Search Documents

By T. Nghipulile, M. Moys, M. Bwalya, H. Simonsen

The quest for efficiency in comminution is an ongoing concern as comminution usually constitutes a major cost component in the metal production industry. Such improvements can be made by circuit optimization or development of more efficient equipment. A novel crusher, known as the rotary offset crusher (ROC), promises to deliver in this space. The ROC was invented in 2002 by Michael Hunt, Henry Simonsen, and Ian Sinclair, but failed to garner enough support to progress to production. The original design concept was recently rekindled, and a laboratory version of the crusher has been built and commissioned at the University of the Witwatersrand. The crusher is simple in design, with two cylindrical discs that are parallel to each other, and, as the name implies, there is an offset between the vertical axes of the discs. The top disc has a conical section on its lower face, and this creates a crushing zone between the opposite faces of the two spinning discs. Centrifugal motion transports particles through the crushing zone. Batch experiments have been conducted with quartz at various crusher settings (discs offset, rotational speed, and vertical exit gap) for various feed size distributions. The indications so far suggest that the disc speed is a key factor affecting the performance. Size reduction ratios as high as 11 were recorded from experiments with quartz at a speed of 830 r/min.

Jan 1, 2021

By Z. C. Shen

As core part of flotation column, aerator has been always priority research. A new type of porous aerator made of stainless sintered microcellular material is designed , which diameter is between 20µm to 40µm. High bubble surface area flux is obtained at low air pressure 20kPa by this type of aerator in water. In order to extend its applied range ,experiments were carried out in alkali slurry (pH=12) , resulting with porous aerator clogged after working 20 days . Sampling the cross-section of aerator detected by microscope and X-ray diffraction ,the reason clogging was found. Then plugging aerator was reactivated after putting it in acidic liquor treated by ultrasonic for about ten minutes. On-line aerator maintenance can be done in no down time , and it can be repetitive-used after recovered ,so reduced capital costs.

Jan 1, 2014

By K. Morsi, S. K. Kassegne, K. S. Moon, A. Numula

"Current Activated Tip-based Sintering (CATS) is a new process for the powder-based manufacturing of macro, micro and possibly nano-scale features and shapes. CATS enables the selective sintering of powders by localizing current activation conditions through an electrically conducting small tip (either in the stationary or moving mode). This paper presents preliminary experimental results on the CATS of reactive mixtures of Ni/Al powder to form nickel aluminide intermetallics. Preliminary investigations on the effect of current on the reaction characteristics are discussed.IntroductionSpark Plasma Sintering (SPS) has been the subject of intense research over the past decade [1,2, 3,4,5,6]. The process boasts remarkable advantages which include ultra fast heating rates (hence by-passing low temperature non-densifying sintering mechanisms), considerably lower sintering temperatures and shorter sintering times than achieved in conventional sintering. The process is however limited to the generation of simple geometries on the macro-scale. Recently three of the authors conducted work on a novel process ""Current-activated tip-based sintering (CATS)"" [7], where electric current is passed through a conducting tip that is placed or allowed to travel over a powder bed/compact to locally sinter powders. lD, 2D and 3D micro-scale sintered shapes can be generated with the possibility of 3D rapid prototyping on the macro/micro or nano-scale. Although CA TS of single phase powders has been conducted, the CATS of reactive powders has not yet been investigated.The Ni-Al phase diagram contains five intermetallic compounds, AhNi, AhNh, AlNi, AhNi5 and NhAl. Out of these intermetallics, NiAl and NhAl have received the vast majority of scientific and industrial interest [8]. NhAl can be formed by reaction synthesis, where nickel and aluminum reactant powders are heated to a reaction ignition temperature at which the reactant powders are converted to the intended intermetallic product. The reaction is exothermic which gives rise to considerable compact self heating, thus instantaneously raising the compact temperature by several hundred degrees which facilitates sintering [8]. Applying and electric current locally would not only provide for a rapid local reactive sintering, but would generate a number of intriguing scientific investigations. For example, of interest would be, how would the reaction propagation and microstructural/phase evolution be affected by the temporal and spatial temperature and current distributions."

Jan 1, 2011

By K. Morsi, P. Mehra

"Spark plasma sintering has gained a considerable amount of attention over the past decade, due to its rapid sintering rates, and low temperature requirements, but has so far been usually limited to the production of simple geometries. The present paper examines the current-activated production of extended geometries through the process of spark plasma ""extrusion"". Of interest in the present study is exploratory research into the effect of electrical current activation on the reactive consolidation of powder systems to form intermetallic materials.IntroductionSpark Plasma Sintering (SPS) has been the subject of intense research over the past decade [ 1,2, 3,4,5,6]. The process boasts unique advantages which include ultra fast heating rates, shorter sintering times and lower sintering temperatures than needed in conventional sintering. The process is however limited to the generation of predominantly simple geometries. Recently one of the authors investigated the spark plasma extrusion of aluminum, where an aluminum powder compact is directly (Joule) heated through an applied DC electric current. Here extended geometries can be generated under the influence of electric current. A number of heating sources were identified including the heat source from current, i.e. Joule heating, frictional heating and heat from the deformation energy. However in the case of reactive powder systems, an extra ""one-time"" transient heating source can be supplied. By considering combustion synthesis of powders, this heating source is derived from the reaction between elemental powders to exothermically form a product at some ignition temperature [7]. This exothermic energy heats the compact to the maximum ""combustion temperature'', which could be hundreds of degrees higher than the ignition temperature. Hence a high temperature processing window (of short duration due to heat losses to the surroundings) becomes available in which the material is most suitable for stress-induced deformation and consolidation. For reactive spark plasma extrusion, two scenarios can be envisioned. The first is where the reactive powder compact is ignited through the application of current, and extruded within the high temperature processing window (also under the influence of current). The second scenario is to allow the heat of deformation/friction to heat the material during extrusion, to simultaneously force a reaction and consolidation. Here it is expected that the processing window will be very small if feasible."

Jan 1, 2011

By Di Yang

The influence of high density (104 -105 A/cm2) electric current pulses (70 us duration) and continuous DC (~103 A/cm2) on the flow stress and ductility in tension of a high carbon steel wire were determined at 204°, 427° and 649°C. Electropulsing (100 pulses per second) with an effective current density of 100-200 A/cm2 gave a 10% enhancement in the uniform elongation of the wire at 204°C, but had no effect at 427°C and 649°C. In contrast, continuous DC either had no significant effect on the ductility or gave a decrease. The electropulsing per se decreased the flow stress only slightly at 204° and 427°C, but gave a significant decrease at 649°C. Continuous DC increased the flow stress at all three temperatures. The present results along with those by others suggest that the enhanced ductility by electropulsing and the reduction in flow stress may be further increased by raising the effective current density through increases in either the pulsing frequency, maximum current density of each pulse or pulse duration. This could conceivably increase the reduction per pass during wire drawing or the number of passes between anneals.

Jan 1, 2001

By Zou Zhongpping

Under the new normal state, blast furnace outputneeds to be adapted to the market demand, however the limitation in blast furnace output has significant impact on blast furnace operation and is prone to cause inactive furnace hearth and higher fuel ratio. To address such problems, some practices to maintain stable and smooth operation of blast furnace in case of output limitation are proposed based on data analysis philosophy, which allows the blast flow and hence the top pressure to be determined based on the hot metal output, and adequate kinetic energy of blast supply can be assured by adjusting the tuyeres. Matching between the oxygen enrichment and the pulverized coal injection is also proposed based on theoretical flametemperature, and burden distribution cycle calculation method is proposed, whichoffersnew approach for analyzing the change in burden distribution pattern.

Oct 30, 2017

By H. O. Seigel, J. C. Gingerich, E. O. Köstlin

"To satisfy their continuing need to replenish or expand their ore reserves, mining companies are faced with the dilemma of arriving at a proper balance between the dual avenues of discovery through in-house exploration and of acquisition of properties that are relatively proven or are even in production. The returns from exploration activities may be spectacular, but are unpredictable. The allure of an acquisition lies in its promise of quick and risk-reduced addition to reserves. However, it is historically clear that quantum increments in shareholders’ values have arisen primarily through major exploration discoveries, rather than through major late-stage acquisitions. Late-stage acquisitions can prove highly profitable, sometimes based upon the planned use of superior mining or metallurgical technology, but more often occur as the result of unexpected windfalls. At the other extreme, they can become expensive failures through inadequate due diligence, or unforeseeable factors.Citing numerous case histories and industry statistics, it is concluded that a judicious combination of both exploration activity and the acquisition of prospects is the most advantageous strategy for adding new ore reserves. A skilled exploration staff is essential for success, be it through exploration discoveries or through opportunistic acquisitions, preferably at their early stages. In the future, it is anticipated that there will be fewer opportunities for acquisition because of reduced funding for junior exploration companies, leading to increased competition and higher costs for fewer properties, both in the advanced exploration and mining stages."

Jan 1, 2002

By P. Radziszewski

In comminution research, ore breakage and wear are usually studied independently of one another. Much of this is due to the fact that wear is usually a slow process compared to ore kage. However, the abrasion wheel test used to determine the abrasive wear contribution to total steel media wear provides the opportunity to study not only abrasive wear and friction but also ore breakage. In this paper, we will explore the use of the abrasion wheel wear test device to study abrasive wear, friction and ore breakage using standard Ottawa foundry sand. We will look into the feasibility of applying the work index as well as t10methodologies to this test set-up. We will also look at how the work index results evolve with abrasive wear and friction. We will then discuss the merits of pursuing the use of this abrasion wheel test for not only wear characterization but also breakage characterization.

Jan 1, 2014

By Charles H. Jacoby, Leo E. Read

IN diamond coring salt beds to evaluate deposits, special techniques are applied to standard slim hole drilling to obtain a representative sample of the water soluble sodium chloride. Industrial consumers generally require a run-of-the-mine material of 98.0 pct sodium chloride. Since no commercial beneficiation has yet been devised to upgrade the lower quality salt beds, the only processing is crushing and screening to the size required by the customer. Coring salt sections has recently become important not only in dry mining, but also in the development of brine cavities by hydraulic fracturing and the formation of jugs for storing liquid petroleum products. Drilling Fluid: The fluid used in coring salt beds in New York, Ohio, and Michigan is a thoroughly saturated brine made from 3.0 lb rock salt per gal of make-up water. This mined rock salt, -4 mesh +10 mesh, is dissolved in a lixator, a double-bottomed cone hopper that turns fresh water to fully saturated brine.

Jan 5, 1957

Addressing community concerns in relation to an economic activity, particularly when it causes significant community impacts, is especially important for the development of extractive industry projects. Pipelines comprise an integral part of many hydrocarbon developments, which may cause different effects on local economic development, communities and the environment compared with open cast mines. This paper explores community impacts associated with a case study of the oil pipeline æEastern Siberia-Pacific OceanÆ in the Republic of Sakha (Yakutia), Russia. Based on semi-structured interviews, conducted in 2006 - 2008 in Russia, the paper investigates claims of local communities about potential impacts of the pipeline development of their environments and economic activities as well as community claims for greater involvement in sharing the benefits from this major infrastructure project. A community of Indigenous people, Evenk, is likely to be most profoundly affected by the development due to impacts on their traditional activities such as hunting and reindeer herding. The paper examines in detail the regional economic, social, environmental and Indigenous peoples concerns over the construction of the oil pipeline and investigates actions and methods adopted by community organisations to voice their concerns about the pipeline development. Finally, the paper assesses the process of interaction between the pipeline developers and regional stakeholders.

Jan 1, 2009

By CASSANDRA L. HOEBBEL, Emily J. Haas, MARGARET E. RYAN

In recent years, there has been increasing interest in the role that individual factors play in health and safety (H&S) outcomes in the mining industry. Two surveys, one measuring self-reported routine safety performance and one measuring individual perceived competence in the non-routine knowledge, skills, and abilities (KSAs) critical to emergency response, were administered to two samples of mineworkers in separate research studies over a 2-year period (N=2,020 and 696, respectively). Eight demographic items were common to both surveys and their associations with each performance outcome were tested in response to a series of exploratory research questions.

Jan 9, 2022

By K. Soga

DOWA has long been specialized in the treatment of complex massive sulfide ores from exploration through smelting. Its competitive advantage derived from ore dressing technology to dress and concentrate complex ore to various kinds of metals concentrates. With this technology, the company recovers as many as seventeen different nonferrous metals. Therefore, it is crucial for the environment management and recycling business both to recover valuable elements like gold, silver, copper etc. and to handle hazardous elements in safety. From this view point, the nonferrous metal industry has a potential to play an important role; that is "The Anchor of Recycling" or "The Joint of Recycling Loop". By utilizing these mining, smelting and refining technologies, know-how and facilities, DOWA became a leading waste treatment, soil remediation and metal recycling company in Japan. This knowledge is now being applied in China .

Jan 1, 2007

By C K. McKenzie

As more and more mining operations around the world either switch to, or trial, electronic initiation systems, the breadth of knowledge and experience regarding their effective application has widened considerably.In South America, for example, there is a strong perception that in order to achieve the finest possible fragmentation, very short electronic delays must be used between successive holes within a row. Limited field studies involving measurement of fragmentation have been conducted to support that paradigm and there are few long term studies which have been strongly supported by measurements of productivity either in the pit, in the plant, or in the leaching pads.On the other hand, some well documented studies have been conducted in North America, showing not only the impact of delay timing on fragmentation but also the effect on semi-autogenous grinding (SAG) mill productivity over extended periods of in excess of 12 months. To date, those studies suggest that optimum timing is considerably longer than the times commonly used in South America.This paper explores the current knowledge of the effects of delay timing on issues ranging from size distribution to vibration impacts in pit walls, to vibration and overpressure impacts in surrounding communities. It also explores how fragmentation modelling can be adapted to reflect fragmentation trends that have been reported in various technical conferences around the world.

Nov 8, 2011

By Nicolle Krusberski

Potential errors in XRF analysis are discussed and investigated with specific reference to the analysis of ilmenite samples. A selection of ilmenite samples was chosen and prepared using two XRF preparation techniques: pressed powder pellet and unroasted fusion bead. The merits of the two methods have been discussed in this paper for ilmenite analysis by XRF. Recommendations have been made regarding the use of pressed powder pellets especially with regard to the mineralogical effects that were evidenced during this investigation. The fusion bead technique was found to be far more accurate and able to meet short turnaround requirements provided the calibration methodology used is specific to the grade of samples analyzed.

Jan 1, 2014

By Gary J. Massoth

Wherever hydrothermal fluids vent from the seafloor they will buoyantly rise (up to 100?s of meters) while mixing with seawater before attaining density equilibrium and dispersing laterally as neutrally buoyant plumes commonly 50 to several 100?s of meters in thickness and with order-of-magnitude or greater breadth. Although these plumes are typically >10,000-fold dilutions of vent fluids they can be reliably detected using sophisticated physical sensing and chemical techniques. Hence, hydrothermal plumes are spatially large targets compared to the actual sites of seafloor fluid discharge and resulting mineralization. For this reason plume prospecting techniques evolved over the past 20+ years have been widely used to systematically explore over 10% of the 60,000-km-long system of mid-ocean ridge (MOR) spreading centers for hydrothermal activity. While plume detection and gradient mapping can be used to home in on venting sites, plume chemical signatures provide additional insight regarding the nature of the fluids being discharged on the seafloor. We have applied the systematic plume prospecting techniques developed on MORs to the volcanic frontal arc setting as part of the NZAPLUME (New Zealand American PLUme Mapping Expedition) surveys. NZAPLUME I in March 1999 marked the first systematic reconnaissance of any intra-oceanic arc for submarine hydrothermal activity. Seven of thirteen previously mapped volcanoes that comprise a 260-km-long section of the southern Kermadec arc northeast of New Zealand were confirmed to be hydrothermally active. On average, one hydrothermally active volcano was found along each 35 km of arc front, a rate comparable to slow- and intermediate-rate spreading MORs. During NZAPLUME II in May 2002, thirteen previously unknown volcanoes and 8 satellite cones were first swath mapped for bathymetric detail and then surveyed using plume prospecting techniques. Three active venting sites were discovered along this 580 km-long arc section, bringing the total to 10, or 39% of 26 volcanoes surveyed overall, still an appreciable frequency rate for venting sites compared to MORs. While only chemical results for NZAPLUME I are available, the arc plumes characterized so far are chemically diverse and rich compared to MOR plumes. This diversity and enrichment was most evident as ultra-high concentrations of CO2, sulfur gases (St = SO2 + H2S), and Fe within plumes over several volcanoes. We suggest the fluids discharging from the seafloor at these sites are volcanic fluids, i.e., hybrid fluids comprised of MOR-like hydrothermal fluids evolved from seawater-rock reaction and fluids exsolved from magma as acid volatiles and liquid brines.

Jan 1, 2002

By CASSANDRA L. HOEBBEL, PATRICK L. YORIO, Emily J. Haas

This study revealed significantly less favorable perceptions of the existing organizational safety climate among workers in the underground coal-mining sector compared with those in the industrial-minerals and sand, stone and gravel (SSG) sectors. Consequently, it is important to consider pragmatic ways in which health and safety management systems (HSMS) in coal mines can alter processes to improve these perceptions. Given the interdependencies of safety climate factors and HSMS elements, researchers explored mineworker perceptions of the supportiveness of organizational safety climate factors among mineworkers and identified significant differences in perceptions across sectors. In this paper, we suggest that health and safety professionals in underground coal mining and organizations with fewer resources or less mature HSMSs focus on these factors to bolster support for proactive safety performance. Potential barriers to implementing or improving relevant HSMS elements and ideas to help foster more favorable perceptions of organizational safety climate are also discussed.

By Y. Zhang, C. Zhou, M. Girman

Wireless technologies are increasingly being implemented in underground mines for various purposes such as communications, tracking, remote control, remote sensing, and environmental monitoring. However, the adoption comes with risks as common wireless systems, such as WiFi, Bluetooth, IWT (Innovative Wireless Technologies) wireless system, often operate in the unlicensed ISM (industrial, scientific, and medical) band. The shared nature of the ISM band can lead to interference among devices and consequently cause performance degradation and reliability issues. In this study, we developed two wireless communication evaluation boards as a tool to evaluate the performance and reliability of a wireless system with the presence of electromagnetic interferences (EMI) from other wireless systems in underground environments. We adjusted various parameters including signal power from adjacent frequency channels, noise power within the same channel, the movement of personnel, and communication packet size. Our findings indicate that, while the power of the EMI source plays a key role, the motion of personnel in the tunnel also has a strong impact on performance, and this impact increases as the power of EMI sources increases. In noisy environments, smaller packet sizes are preferable as they enhance the likelihood of successful transmission. High levels of interference or noise can lead to increased packet loss or error rates, potentially causing communication links to fail completely or become ineffective. The evaluation boards utilized in this study are based on a practical wireless transmission system deployed in a remote controller for a heavy mining machinery used in underground coal mines. The results and findings presented in this paper can aid in the design of wireless systems that are resilient to EMI in underground mining environments.

Feb 1, 2025

By Wayde Esplin

At the Barrick Goldstrike processing facilities in northeastern Nevada, sulfide ore is pressure-oxidized at a temperature of 440° F and 420 p.s.i. in six autoclave circuits. The low pH, high temperature, and abrasive characteristics of the oxidized slurry present many new and unique maintenance challenges. To meet these challenges, the Barrick Goldstrike autoclave department formed a reliability group in August 1998. One of this group's critical missions is to reduce both maintenance costs and unscheduled downtime through the application of predictive maintenance technologies and Reliability Centered Maintenance Analysis. This paper discusses some of the successes of the reliability program at the Barrick Goldstrike autoclave.

Jan 1, 2000

By Jacob Carr, Rebecca Knuth, Emily J. Haas, Marvin Cheng, Bob Bissonette

Many industries, including mining, are experiencing an increase in the use of robotic and other artificial intelligence (AI) systems to improve efficiency, productivity and precision. For example, a 2023 survey showed that mining industry executives wanted to integrate more autonomous equipment to improve productivity and alleviate workforce shortages (Haas, 2024). This feedback was coupled with an increased appetite to advance the types and uses of automation and AI in the workplace. However, there is also an increasing concern about the ways that robotic applications may unintentionally affect worker safety. Humanmachine interaction poses potential risks, especially when industrial robots operate near workers in specific environments (such as drilling, handling and transporting materials, equipment inspection and lifting heavy loads). Research has explored the unintended consequences of introducing new technologies or processes in the workplace to include incidents such as being struck by equipment and challenges around data privacy (Lööw et al., 2019; Khurram et al., 2025; Haas and DuCarme, 2015; Almeaibed et al., 2021; Zio and Miqueles, 2024). More recently, the use of digital twin technologies and simulations (hereafter referred to as digital twin systems) has been boasted as a tool that can help prevent unintended consequences around worker safety by identifying and mitigating risks before a worker completes a task in tandem with a robot or other new technology. Digital twin systems produce a virtual replica of a physical environment or process (Almeaibed et al., 2021; Zio and Miqueles, 2024; Saes, 2024). To this end, this article explores the potential role of digital twin systems in enhancing safety within mining and other similar environments. It will primarily focus on environments where robots and human workers may interact, although digital twin systems can be useful with other technology applications. First, we define digital twins and digital simulation as components of a system. Then, we highlight possible applications of digital twin systems in mining to replicate real-world processes, followed by potential benefits of their use and where more research may be needed.

Oct 1, 2025

By K. C. Corin, M. Tadie, R. M. Manenzhe

The near depletion of high-grade ores, among other factors, has necessitated the consideration of alternative PGM sources. Various factors in the metallurgical processing of ores result in valuable minerals being lost to the tailings, and hence, PGM tailings are a possible alternative PGM source. However, as the value residing in PGM tailings remains unquantified and uncharacterised, there is a challenge in knowing the recoverable fraction of value contained in PGM wastes. This paper outlines the in-situ techniques of oxygen uptake and EDTA extraction for their possible use for determining the recoverable value in PGM tailings. Both methods have shown efficiency in determining the weathering of sulphide minerals and sulphide-bearing ores. Keywords: PGM tailings, tailing retreatment, oxidation, oxygen decay, EDTA

Jan 1, 2020