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By S. D. Viljoen

The use of ceramics to protect equipment subjected to wear in abrasive and corrosive applications has been accepted by most plants as the industry norm. Little is, however, known about alternative special ceramic based products which are available for the protection of plant assets. With careful engineering, impact resistant ceramics can be used in high impact zones using modern ceramic technology. Properly selected and properly installed, ceramics will provide a tough wear resistant lining for protection against abrasion and impact. Basalt, on the other hand, is widely used in coal washing plant process pipes with varying degrees of success. Basalt is normally not used for the lining of bends, ?T? pieces or reducers due to the reduced wear resistance compared to alumina ceramic. The advantage is a much reduced initial capital cost. A patented ceramic composite non-return valve solved an old problem encountered in the operation of medium sumps. The design approach overcomes the lack of functionality of alternative designs and reduces valve wear while preventing medium settlement during plant shutdown periods. Direct bonded ceramic pulley lagging is becoming the industry norm, eliminating most of the problems encountered with conventional pulley lagging systems.

Jan 1, 2010

By Phillip J. Maddex

After the presentation of a co-authored paper, "The Cost of Transporting Ores and Raw Materials in World Markets", at the February SME meeting, one questioner commented, "You have been talking about the large shipper and ship loads. What does the small shipper do?" This paper will attempt to answer that question, at least in part. Probably the questioner hoped to hear about specific new tools and new techniques that he could apply. But one paper could only scratch the surface of the vast fund of information available; so rather than talk specifics we should take basics, that is, people, management and technology.

Jan 1, 1967

By M. J. Klishis

This paper presents the findings of a study on roof bolters' hazard exposure. A "micro-analysis" of accident data was combined with ergonomic observations of roof bolter operators to categorize bolting-related injuries and a checklist was constructed. Bolting-related problems were identified as situations that could expose bolter operators to hazards. Approaches to avoid these situations were applied at six mining operations to evaluate specific problems in roof bolting operations. The re-search emphasized the importance of analyzing worker behaviors in the context of mining situations and equipment design problems that lead to human error accidents.

Jan 1, 1995

By Monique Pharand, Jeet Basi, Simon Hille

"High quality activated carbon is essential in the recovery of gold in Carbon-in-Leach (CIL), Carbon-in-Pulp (CIP), and Carbon-in-Column (CIC) circuits. Goldcorp’s Campbell complex at Red Lake Gold Mines (RLGM) experienced a period of low soluble gold (Au) recoveries during Q3 2013, during which time the processing plant saw higher than typical Au grades in the CIP tails solution stream. A technical review identified that the CIP circuit may be experiencing a carbon-fouling issue. To further understand the degree of fouling, and to troubleshoot the low recovery problem, samples of carbon were collected from the CIP, elution, acid wash, and regeneration circuits, and submitted for characterization test work. This paper summarizes the steps taken to remedy the carbon-fouling problem at RLGM resulting in increased overall Au recovery.Overview of Red Lake Gold MinesRed Lake Gold Mines is located approximately 450 kilometres northeast of Winnipeg, Manitoba, in Ontario’s western boundary region.All mining is carried out through underground operations, utilizing overhand cut and fill, underhand cut and fill, and long-hole mining methods. Ore types include: silica-replaced carbonate veins with free milling gold, siliceous replacement-type mineralization (rich with arsenopyrite) marginal to veins, broad disseminated sulphide mineralization along major shears, and some minor sulphidized chemical sediment-hosted ore. The operation is supported by two milling complexes: Red Lake, and Campbell.Process DescriptionThe Campbell processing plant's main unit operations consist of grinding, gravity concentrating, flotation, autoclaving, leaching, carbon-in-pulp (CIP), carbon elution and reactivation, electro-winning, bullion smelting/refining and cyanide destruction, and concentrate handling. A schematic of the plant flowsheet is shown in the figure below.BackgroundHigh quality activated carbon is essential in the recovery of gold at many CIP/CIL/CIC processing plants. At RLGM, gold-bearing ore is milled and cyanide is added to leach the gold from the solids into solution. The dissolved gold then comes into contact with activated carbon, and adsorbs onto its highly porous surfaces. Gold is then recovered by separating the activated carbon from the main slurry for further refining. As such, the characteristics and quality of the activated carbon have a significant and direct impact on overall gold recovery."

Jan 1, 2016

By G M. Tranell, M Tangstad

The CO2 footprints in the production of Mn-ferroalloys and silicon/ferrosilicon are correlated with the fossil carbon consumption. The CO2 emissions may be reduced in the Mn-ferroalloy process by increasing the degree of prereduction and reduction of carbonate materials, while the silicon/ferrosilicon process is optimised based on silicon yield. By changing the fossil reductant into biogenic reductants, the global warming potential will be decreased even more. Even if the reductants are biogenic reductants, there will still be a global warming potential (GWP) in eg the electrode consumption and the CH4 emissions in the charcoal production. To reduce the use of fossil reductants there are also more disruptive technologies like the use of H2 that at least for the silicon production is on a very low technology readiness level (TRL). Using metallothermic processes will reduce the use of carbon but requires carbon neutral metal reductants. Electrowinning can have low CO2 emissions, and the electrowinning of pure Mn is a technology of high TRL. Salt and oxide electrolysis is under investigation for both Mn and Si production however the research is still on a low TRL. The use of CCS/CCU (carbon capture storage/utilisation) is a part of obtaining carbon neutral processes. Last, the energy mix used for these energy demanding processes is discussed.

Aug 21, 2024

By Martin B. Hudson, Daniel Brescia, Zhangwei Ning

Due to the complexity and sensitivity of surrounding environments, instrumentation and monitoring (I&M) is critical for many urban deep excavations. The objects to be monitored include shoring bulkheads, retained embankments, adjacent buildings and roads as well as underground utilities. However, there are also plenty of constraints on the implementation of I&M such as: congested site space, difficult access to instruments, coordination among multiple contractors, and installation permits for private or public properties. Because of these constraints, sometimes the implementation of the initially planned I&M is delayed, its scope is reduced, and/or the continuity of monitoring is interrupted. For these reasons, it is important to implement the I&M with robust and redundant capabilities while providing minimal interference to the project construction and schedule. This paper describes state-of-the-art I&M technologies including automatic motorized total station (AMTS) with camera and automatic leveling device, reflectorless AMTS and IoT- based wireless sensors based on a case study of an on-going deep excavation project. INTRODUCTION In urban environments, deep excavations requiring the construction of temporary shoring bulkheads are becoming increasingly common, with the associated need to provide protection of the surrounding built environment during construction. Protection of the surrounding environment requires planning, engineering, construction, monitoring, and excessive shoring movement mitigation. The I&M is a vital component of the deep shoring implementation. In public projects, geotechnical I&M is often placed within the general contractor’s scope, whereas the majority of deep excavations are privately undertaken. For those private developments, sometimes the developer contracts the geotechnical I&M directly with the project geotechnical engineer or by a geotechnical I&M specialist hired by the project geotechnical engineer. In either the public project or private development case, the effective deployment of the I&M system relies heavily on coordination and collaboration with the project contractor.

Jan 1, 2018

By F. Tanaka

Copper losses to discard slag have long impacted on the profitability of copper smelters. Businesses based on the treatment of secondary materials have also revealed that copper losses are indices of precious-metals losses. Many custom smelters are thus required to obtain more reliable controls for reducing copper losses than ever before. Mitsubishi Materials Corp. has cooperated with academic research institutes in conducting research projects on the pyrometallurgical fundamentals of copper smelting systems, including mutual evaluation of magnetite behavior between synthetic and industrial slags. The state-of-the-art pyrometallurgy has subsequently been introduced to Naoshima smelter for controlling the Mitsubishi process. The revised controls function successfully and the operational results demonstrate that avoiding the discharge of solid magnetite from the S-furnace is quite effective to reduce copper losses. Magnetite behavior has been controlled over the Mitsubishi process so as to reduce copper losses while satisfying the needs of recycling businesses growing in Japan. In-situ estimation of magnetite behavior using the absorbed heat from the melts to cooling water will also be discussed.

Jan 1, 2007

By Y. Luo

The rock breakage process in drilling is a main source of noise in roof bolting operations, especially when hard rocks are encountered. Proper control of drilling operation can provide an opportunity to improve energy efficiency of drilling and to reduce noise and heat generated from bit-rock friction. Drilling tests have been conducted in laboratory settings to confirm this noise-reduction strategy. Preliminary results show that the drilling parameters, penetration and rotational rates can be controlled to achieve in a desirable range in drilling medium hard rock. Based on the theoretical and experimental studies, rational drilling control strategy is developed for noise control while maintaining a safe and productive roof bolting operation. Applying this strategy in underground roof bolting operation, the noise exposure of roof bolter operators will be significantly reduced.

Aug 1, 2013

By R. J. Craig

Introduction All mining operations produce rock dust. Inhalation of rock dust, particularly if it has a high silica content, causes silicosis. Silicosis is, therefore, recognized as a hazard of the mining industry and has been made compensable throughout most of Canada. Most of the dust in any mining operation is caused by rock drilling and blasting operations and the movement and transportation of broken rock. Dust from blasting cannot be eliminated, but it can be controlled by means of increased ventilation, the use of water sprays, and the control of blasting hours. Dust from ore movement can be reduced by keeping the broken rock in a moist condition at all times. The dust from the rock drilling operation has been found to be the most difficult to control. Concentrations of dust caused by rock drills in stopes can usually be reduced to the safe minimum of 300 particles per cubic centimeter (p.p.c.c.) by diluting the air with increased ventilation. In development headings, where the machines are more confined, this is not always practicable. Therefore, the dust must be eliminated at its source. This paper deals with the reduction of dust from Leyner machines by adopting improved designs.

Jan 1, 1947

By W. A. Heitbrink, J. D. Ashley, R. E. Gresh, J. A. Organiscak, A. B. Cecala

Many different types of mobile equipment used in surface coal mining utilize enclosed cabs to protect equipment operators. The overburden removal process is extremely dusty and can cause excessive exposure to respirable dust, especially crystalline silica. After equipment is used for years, many components of the enclosure deteriorate and its effectiveness is greatly reduced. This report discusses a cooperative research study performed on an Ingersoll Rand DM45E surface drill, retrofitted with a new Sigma pressurization and filtration system. Respirable dust concentrations were substantially reduced from 0.64 mg/m3 during pre-testing to 0.05 mg/m3 during post-testing with the new system, representing a 92% reduction in dust levels in the drill cab. This new system appears to be a very well-built and sturdy device, well-suited for the mining industry.

Jan 1, 2002

By Michael Schmitz, Eugene Ahrenholtz, William A. Heitbrink, Jeanne A. Zimmer, Andrew B. Cecala, Ernest S. Moyer, Earle H. Andrews, Chris C. Coppock, John A. Organiscak

Many different types of surface mining equipment use enclosed cabs to protect equipment operators from health and safety hazards. The overburden removal and mining process can be extremely dusty and can cause excessive dust exposure. To study this issue, a cooperative research effort was established between the National Institute for Occupational Safety and Health, U.S. Silica Co., Clean Air Filter Co., and Red Dot Corp. in an effort to lower respirable dust levels in an enclosed cab on an older surface drill at a silica sand operation. Throughout this research effort, a number of modifications were incorporated into the drill's filtration and pressurization system, as well as in other areas, to improve its design and performance. An average cab efficiency of 93.4% was determined with gravimetric sampling instruments when comparing the outside with the inside cab dust levels on the final design. Although this study considered just one operation, the goal was to identify cost-effective improvements that could be implemented on all types of enclosed cabs to lower respirable dust concentrations. Two critical components for an effective enclosed cab system are having a properly designed, installed, and maintained filtration and pressurization system, along with a method for maintaining structural cab integrity, which allows the cab to be positively pressurized. Another important component is maintaining cab cleanliness. Although this research was originally directed toward the mining industry, it is also applicable to agricultural or construction equipment.

By Orica Chile, Orica Brasil, Orica Brasil Victor Morais, Kinross Paracatu Leopoldo Muñoz, Kinross Paracatu Luis Marinho, Gubio Barsottini, Orica Brasil José Vergara, Lucas Steffen, Orica Brasil Washington Vilas

In drill and blast activities, it has been a challenge to sculpt walls accordingly to what has been designed in state-of-art mining design software. Obviously, the perfection of making neat and smooth walls – using aggressive sources of energy, like explosives – are time-and-money consumable and, sometimes, even unnecessary. But undoubtedly, it is vital to guarantee solid walls, safe operations environment, beyond to avoid ore losses and pit constraints caused by poor rock breakage on detonation. Kinross Gold Corporation owns the biggest Brazilian Gold Mine, located in Minas Gerais state. Morro do Ouro mine has reached over 30 years of operation, and due its mature age, the complex has developed its pits, becoming them deeper and surrounded by high walls.

Feb 6, 2023

By Michel G. Grenier

Compliance with Diesel Particulate Matter (DPM) exposure regulation is currently performed using timeweighted average (TWA) sampling on underground mine workers. These samples are collected in the span of an entire shift and the resulting concentrations are compared to a legislated exposure limit. While this is very useful to determine the exposure level of an individual to DPM, it fails to clearly identify causes of exposure and highlight opportunities that could help reduce the exposure of workers in the course of the work shift. Real-time DPM monitoring measures the worker?s exposure as a function of time and helps identify circumstances where corrective actions can be taken or design changes can be made by the individual or the employer to reduce the overall exposure of the worker and peers. This work focused on obtaining DPM concentrations using a real-time polycyclic aromatic hydrocarbon (PAH) monitor. The aim was to demonstrate that this instrument, while not a direct DPM analyzer, was able to provide a concentration profile that could easily be linearly correlated to standard TWA elemental carbon measurements. In addition, several instances of improvements that could be implemented to reduce the exposure of underground employees were demonstrated.

May 1, 2010

By Michael Wieland

For shooting rock properly, some relatively fixed quantity of rock work is required from the total charge mass, while keeping the overall toxic fumes to a minimum. The overall fumes weighted for the toxicity of different species and taken per unit charge mass, ??, are represented by a relative fume toxicity (RFT) formula. The worst two contributions are often carbon monoxide {CO} and total nitrogen oxides {NOX}, so the traditional Russian formula RFT-R formula suffices, though a generalized form RFT-G with more terms is worth checking. Using the work-principle model from thermodynamics, the rock work per unit charge mass, ??, is found from the reduction in internal energy for the reaction zone. This resolution technique for rock-work invokes the usual assumption that the quick irreversible process occurs without notable heat transfer to the rock (adiabatic); rock-work is not resolved, when this restriction is untenable. The ratio of ?? to ?? yields the weighted toxic fumes divided by the rock work or the readjusted fume toxicity ??, where ?? = ??/??. For convenience, graphical trends of ??, ?? and ?? were normalized using reference results for a stoichiometric (ANFO) mixture of ammonium nitrate (AN) and fuel oil (FO) shot under nominal rock confinement, noted later.

Jan 1, 2006

By B. Tiryaki, M. Ayhan, O. Z. Hekimoglu

Coal shearers are one of the major sources of dust and fines in underground coal mines. Despite considerable research investigations, no comprehensive in situ investigations coupled with extensive laboratory studies on the effects of drum design on generation of dust and fines have been found. It may be for this reason that many major shearer drum manufacturers persistently employ a certain drum-lacing pattern on current coal shearers, which is believed to cause excessive dust and fines in coal mines. This paper shows how respirable dust and fines are minimized under near-identical conditions when the drum lacing pattern was changed from a triple-tracking to a single tracking arrangement. A series of laboratory trials simulating in full scale the practical cutting action of tools was followed by extensive long-term underground trials during production operations in OAL (Cayirhan) Lignite mine in Turkey. The results are presented and discussed, and recommendations for proper drum-lacing in terms of respirable dust and fines are made.

Jan 1, 2002

By A Tsang, D La Rosa, L Julian, W Hunt, R Pratama

Mineral extraction is facing the twin challenges of finite resources and increasing environmental and economic costs. Society’s growth is matched by an increase in demand for the earth’s resources. It is incumbent on us as contemporary mining professionals to promote and facilitate ethical and efficient practices. Technological developments have and will continue to allow a decrease in viable cut-off grades, creating new economic opportunities from deposits that were previously uneconomic. Mining low-grade deposits however, even with perfect recoveries, will have a significant environmental cost for the metal won. The greatest opportunity to increase metal with the least environmental cost is to increase the metal yield from existing mines. The determination of mining polygons is a critical juncture where rock is typically subjected to the binary grading of either ore or waste. This is undertaken using a number of factors, such as the mining equipment being used and the recovery in the processing plant. Traditionally, mining polygons were generated on the in situ grade control model. This ignores the complex differential blast dynamics that occur during blasting. Two opportunities exist to improve metal yields: optimise the blast design to achieve the post-blast muck pile that will support the greatest outcome; and generate optimised polygons on the post-blast muck pile. A data set from a Canadian Gold deposit is used to demonstrate the potential benefit of iterative blast movement modelling and grade control polygon optimisation on metal yield. The impact of blasting on the total recoverable metal is presented, highlighting blast design as a critical process in the mining value chain.

Sep 1, 2024

By W. D. Monaghan

Flame cutting and welding is one of the major causes of fires and explosions in underground U.S. coal mines. On May 20, 2006, a flame cutting operation at the Darby Mine No. 1 led to an explosion that resulted in five fatalities. On January 22, 2003, another explosion caused by flame cutting at the McElroy Mine resulted in three fatalities and three serious injuries. On June 22, 1999, a flame cutting and welding operation at the Loveridge Mine caused a fire that resulted in sealing of the mine for an extended period. Finally, on March 19, 1992, an explosion at the Blacksville No. 1 Mine that was caused by welding resulted in four fatalities. The National Institute for Occupational Safety and Health (NIOSH) conducted a study on fires and explosions in underground U.S. coal mines that were caused by flame cutting and welding operations to determine the root causes of these types of fires and explosions. The methodology included interviewing mining personnel who perform flame cutting or welding operations in underground U.S. coal mines and visiting mines to observe these operations, and MSHA reports of investigations and accidents statistics were analyzed. The results were used to identify and compare differences between flame cutting and welding practices and techniques in small and large mines, Eastern and Western mines, low seam and high seam mines, room and pillar and longwall mines, and between experienced miners and new miners. As a result of this study, best practices and interventions were developed to reduce the number of fires and explosions caused by flame cutting and welding. This paper provides a summary of this work. Disclaimer: The finding and conclusion in this report are those of the authors and do not necessarily represent the views of the National Institute for Occupation Safety and Health.

Jan 1, 2009

By Neal I. Rosenberg

There is an old education maxim that a good teacher "first tells 'em what he's gonna tell 'em, then he tells 'em, and finally he tells 'em what he told 'em. I'm sure this says something about me as a teacher, and therefore as a student as well, but I'm going to begin by violating that maxim. The first thing I'm going to do is tell you what I'm not going to tell you. I'm not going to tell you that my company has found the solution to frozen coal problems. I'm not going to tell you that there is a miraculous new formula, and your frozen coal worries are over. Actually, it is really questionable whether there is a single step or process which will provide the answer. On the other hand, I do believe that at Union Electric we have made significant improvements in our ability to deal with frozen coal over the last couple of years, and I propose to describe some of the things we have done, what conclusions we have drawn so far, and the direction in which we are now headed. It would be well here to give a brief picture of the Union Electric system and the frozen coal problems we face. Union Electric is an investor owned electric utility with headquarters in St. Louis, Mo. Total generating capability is on the order of 6800 megawatts, which snakes us 24th or 25th largest in the United States. Power generation is by steam (both coal and oil fired), hydro, pumped hydro, and combustion turbine units. Although that is a diverse power supply, by far the largest source is our four coal fired steam plants. One receives coal exclusively by barge, the other three by rail. It is at these last three plants that the frozen coal difficulties arise.

Jan 1, 1980

By S. G. Tsimas, A. K. Moutsatsou, G. K. Parissakis, M. A. Komiotou

For Greek kaolin producers, a considerable proportion of whose output is from deposits containing more than 4 wt% Fe2O3, the colouring resulting from iron oxide impurity represents a serious problem that necessitates upgrading of the ore to meet commercial specifications. Autoclave leaching with oxalic acid for 1 h at 120 degrees C and 5-6 bar was shown to reduce Fe2O3 by up to 90% without affecting the structure of the kaolin, which maintained its physicochemical properties. The iron oxalate product can either be removed from solution or precipitated as iron hydroxide with recycling of the oxalic acid

Aug 1, 1995

By J Merrells

Fluor, together with our clients, has yielded significant reductions in the total cost of mining projects by employing a systematic and methodical process of cost reduction. This paper outlines this structured approach to reducing the total cost of projects through the gathering of information, the evaluation of the zero base design, and the development of the execution strategy for the project in the study phase.Over the recent iron ore boom the cost of growth projects escalated rapidly due to a variety of factors including the engineering cost of re-designing facilities, construction in remote areas and an increase in the ‘perceived’ capital requirements for maintainable and operable facilities.Fluor has made strategic steps towards safely reducing the capital intensity of projects, by working with clients to develop zero base designs which utilise the minimum technical requirements in order to meet the function of the plant and then add cost for safety, maintenance and operability only where clearly justified.This paper has set forth a structured three phased approach to focus the team on reducing capital cost while maintaining a low increase in engineering effort.The initial ‘gather’ phase focuses the team on acquiring information and identifying decisions that will need to be made so that the team can prioritise and focus the attention on areas that will provide the greatest benefit. Within this phase the identification of zero base design requirements, review of lessons learnt and analysis of capital cost levers, allows the team to identify the key decisions on the project that will affect the capital cost.In the subsequent ‘evaluation’ phase the team established the zero base design, using the hierarchy of cost reduction as a guide to focusing the team’s attention on high yielding cost saving opportunities.In the final phase the team develops the execution strategy which will yield the least cost using strategies and tools such as modularisation, standardisation, replication, strategic sourcing and 3D design.CITATION:Merrells, J, 2017. Reducing total project cost in the study phase using zero base design, in Proceedings Iron Ore 2017, pp 621–626 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 24, 2017