate.Cyclic voltammograms are also suitable for identification of reaction sequences. Voltammograms with carbon paste electroactive electrodes containing metal sulphide additions reveal information about the dissolution behavior. The stripping voltammetry can be applied to analyze metal ions and organic additives (e. g., thiourea) in extreme low concentration. Typical application of the various methods studied with microcomputer controlled measurement system are explained by examples selected from copper hydrometallurgy.IntroductionThe use of electroanalytical methods in metallurgical process control can be dated back to the starting period of industrial copper refining, when the deposition of the metal ions was followed electro-gravimetrically by weighing the electrode with deposits (1). The principles of metal deposition and dissolution have not changed but the methods to follow these phenomena were subjected to noticeable developments and especially the introduction of polarographic investigations by Heyrowsky (2) has greatly contributed to the progress in electro-analysis. A review about the fundamental work on the electrochemical kinetics in earlier time is compiled in a monograph of Vetter (2). With the steady improvements in the instrumental techniques, it is nowadays possible to apply several current and potential modulations for measurements with improved selectivity and sensibility. There is however, still a lack in theoretical interpretation of the data obtained. More theoretical information are already available for linear voltametric methods for systems where reduced as well as oxidized species are dissolved in the electrolyte (4, 5). Some recent investigations have also shown the reliability of these techniques to study electro-crystallization (6, 7). Main fields of the application in the hydro - and electro-metallurgy are:"

Jan 1, 1989

By M. Courtin, D. Berthelot, M. Haggis, D. McClarty, R. Payne

Over forty years of uranium mining in the Elliot Lake region of Ontario (1956–1996) has resulted in the production of over 300 million pounds of uranium. With the completion of mining activity, Rio Algom Limited and Denison Mines Limited are utilizing progressive environmental technologies and management systems to reduce and manage the environmental risks associated with the 150 million tonnes of potentially acid-generating tailings in nine regional waste management areas. Water covers designed to reduce oxygen entry and, thereby, significantly inhibit acid generation, have been applied at six of the sites with the Quirke site serving as a demonstration site for the Mine Environmental Neutral Drainage program. All five of Rio Algom Limited’s effluent treatment plants are monitored and controlled from a central control station utilizing a Supervisory Control and Data Acquisition (SCADA) system based on “Fix Dmacs” technology. Scheduling, auditing and reporting of plant operating and environmental monitoring programs for the entire watershed are controlled utilizing the Regional Environmental Information Management System (REIMS). Proper application of these technologies and management systems facilitates delivery of cost-effective environmental monitoring, care and maintenance programs at these sites and provides tools to demonstrate compliance with all environmental performance criteria.

Jan 1, 1999

By V A. Chanturia, T N. Matveeva, V V. Getman, A Yu Karkeshkina

The development and application of new effective environmentally friendly reagents for the flotation of thin and ultrathin mineral components is an urgent task. The analysis of the nomenclature of chemicals, including flotation reagents and flocculants, showed that water-soluble polymers (WSP) might be used in flotation separation of fine grinding products containing non-ferrous and precious metals. Water-soluble polymers that are responsive to temperature changes are the most attractive as reagents during flotation. These are the thermo-responsive polymers or thermomorphic polymers. The presence of nitrogen and oxygen atoms in the polymer molecule contributes to the formation of a coordination bond with non-ferrous and precious metals. A research conducted at the ICEMR RAS within the framework of the scientific school of Academician of the Russian Academy of Sciences Chanturia helped to develop a method of flotation of finely ground mineral particles containing valuable components using modified thermomorphic polymers. The paper focuses on the experimental study of poly (vinyl caprolactam) (PVC) as a flotation reagent for gold recovery from finely ground mineral products. PVC is a ready-made water-soluble thermosensitive polymer that does not require complex synthesis. PVC has a high ability to form complexes in an aqueous environment when heated. According to experimental data, the polymer interacts with gold nanoparticles, contributing to the extraction of gold from fine mineral products and the tailings that makes it perspective as an additional flotation agent for the processing of gold-containing ores.

Aug 24, 2022

By Tim Wolf

The paper "Weld Notch Affects on Pulley and Belt Conveyor Reliability" has done an excellent job of describing theoretical fatigue and fracture mechanics methods used in modern weld design. From this foundation, we intend to further detail areas previously discussed and present new research in the application of these principles to pulley weldment life prediction. Affects of changes in alternating stress range, mean stress, and residual stress have been investigated using controlled laboratory fatigue tests on a pulley weldment. Comparisons between these results, weld codes, and theoretical fatigue predictions will be made and discussed.

Jan 1, 1998

By W. Q. Zhao

In order to raise the utilization rate of phosphate resource of Al-Jalamid Mine in Saudi Arabia, a flotation experiment for its phosphate rock was carried out by using WF-01collector that have been produced by Wengfu Phosphate Mine. The results showed that WF-01 collector had extensive adaptability for Al-Jalamid phosphate rock, and the grade of phosphate concentrate could be up to 33% P2O5 mixing the upper, middle and lower beds rock as well as its 80% more recovery.

Jan 1, 2014

By Allan A. Este, Bruce Arthur

"Rio Algom's Stanleigh Mine and Mill Operation Was' officially started up in August 1983. In September 1982, Rio Algom contracted Estonix International Inc. from Lively, Ontario, to develop and implement two innovative programs: (1) Work Renovation Planning, and (2) Systems Performance Training. This paper deals with the development and implementation of these two concepts relative to the plants technology from start-up to present and the exceptional results achieved. This paper discusses how a small but motivated workforce resulted in the smooth transition from startup to full production. It also deals with how these concepts were applied elsewhere in the organization which permitted a successful transition and downsizing of the over-all operation.IntroductionRio Algom Limited produces uranium in Elliot Lake, Ontario. In the late 1970s Rio Algom entered a contract with Ontario Hydro to supply uranium from its Stanleigh property, which had been idle since 1960. The mine was subsequently upgraded, and a new modem mill was designed and built, commencing operation in 1983.From then until September 1990,Rio Algom had three producing mines and mills in the Elliot Lake area. Quirke mill, with a capacity of 6350 tonnes per day, operated continuously from 1968. The Panel mill with a 3000 tonnes per day capacity, operated since 1979. Stanleigh mill continues to operate under long-term contracts, although at a production rate about 25070 lower than its rated capacity of 5000 tonnes per day.Both the Quirke and Panel mills, although not entirely similar, were conventional uranium mills utilizing crushing, grinding, leaching and ion exchange. As such, and in keeping with the traditional management style, there was a rather large mill operating workforce, which utilized a line-of-progression job classification system."

Jan 1, 1993

The steps for the beneficiation of iron ores differ from ore to ore, depending on the mineralogical phases of the particular iron ore and the nature of the association of the gangue minerals with iron oxide in that ore. The extent to which the beneficiation can be undertaken economically depends both on the amount and the nature of the gangue. The analysis of the phases present in an orebody optimises the mining and process operations (separation, beneficiation, sintering, etc).X-ray diffraction (XRD) provides qualitative and quantitative information about the main ore phases as well as the gangue mineralogy and the amorphous content present in a sample. In addition, modern quantification methods such as Rietveld refinement allow the calculation of the distribution of elements in solid solutions such the substitution of Fe with Al in goethite or hematite.The use of high speed detectors has made XRD an important tool for grade and process control. Finger printing of XRD data can facilitate multi-dimensional mapping of ore deposits and drill cores, identifying regions of favourable mineral compositions. Grade control using XRD can be completely automated and controlled remotely.The two case studies in this paper demonstrate how XRD and finger printing can be used for grade control, process optimisation and quality control of a goethitic and a magnetitic iron ore. The enormous potential of XRD as an inexpensive, reliable tool, useful in the characterisation of iron ores will be demonstrated.CITATION:K÷nig, U, 2013. Application of x-ray diffraction to iron ores - potential implications for grade control and downstream processing, in Proceedings Iron Ore 2013 , pp 275-280 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 12, 2013