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By G. W. Barton

Process Systems Engineering (PSE) can be defined as the integrated usage of computer-based design and analysis tools. As such, PSE is becoming increasingly important in the chemical and petrochemical industries. This paper shows how a range of PSE techniques have been applied to the zinc electrowinning process. Topics discussed include model development, parameter estimation, steady-state and dynamic model applications, steady-state optimisation and neural network modelling.

Jan 1, 1994

By Selwyn Pearton

Pumpable emulsion explosives have been available to surface and underground massive mining operations for decades and through their unique properties offer significant advantages through improved safety, reliability and performance. Despite their advantageous properties, the benefits of pumpable emulsions have been unavailable to narrow reef mining operations due to the void in technology necessary for their successful implementation within the challenging environment. Despite efforts to promote and enhance the safety and performance of bulk emulsions for narrow reef stoping, little research has been undertaken to advance the pump technologies required for their implementation. This has resulted in a gap in knowledge and technology and as a consequence the successful implementation of a pumpable emulsion system has consistently eluded the narrow reef environment.

Jan 1, 2015

By S. P. Pearton

"Pumpable emulsion explosives have been available to surface and underground massive mining operations for decades, and their unique properties offer significant advantages in terms of improved safety, reliability, and performance. However, the benefits of pumpable emulsions have been unavailable to narrow-reef mining operations due to the lack of technology necessary for their successful implementation in this challenging environment. Despite efforts to promote and enhance the safety and performance of bulk emulsions for narrow-reef stoping, little research has been undertaken to advance the pump technologies required for their implementation. This has resulted in a gap in knowledge and technology, and as a consequence the successful implementation of a pumpable emulsion system has consistently eluded the narrow-reef environment.The purpose of the following investigation was to evaluate the viability of pumpable emulsion explosives for use in South African narrow-reef mining operations. By approaching the problem from multiple perspectives, this research aimed firstly to propose a theoretical framework and suite of equipment suitable for the implementation of pumpable emulsions within the narrow-reef environment. Through the development of this suite of pumpable emulsion technology, tests could be undertaken on the proposed narrow-reef emulsion formulation and pumpable emulsion technology to obtain the necessary understanding of the performance of the system under controlled operating conditions prior to its implementation in the broader mining industry."

Jan 1, 2015

By Gilbert Chuah, Peter Middendorp, Joost Bakker, Soon-Hoe Chew

"The Rapid Load Testing (RLT) of foundation piles has been applied worldwide since 1984. Several International and national codes are available, such as the Japanese Code of Practice (2002), ASTM D7383-2010, German recommendation on Piling (2012) and Eurocode (2015). RLT methods like Statnamic and StatRapid are gaining popularity in Asia, Europe and North America. For checking the performance of piles, they are more economical, faster and environmentally friendly than Static Load Testing (SLT), while yielding good correlations with SLT results through an objective analysis method. To date (October 2016) hundreds of piles have been successfully tested by RLT method in Singapore. A number of these RLT tests were coupled with static load testing correlation tests, some of them with instrumentation for shaft load transferred. Examples of some correlation results for foundations installed in various geological formations in Singapore are presented in the paper. The findings from these results indicate that loading rate effects are negligible for Rapid Load Test results when foundations are socketed in competent non-cohesive soil layers and derive most of their capacity from these soil layers.INTRODUCTIONRapid Load Testing (RLT), by which a quasi-static load is applied to a foundation pile, is used increasingly as an alternative to Static Load Testing (SLT) for cast in-situ piles, such as drilled shafts or bored piles. It is recognized nowadays that the determination of the pile capacity with Dynamic Load Testing (DLT) through signal matching techniques such as CAPWAP, TNOWAVE and AllWave-DLT, yield a wide spread of results for cast in-situ piles (Stahlmann et. al, 2012), making it practically very difficult, if not impossible to calibrate the DLT results with SLT results. This spread is due to the empirical and subjective assumptions that are used to interpret the test data, especially for cast insitu piles (Holeyman et al. 2001, Viana da Fonseca in 2008, Herten et al, 2013). This is further complicated by the inhomogeneity of the concrete and variable cross-sections over the pile length for the cast in-situ piles."

Jan 1, 1900

By D. R. Gladwell

This study examined the-feasibility of clay mineral identification and quantification by reflectance radiometry and subsequently developed a computer algorithm for deconvolution of the component spectra. Clay mineral analysis of 53 rocks and soils from Alberta, Saskatchewan, Ontario and Nevada by X-ray diffraction (XRD) compare favourably with the radiometric determinations. The application of the technique to precious metal exploration was examined at the Horse Canyon epithermal gold deposit, Cortez Mine, Nevada where low levels of illite and kaolinite are present alongside local silicification. Consequent on the success of the laboratory and field work a field portable clay mineral analysis system was designed and constructed.

Jan 1, 1985

By G. H. Gale, M. A. F. Fedikow, L. B. Dabek

Abstract-Rare earth element (REE) data are reported for ores, sulfide-bearing rocks and host rocks from massive sulfide deposits and barren sulfide facies iron formations in Proterozoic volcanic rocks of the Flin Flon-Snow Lake area, Manitoba. Some of the rare earth elements (e.g., Eu), are selectively leached in zones of intense alteration and redeposited together with the sulfides and silicates in the uppermost parts of the alteration zones and at the rock-water interface. Chondrite normalized REE profiles of layered sulfide ores and exhalites proximal to the deposits typically have positive europium anomalies and are enriched in light REE. In contrast, barren sulfide facies iron formations exhibit negative or ‘normal’ Eu profiles. REE data are useful to explorationists in determining the presence of ‘off-hole’ metal-bearing sulfide zones, in distinguishing metal-poor sulfidic layers related to ‘economic’ hydrothermal activity from barren sulfide facies iron formation and in some instances as a means of establishing ‘ore-equivalent’ strata.

Jan 1, 1997

By G. H. Gale, M. A. F. Fedikow, L. B. Dabek

Rare earth element (REE) data are reported for ores, sul?de-bearing rocks and host rocks from massive sul?de deposits and barren sul?de facies iron formations in Proterozoic volcanic rocks of the Flin Flon-Snow Lake area, Manitoba. Some of the rare earth elements (e.g., Eu), are selectively leached in zones of intense alteration and redeposited together with the sul?des and silicatesin the uppermost parts of the alteration zones and at the rock-water interface. Chondrite normalized REE pro?les of layered sul?de ores and exhalites proximal to the deposits typically have positive europium anomalies and are enriched in light REE. In contrast, barren sul?de facies iron formations exhibit negative or ‘normal’ Eu pro?les. REE data are useful to explorationists in determining the presence of ‘off-hole’ metal-bearing sul?de zones, in distinguishing metal-poor sul?dic layers related to ‘economic’ hydrothermal activity from barren sul?de facies iron formation and in some instances as a means of establishing ‘ore-equivalent’ strata.

Jan 1, 1997

Australia has a long history of underground mining. Even withadvances in open cut mining equipment, techniques andeconomics, many orebodies are still best mined by undergroundmeans. In addition, modern exploration tools are æuncoveringÆorebodies that are at increasing depths. South African mines arecurrently producing from below 3 km, and developing down to5 km depths û it is likely that Australian mines will also becomemuch deeper over the next 20 years. One of the most significanttechnical challenges in deep mines is the problem of heat.Community expectations and legislated standards continue todrive operations towards improving the working conditions inmines. The hazards and costs associated with chronic hotworking conditions (heat illness, poor safety, poor productivity,higher operating costs and poor morale) are also becomingincreasingly recognised (Brake, Donoghue and Bates, 1998). Theexposure of miners to many other occupational hazards has beenreduced over the past 50 years. However, despite air-conditionedcabins greatly reducing the heat stress on mobile plant operators,there are still many Australian mine workers subject to levels ofthermal stress that existed a century ago. There are severalreasons for this, including a frequently-poor understanding of thephysiology of working in heat by mine management, no agreedmining code of practice for working in heat, the lack of a robust,practical-sized instrument to measure heat stress, the costpressures on the industry and, to some extent, deep-seatedtraditional management and worker practices. Howeversignificant progress has been made in many of these areas (Brakeand Bates, in press), with the net result that there is likely to be a trend towards installation of refrigeration of some form in manyAustralian mines in the future. This will add directly to the costof operation, but will also have direct and indirect benefits,including cost benefits. It should also be noted that Australia isnot at the forefront of adopting practices to manage temperaturesin the workplace: South African metal mines usually haverefrigerated cooling, and Canadian mines spend large sums onheating, with heating costs (averaged over a full year) of up to$A1 per tonne mined (Bandopadhyay et al, 1997). The history of mine refrigeration dates back to 1919 when thefirst plant was installed at Morro Velho, Brazil. By 1965, the totalinstalled capacity (worldwide) reached about 100 MW(R)i. Since 1965 the growth in mine refrigeration capacity has beenexponential, with a doubling every six or seven years (Howes andNixon, 1997). South Africa is by far the largest user of minerefrigeration, with over 300 refrigeration machines installed. This paper discusses the key design issues associated with theapplication of refrigeration in underground metal or coal mines.Whilst the emphasis is on large, surface plants, small, surface orunderground refrigeration plants can also be very effective in thecorrect application and many of the principles of design andoperation are the same.

Jan 1, 2001

By M Mohammad Khani

An economic block cave is dependent to the characteristics of the rock mass at stages of caving. These are cave initiation, propagation and ore flow. In this research, the rock engineering system (RES), first established by Hudson (1992) to solve complex rock engineering problems, is introduced and verified against the well-established caving parameters established by Laubscher. There are two types of factors influencing caving and these are natural (cannot be controlled) and induced (operator controlled). A RES based interaction matrix is developed by determining the rating parameters required to reproduce the caving database using Laubscher’s caving parameters. This provides the relative importance of the parameters in the interaction matrix. After discussing the rock mass caving process and identifying all the effective parameters, an interaction matrix is introduced to study the cave initiation of rock masses. The expert-semi-quantitative (ESQ) coding method is utilised to assign the numerical value to each parameter’s interaction. Thereafter, the interaction intensity and dominance of each factor in the system is determined to classify these factors. Finally, all the parameters affecting caving operation and their weights on the RES system are identified. This new application of RES in block caving is very efficient and useful for any stage of caving studies and helps experts to make decisions more accurately.CITATION:Mohammad Khani, M, 2016. The application of rock engineering systems to block caving to identify the effective parameters, in Proceedings Seventh International Conference and Exhibition on Mass Mining (MassMin 2016), pp 853–860 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2016

By David J. Reddish

Longwall systems are inflexible in layout, intolerant of disruption and represent a substantial investment. It is therefore essential drat all understanding of the likely strata behaviour and support requirements is obtained prior to panel development. For many tears rock mechanics engineers have applied numerical modelling based kill finite element techniques to the design of the support and layout of underground excavations. Whilst such design methodology has worked well in civil engineering and hard rock situations, it has been less reliable when applied to excavation design in the soft rocks of the coal measures. This lack of reliability has been identified largely as being the result of the utilisation of unsatisfactory input data, This paper describes the results of an ongoing research programme at the University of Nottingham in which a novel rock mass rating system known as the UK Coal Mine Classification system was developed to enable the prediction of the strata properties that are required as input parameters for use in numerical modelling of the deformation of soft rocks around excavations such as roadways and longwall faces in coal mines. The paper describes the development of the system. the way in which classifications are applied to derive input data for numerical models and gives two case studies ill which deformations and stress re-distributions around coal mine excavations have been simulated by numerical modelling using the FLAC finite difference code.

Jan 1, 2000

By B Hawkins, S Durkin, V Lawrence

The requirement for secondary egress from underground workings has long been regulated in Australia. Escape way systems have evolved from simple airleg rising ladders and timber ladders to steel galvanised ladders and more recently fully enclosed polyethylene ladders.The polyethylene ladder, Safescape Laddertube, was introduced to the underground mining industry in 2010. It is an enclosed cylindrical modular plastic ladder designed for use in underground escape ways and access ways. Since its first installation in May 2010, the Laddertube has been installed in 43 mines across four countries, totalling 8800 m of ladders installed to December 2013.The Cracow Gold mine is one operation using Laddertube, located 500 km north-west of Brisbane, Queensland, Australia. Upon discovering and developing both the Empire and Roses Pride orebodies, a safe and economically viable secondary egress system and surface primary ventilation exhaust shafts were necessary to support development and production activities to these workings. The need arose to merge these two critical requirements together between surface and underground mine workings some 200 m and 400 m respectively for each orebody. Neither egress has intermediate access points within their full service length from top to bottom. Several options were considered, the preferable and most feasible method adopted was Laddertube.The longest egress length requiring Laddertube within the two vertical surface exhaust shafts was 400 m long, within a 3.5 m diameter shaft. Due to the length of the vertical Laddertube system in both egresses, personnel are to be assisted by mechanical means using the Extended Ladder Climb Assist system.The Gossan Hill mine also uses Laddertube for their escape ways. Part of the Golden Grove operation, Gossan Hill is an underground sublevel open stoping mine located in the mid-west of Western Australia.With a considerable mine life remaining and a history of acidic water and stress related deterioration in vertical openings, the mine operators sought an escape way solution that would provide for the long-term needs of Gossan Hill. Laddertube was selected due to its non-corrosive properties and the ability to fill in around the ladder way to provide stability to the raise opening.Laddertube is a recent development in escape way systems, and is effectively being applied in a variety of operations, meeting the specific needs of underground mines.CITATION:Durkin, S, Hawkins, B and Lawrence, V, 2014. The application of Safescape Ladders at the Cracow and Golden Grove operations, in Proceedings 12th AusIMM Underground Operators’ Conference 2014 , pp 311–318 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Mar 24, 2014

By S Tyrrell, B Jackson, K Matson

Northern Star Resources Limited Jundee Gold Mine in Western Australia operates a comminution circuit that consists of a primary crusher, 3.85 MW semi-autogenous grinding (SAG) mill, 1.8 MW ball mill and pebble recycle crusher. In 2017, a secondary crushing circuit was installed to remove the SAG mill throughput bottleneck and increase production of highly competent underground ore from 1.35 to a minimum of 1.7 Mt/a.This paper discusses the findings from the trial phase, the circuit design, project delivery, site optimisation, and the plant performance.CITATION:Matson, K, Tyrrell, S and Jackson, B, 2018. The application of secondary crushing at the Jundee gold mine, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 485–496 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

By S. Castro

The aim of the present paper is to review the current technologies for arsenic removal in the copper metallurgical industry, and to show the progress made with some promising emerging strategies, involving the pre-treatment of copper-arsenic concentrates by selective flotation or by alkaline leaching with Na2S-NaOH solutions. The advantages of alkaline leaching are the selective dissolution of arsenic and antimony, the high extraction yield, and the practically nil loss of copper, which remains in the clean copper concentrate as a CuS residue. Alkaline ?cured? ? a procedure similar to ?acid-cured? in conventional leaching ? improves arsenic extraction and reagent consumption, making this an interesting technology for the treatment of high As-Sb concentrates. In light of recent advances on the selective flotation of enargite and tennantite, the importance of redox conditions to control the flotation/depression of enargite-tennantite from copper sulfides has been well established. However, problems of selectivity must still be solved. Additionally, the limitation imposed in some cases by the need to recover the molybdenum by-product must be considered. The application of selective flotation to obtain a high-arsenic or ?dirty? concentrate and its sub-sequent treatment by the alkaline leaching process is suggested.

Jan 1, 2014

By Richard E. Beane

For several decades, the minerals industry has used leaching techniques to extract metals from rocks whose grade was too low to be treated profitably using conventional metallurgical techniques, and, as of 1972, about 15% of domestic copper production was derived using leaching methods (Beall 1). Increasing interest is currently being directed toward solution mining, particularly with respect to copper, for basically two reasons. In the first place, geological exploration has outlined several copper deposits of large tonnage and 1m', grade which are buried at sufficient depth to preclude open-pit mining which would make such mineral deposits ore deposits. Nevertheless, these occurrences provide significant potential if they could be treated by chemical leaching in situ. Secondly, the porphyry deposits of the western united States, which provide by far the largest percentage of domestic copper, do not terminate geometrically with sharp borders. These large disseminated bodies commonly decrease in grade laterally away from volumes of rock containing ore grade metallization, and the distinction between ore and waste is strictly economic. In order to extract ore grade material from the ground, a significant amount of rock containing sub-ore-grade copper must also be removed which, when placed on dumps, is amenable to solution mining. These two considerations clearly indicate the reasons for the growing interest in solution , leaching techniques--namely the ability to exploit deeply buried low grade deposits and the expansion of reserves in deposits currently under production.

Jan 1, 1977

By Bukovinsky SB

The smelting, refining and hydrometallurgical operations practised in the winning of non-ferrous metals are associated with severe aqueous and high temperature corrosion problems.With the increasing costs of maintenenace and the utilization of computerization to control the processes, the trend in recent years has been to spend more capital on improved and proprietory grades of engineering materials, which offer greater reliability and more cost effective plant performance.The problems which have plagued stainless steel users for many years are the alloys' poor performance in chloride or other halide media where pitting, crevice or chloride induced stress corrosion cracking may occur, have been essentially solved by the new proprietory grades. The controlled additions of minor alloying elements including rare earth metals have led to the development of stainless steels with high mechanical strengths, improved corrosion resistance, and high temperature corrosion resistance and structural stability.

Jan 1, 1985

By L. F. Haven

"The desirable shovel speed-torque curves are described, along with the characteristics of the more important electrical components used to approximate these curves. A particular shovel regulator system combining these components is discussed in detail and some of the advantages and disadvantages of the system are given.INTRODUCTIONIN 1959, STATIC CONTROL was for the first time successfully applied, installed and operated on a mining machine in North America. Since that time, a great deal has been learned about this control by the people maintaining these machines as well as by the de-signers.In 1961, the first SCR (Silicon Controlled Rectifier) or thyristor control system was installed on an excavator. This control differed from the earlier static control in that thyristor excitors supplied the generator fields directly. The development of thyristors of a sufficient rating to supply amounts of phase-controlled power to the generator fields eliminated the bulky Mag. Amp. -Rectifier combination previously used."

Jan 1, 1969

By Murray Hughes, Neil Brown, John Carran

"A control system architecture has been developed using the Ward-Mellor structured analysis techniques for real-time applications. This approach has produced several advantages over traditional control system implementation methods including:•,partitioning of the control system into discrete control functions.•,easy identification of the interaction between individual control functions and the rest of the system including the impact of changes at the control system boundary (i.e. additional inputs or outputs).•,simplified control software testing.•,a closed loop design, implementation and documentation process.This paper describes a generic control application in which the process specification and control system design are logically linked. Both components are used by process engineers for on-going development.IntroductionAluminium is reduced from alumina in multiple electrochemical semi-batch reactors. Raw material additions and molten metal withdrawal are made at discrete intervals ranging from seconds to days. The electrolytic reduction process is continuous, despite the semi-batch nature of the material inputs and outputs. The chemical and physical processes that occur within each reactor are complex and interdependent, therefore simple methods used for the control of many chemical processes are impractical. The process control system is required to optimise operating efficiencies within the safe operating zone.The process control of aluminium reduction cells is heavily biased towards calculation of process variables with relatively few measured sensors. Each cell is controlled independently of the other cells, although changes to process conditions and raw material . quality will affect all cells. The process responds relatively slowly and with significant time lags. Measurements and process variable calculations occur each second, however the accuracy and precision of actuator response and sensor sampling are measured 111 milliseconds. Time-based scheduling is a significant component of reduction cell control."

Jan 1, 1994

FROM time to time articles have appeared in the technical press on the interesting subject of surface combustion. The theoretical part of the problem has, for practical purposes, received ample consideration in those articles, but the number of practical applications of surface combustion referred to has generally been very small.It is the writer's object to review some recent developments in surface combustion, and also to try to arrive at an estimate of its advantages and possibilities. It is not necessary for this purpose to dilate upon the phenomenon of surface combustion itself. Many interesting things have been said on the subject by Pro£. W. A. Bone, of Leeds, to whose researches the recent developments are largely due. A few illustrations may make clear what is meant by surface combustion.Prof. Bone, in an experiment, took a platinum crucible, which he heated in the flame of a Meker-burner. Then he turned the gas off for a second, and, opening the stop-cock again, allowed the combustible mixture to impinge upon the crucible, thetemperature of which was still well below the ignition temperature of the gas. Although no flame was visible at this stage, it was soon clear that, nevertheless, the gas and air had continued to combine, as the crucible would attain a red heat after a few seconds.Another instance of surface combustion was shown by a Mr. Fletcher, in 1882. He placed an iron ball, weighing 3 lb., on a slab of fireclay, heated it for a few seconds with a blow-pipe, and blew the flame out, leaving the gas-mixture still...

Jan 1, 1915

This paper deals with the application of table flotation to two unusual mineral dressing problems. Both problems involved the removal of interfering minerals at sizes too coarse to normal froth flotation.The first problem was the removal of arsenical minerals from Broken Hill gravity concentrates without further size reduction. Table flotation without grinding of the original concentrates gave almost complete rejection of the arsenic from the concentrates. A typical test result was a reduction of arsenic in jig concentrate from 0.75% arsenic to 0.007% arsenic.The second problem was to develop a method to produce a high grade calcium carbonate concentrate from coastal dune sands containing about 10% silica and about 80% calcium carbonate. The sands were about 30 mesh British Standard Screen (B.S.S.), and for economic and other reasons it was stipulated that the separation be made without grinding. Again, table flotation gave excellent results. A concentrate was produced containing 99.62% acid soluble material, representing a recovery of 98.69% of the calcium carbonate in the feed with a rejection of 96.44% of the silica.The investigations' were carried out at the Kalgoorlie Metallurgical Laboratory, under the Department of Mines...

Jan 1, 1954

By J-P Franzidis

Mill operators have traditionally been forced to rely on grade-recovery curves and overall flotation rate constants when analysing proposed improvements to plants. This has led to loss in money and time when a proposed change that showed potential in laboratory scale tests failed to show improvement in the plant. Frequently, this is a result of the operators being unable to gain insight into how and why the proposed change affected the flotation performance. This is due to the classical models not including any description of the subprocesses of flotation and their individual contribution to the overall flotation performance. A new flotation model has been developed as part of the AMIRA P9 project that separates the flotation process into subprocesses and includes the contribution of both the pulp phase and froth phase to the overall flotation recovery. It is not possible to determine the individual components of this new model on traditional pilot plants as they lack the required flexibility and scale. Therefore a new pilot plant has been developed known as the Floatability Characterisation Test Rig (FCTR) that has the flexibility and features required for the determination of the flotation subprocesses. The flexibility and features of the FCTR also make it an ideal tool for investigations into many different aspects of flotation research. These include the effect of reagents, grinding, and power on the flotation performance. This paper will describe the methodology for using the FCTR in these fields of research and highlights the advantages of using the FCTR over traditional methods.

Jan 1, 2000