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By M. L. Mendes, J. Q. Nojiri, S. C. Botelho, A. P. Campanha

In February 28, 2001 JOULE coordinated the first tests with an electronic detonator in South America at an iron ore operation - ITABIRA MINES from the Brazilian COMPANHIA VALE DO RIO DOCE (CVRD) - the largest producer and exporter of iron ore in the world. ITABIRA MINES (CAU and CONCEI O) belong to one of the complexes, called the Southern System, producing 56 million tons of ROM as well as concentrated products and pellets. This paper is going to describe the tests at ITABIRA MINES with results indicating the improvement in the excavator productivity and reduction of the mining global costs (due to the better performance of the equipment and potential reduction of the maintenance cost).

Jan 1, 2002

By A. Anani

The goal of hot mix asphalt (HMA) design is optimal material blending to meet Superpave specifications. HMA cost minimization has being modeled as linear programing (LP) (Awuah-Offei et al 2011) and mixed integer LP problems (Brown et al, 2012) and solved with commercial software such as LINDO and CPLEX. Often these software, which are designed to solve general optimization problems, have licenses that cost thousands of dollars. The objective of this study is to develop a novel solution algorithm to the HMA optimization problem presented by Brown et al. (2012), which will negate the need for expensive commercial packages and is specific to this problem. This novel algorithm is based on the branch and bound algorithm for solving mixed integer problems. The algorithm is incorporated into a software package with an easy-to-use graphical user interface. The developed algorithm is validated using a real-life HMA problem. Using this solution algorithm will save companies thousands of dollars, otherwise used to purchase software licenses.

Feb 23, 2014

By Malcolm Wills

Boddington Gold Mine commenced operation in 1987 with an initial production of 3.0 Mt/y at a grade of 3.5 git. Head grade has reduced over the life of the mine and the major response to the drop in grade has been to increase mining rates and increase plant throughput. A capital expansion was carried out in 1996 increasing the throughput to 6.0 Mt/y and since that date tonnage has been increased without major capital expenditure. BGM's current mill throughput is 8.77 Mt/y ( 1999). In 1999 the combined basement plant and direct leach plant processed 8,770,055 tonnes to produce 233,507 ozs or 7.262882 tonnes of gold at an average head grade of 0.83 git. With grades of 0.83 git, and gold price at record lows, $US251.95loz in August 1999 or $A393.67loz it has been necessary to make and maintain major cost savings to remain profitable. Boddington Gold Mine has achieved this by a number of steps including a productivity study by outside consultants.

Jan 1, 2000

By Dennis A. Clark, Brent Larsson

Tunnelling today is a lot more than drilling and blasting. The developments in drilling and blasting technique have made it pos¬sible to save costs both by increasing the advance per round and optimizing the demands on the final contour. Increasing the hole depth by using longer feeds and bigger dril¬ling rigs make the drilling time shorter compared to the set up time. It is important that the deeper holes are followed up by using a suitable cut. The most common cut in Sweden today is a parallel hole cut with one or more large holes; with a diameter corresponding to the hole depth and wanted advance per round. It is often specified that smooth blasting is to be carried out with a specific drill hole spacing. It is extremely rare, however, for specifications to be issued concerning the alignment of the raw of holes closest to the contour holes. It is very easy to ruin the effect of smooth blasting altogether by firing the rest of the round carelessly with an excessively high charge distribution. The drilling and blasting of the contour holes and the line of holes closest to the contour holes is therefore an extremely important part of any underground work. Accuracy and care in connection with the drilling of contour holes is also extremely important since it is possible to reduce the amount of overbreak, the result being more rapid mucking out, smoother and more durable surfaces and also less consumption of concrete for lining purposes.

Jan 1, 1983

By Michael Drozd

The operation of an activated charcoal system has five separate unit operations. These unit operations have common points for CIP, CIL and CIS system, which vary widely in application. a. Absorption b. Desorption (Stripping) c. Acid Washing d. Reactivation e. Carbon Handling ( carbon transportation, sizing, de­watering, etc.) Cost optimization starts with the basic operating parameters (design philosophy) set down at the time of engineering design. This parameters undergo almost immediate change due to site specific ore requirements, throughput changes, operator requirements or reagent availability. Activated charcoal is sometimes viewed as simple, uncomplicated reagent that requires not optimization. To some extent, this statement is true, but under most circumstances, if the time necessary to optimize the use of activated charcoal is available, the effort is rewarded with significant savings. CPL-Carbon Link has embarked upon a program of supplying technical support with its activated charcoal. Several operation in the United States have under taken to have CPL-Carbon Link do an operational survey to determine if potential savings are possible. CPL-Carbon Link has offered to do these surveys for projects that are clients or simply would like to have CPL-Carbon Link review their operation. The information accumulated by CPL-Carbon Link is being used to attempt to fashion industry standards so that a common reference point came be establish for activated charcoal usage.

Jan 1, 2000

By Gavin A. Hunt

In order for mines to operate profitably throughout their life it is important to monitor and maximise ore recovery. A common problem facing many mines is the underestimation of clay type and its distribution in ore at the mine face, blast hole or in the ore stockpile. Too much clay entering the heap leach ore stream for example causes a dramatic reduction in heap leach efficacy and or increased leaching times. The end result is poor leaching performance and much reduced metal production. Poor clay identification and quantification is attributable to many factors, including costly and slow off-site mineral analysis techniques, such as XRD, XRF and petrology, the visual and subjective limitations of the core logging geologist and a lack of suitable low cost, high throughput mineral logging instruments. To get round these problems a new, non-contact, imaging spectrometer - the SpecCam - was developed by Spectra-Map Ltd, to allow high throughput identification and quantification of minerals from mineable material. Its novel imaging design can collect millions of data points (pixels) per day; each pixel contains spectral information that allows a wide variety of mineral types, including the smectite and illite clays, and phyllosilicates such as talc and kaolin, to be identified. Because all the ore can be imaged a much more reliable mineral log can be made. Hence, mapping changes in mineral composition - related to variations in phenocrysts, macrocrysts, veining or wall rock - is possible. Examples of SpecCam data from Goldfields Cerro Corona Porphyry stockpile and from Rio Tinto?s Argyle Diamond mine illustrate the mineral identification and quantification capabilities of the SpecCam. More importantly, for the first time very accurate % abundances for the different minerals can be obtained using an image-based modal count technique. The modular design of the camera, plus its extremely flexible high speed filter, mean that the SpecCam can be easily installed on different equipment, each one suited to different ore recovery problems. For example the SpecCam can be used on an automated portable logging frame to measure drill core, RC chips, hand samples or powder, or alternatively installed on a Geotek multi-sensor core logger for high-throughput, automated logging of drill or blast hole core using co-registered multi-sensor data. An exciting recent development has been the installation of the SpecCam on CommoDas ore sorting equipment, used around the world for 24 hour mill-feed monitoring and automatic ore sorting. Real-time ore sorting decisions can be made as material is monitored on a conveyor belt running at 3m s-1, from which the ore can be automatically sorted into high-grade, low-grade or waste streams for example. The three installation options for the SpecCam mean that most mineral analysis and automated core logging or ore monitoring needs can be met at the mine. For the first time rapid and automatic mineral identification and accurate quantification can be made. All of which allow the mine geologist or metallurgist to make important decisions about maximising the metal recovery process.

May 1, 2007

By C. Milne, T. M. Dyhr, T. E. Wilson

As time progresses, new concerns regarding long-term post-mining effects are identified, increasing mine closure costs. Regulators responding to public interest must take a “worst case” view and require post-closure monitoring or remediation processes. Although closure costs depend on the size and type of operation, general cost categories are defined, and median values (per acre, or per unit of production) are identified. Closure cost categories, as well as amounts, have increased with time. Except for increased efficiency in earth-moving and water management (surface or subsurface), there are no apparent offsets to a steady rise in closure costs. When the historical trend of closure costs is considered, it is probable that additional cost categories will come into being. For mine operators, the challenge will be to anticipate them and devise cost-effective remedies.

Jan 1, 2003

By T. M. Dyhr, T. E. Wilson

Although environmental management costs during mine operation depend on the size, type, climatic and geochemical conditions of operation, general cost categories are identified and mean values, as a percentage of total operating cost, are determined for coal and non-coal surface and underground mines (medium-size) with on-site beneficiation and tailings disposal facilities. Cost trends are charted from 1963 through the present.

Jan 1, 2004

By Joseph A. Dos Santos

"The subject of this writing was first published in 1998 with the emphasis on the hardware cost comparison. Other costs, such as the required land area and spatial volume, were mentioned but not emphasized, as these were not deemed as important for new projects where the space was appropriated as required. During the last decade, these other costs have proven to be more than equal in importance. These costs are emphasized here through specific accounts of actual highangle conveyor installations that demonstrate the importance and the high-angle advantage An update on the progress in sandwich belt highangleconveyor technology is also provided.Origin and progress in sandwich belt conveyorsCover belts of the 1950s. Large volume, highangle conveying by “conveyors with cover belt, dates back to the early 1950s, when such systems were employed at the bucket wheel excavator boom conveyor in German lignite mines to increase the depth of cut without increasing the boom length. Various systems were developed, patented and built. These systems were not a lasting success for various reasons, which are noted by Rasper[1]. In his 1958 “Review of Cover Belt Systems,” Rasper summarizes the characteristics which are worth pursing and those that should be abandoned. The former are akin to good conveyor engineering. The sandwich belt conveyor model. The first sandwich belt conveyor model allowed calculation of the required hugging pressure to develop the bulk material’s internal friction and preclude material slideback. A modern, accurate version of the sandwich belt conveyor model is presented in Fig. 1. This model depicts accurately a derating of the material cross-section allowing an ample belt edge distance that can tolerate normal belt misalignment without material spillage. The calculations must thus recognize that only part of the hugging pressure is imparted onto the material with the remainder transferred belt edge to belt edge affecting a material seal. Mathematical development of the sandwich belt model is covered by Dos Santos and Frizzell in their 1983 article, “Evolution of Sandwich Belt High Angle Conveyors.”"

Sep 1, 2016

By Thomas H. Sheldon

IN the zeal for opening up new ore-bodies, or for. extracting the ore from attractive bodies gal ready opened up, we very often lose sight of the fact, that, after all, the operation of a mine is a business proposition, pure and simple; and for the best working-results should be treated upon a strict business basis. Of course, in every mine of consequence a record is kept of expenditures and receipts, and such glittering generalities as "gross receipts," " net receipts," " mining expenses," .and " per cent. profit," can be told to the cent; but does this . record show economy of management, either as compared with the same record of other months, or as compared to the record of other mines of the' same class ? Moreover, if such a record shows that the cost of mining is high, does it in any way en¬able the manager to put his finger on the leakage? Does it necessarily follow that a mine which makes a profit of, say, 40 per cent on 25-dollar ore, is doing less economical mining than one which saves 60 per cent on 80-dollar ore ? Of course the figures in the latter case look the more attractive, but when it comes to a point of saving everything which can be saved, and of cutting down expenses to the lowest possible cost of operation, the former mine is doubtless on the most firm and economical financial basis. But as the relative merits of the system of mining in the two cases, nothing could be decided without a basis of detailed comparison ; if one system is more economical than the other, why is it so, and wherein does the advantage lie ? This can be shown only by keeping accurately the cost of each mining operation. And no matter how dissimilar two mines may be in character and operation, yet there are a few general heads common to all mining operations. In the first place, it is necessary to break the ore from the solid ground ;

Nov 1, 1905

By Suresh K. Bhatt

A mathematically simulated modeling technique is used in this U.S. Bureau of Mines paper to represent a hypothetical mining operation with existing mining technology and prevalent mining costs. Mining scenarios are prepared and evaluated for potential benefits and costs available through computer-assisted mining. Base criteria, parameters, and methodology are described.

Jan 1, 1991

Quantitative probabilistic ecological risk assessment has been used to evaluate the likely effect on fish diversity and abundance of filtered and bioavailable metals in streamwater affected by acid drainage from the abandoned and remediated Rum Jungle U/Cu mine in the Northern Territory of Australia. The water quality was determined using monitoring data from a gauging station on the East Branch of the Finniss River, downstream of the mine site, and modelled assuming a number of potential water quality management options. The management options ranged from no action, through some flushing options to full catch and treatment of contaminated seepage from the waste rock heaps. The computer code AQUARISK was used to undertake the analyses. Critical criteria for contaminant water concentrations at the site, derived from probability density functions of available fish ecotoxicology data, were found to closely approximate the regulatory trigger values for the contaminants of concern. Modelled predictions of reduced diversity and abundance were also in good agreement with in situ biodiversity measures. Based on a reasonable target of 67 per cent species tolerance for this heavy impacted site, it was found that none of the low cost options for wastewater management was acceptable. Combinations of two of the options approached acceptability. Both of the catch and treat options exceeded the arbitrary acceptability target well. This implied that the more expensive option of liming to pH 10 might be unnecessary at this site. Thus, the use of ecological risk assessment modelling has proven useful in undertaking cost-benefit analyses for this site. The approach provides a management decision-making tool that can be economically used to link expensive on-site environmental engineering options with site-specific ecological goals rather than the previous nebulous aims of æreduced contaminant loadÆ or æimproved biodiversityÆ that often resulted in excessive expenditure without achieving successful environmental benefit.

Jan 1, 2003

By Felipe P. D. Lopes, Jr. dos Santos, Sergio N. Monteiro, Frederico M. Margem

"Natural fibers are gaining attention as a class of low cost, biodegradable and renewable materials that also exhibit some interesting properties for specific applications. In particular, the incorporation of some natural fibers in polymeric matrix composites is nowadays providing opportunity of manufacturing a variety of industrial items, for instance automobile interior components. Among these fibers, ramie (Boehmeria nivea) is one of the least investigated and only recently was studied as polymeric composite reinforcement. Therefore, the objective of this work was to evaluate the possibility of ramie waste reinforced polyester composites to replace conventional building materials, such as plywood, plastic boards and gypsum panels in terms of a cost-benefit analysis.IntroductionThere is a growing concern over the environmental questions that are presently affecting our society in a global sale such as climate changes and generalized pollution. Among the solutions for these questions, the replacement of energy intensive materials, especially those long term degradable such as the synthetic fibers, is already being considered [1]. As a consequence, the past decades have witnessed an increase in research devoted to new biodegradable materials obtained from natural resources mainly the biomass. Important examples are the renewable natural fibers as well as composites incorporated with them [2,3]. In addition to their friendly status with respect to the environment, well know natural fibers like jute, sisal, wood, coir, hemp and flax are relatively low cost and recyclable. In recent works [4,5], the use of these cultivated and abundant lignocellulosic fibers was investigated as the reinforcement phase in polymeric composites.Other less know lignocellulosic fibers have also been recently investigated [6,7]. These are fibers that likewise show a potential of incorporation into the polymeric matrix of composite materials. Most of these less know fibers are typical of tropical regions and, in principle, their application in industrialized composites would represent job opportunities for developing countries in Africa, South Asia and Latin America."

Jan 1, 2008

The National Economic Viewpoint? Any substantial project undertaken by private enterprise would normally be subjected to a Discounted Cash Flow analysis of its commercial viability, and would proceed only if the rate of return was judged satisfactory. A 'national viewpoint' analysis attempts to do the same but from the viewpoint of the community as a whole. The objective is to ensure that those projects are undertaken which yield the best return, economic and social, to the nation as a whole.

Jan 1, 1984

Urban railway systems need high invest- ments, especially if their routes and stations have to be placed in the subsurface. In the FRG the construction and equipment cost of urban underground railway systems are in the range of 60 to 100 Mill DM per km tunnel. For this reason, track sections on the surface and on elevated structures are used as far as that is possible. Considering whole systems, the costs are in a range from to 45 Mill DM per km length for a metro system with about 80 % of its tracks and stations in tunnels and from 20 to 25 Mill DM per km for a light railway system with about 25 % subsurface infra= structure. The amount of route lengths in tunnels depends on the size of a city, the situation regarding above ground structure and free space on the surface, the level of service quality which has to be achieved with the railway system etc. Despite of the urgent needs to improve the transport conditions there very often arise doubts if an urban railway system is really necessary and can be justified in an economic sense. The experience from many cities around the world shows, that there arise a lot of benefits from urban railway systems, especially with larger sections placed under- ground. They are to be found in the interests of the operator (f.e. operating costs), the user (travel time, quality of service etc.) and regarding social aspects (environmental protection, accidents, consumption of energy Etc.).

Jan 1, 1987

By Goutam H. Shahani

Today, the mining and mineral sectors are being impacted by highly fluctuating supply ? demand, extreme price volatility and tremendous market uncertainty on a world-wide basis. This pattern is expected to continue for the foreseeable future. In particular, large consumers of tonnage quantities of industrial gases (oxygen, nitrogen) all have to make informed investment decisions in this uncertain economic environment. Plant owners ? operators need to carefully examine their current and future industrial gas needs in order to develop the most cost-effective industrial gas plant configuration. This can be done by partnering with an experienced engineering company that offers a complete technology portfolio for producing industrial gases. Ideally, the mineral and engineering companies have to work together as a single team to identify the most efficient and economic plant design. This includes an in-depth assessment of capital and operating costs, in order to deliver an optimal solution, taking plant reliability and process safety into account. It is important to consider all the industrial gas needs at a given manufacturing complex, in conjunction with available utilities and infrastructure to develop the best possible long term solution. Oxygen (O2) requirements include: oxygen enriched and oxy-fuel combustion, smelting and hydrometallurgical operations. Nitrogen (N2) is used for annealing. All of these industrial gas requirements have to be examined at a given site over a long term horizon in a holistic manner. Cryogenic air separation was first practiced at a commercial scale in 1902. Since then, the technology has been constantly refined to reduce cost; and improve reliability and flexibility. Today, using advanced engineering techniques, including proprietary process simulation, and modern fabrication techniques, it is possible to build air separation plants that are both low cost and high quality at the same time. It is important to work with an engineering company that owns a complete portfolio of industrial gas technologies, functional engineering capabilities and a variety of plant solutions. Such a partnership can quickly identify a ?sweet spot? for a given situation. By drawing on experience gained from hundreds of projects, it is possible to quickly optimize a given requirement. In situations where a customer wants a complete solution it may be appropriate to provide an air separation plant on a turn-key basis. This will enable the mining and mineral processor to focus on their core business. By using global procurement and construction capabilities it is possible reduce cost and improve project execution, thereby making industrial gas plant procurement simpler and cheaper for the mining and mineral sector.

Nov 1, 2011

By Goutam H. Shahani

The current economic downturn has been at the center of media attention for several years. Today, the mining and mineral sectors are being impacted by highly fluctuating supply-and-demand conditions, extreme price volatility and tremendous market uncertainty on a world-wide basis. There have been numerous plant closings, project cancellations and employee layoffs. In this gloomy economic environment, it is easy to forget that the world?s gross domestic product (GDP) has more than doubled in real terms during the last 30 years. While current market turbulence may continue for some time, the long-term trend is unmistakably upward. Living standards are rising all over the world, thereby creating demand for food, clothing, transportation and housing. This translates into tremendous demand for the mining and mineral sectors. In the future, new capacity and plant expansions will be necessary to meet this need. These investments, which typically have a life span of 30-plus years, will have to be based on long-term economic considerations rather than current market conditions.

Jan 1, 2011

By R Norris, M Dunne

Mining and mineral processing is expected by society and obliged by law to operate in an environmentally friendly fashion, minimising the impact on and avoiding damage to the environment. Substantial efforts by the industry, as well as by process and equipment designers have resulted in many innovative developments, which show that operating in an environmentally responsible manner can be achieved in a cost-effective way. This paper showcases five emerging equipment best practices in industry including installation examples. Flip-flow screening machines are proven worldwide in the dry classification of coal and other minerals, reducing the size of beneficiation plants whilst reducing energy, water demand and media consumption. They also allow the screening of wet/sticky materials not able to be sized using conventional screens. The belt press filter is a small fraction of the operating and capital cost of alternative dry tailings technologies. This gives operators who must dry their tailings a competitive advantage and makes such ægreenÆ operations much more sustainable. The filtercake is disposed with other plant rejects, eliminating the need for tailings dams to be constructed and thus also often increasing mine reserves. Mining applications include coal tailings, sand tailings, sinter plant waste and power station fly ash. Screen-scroll and vibrating centrifuges are widely used in the coal, potash and salt industries to dewater the product to low surface moistures. Inclined plate Lamella separators are used for toxic water clarification and/or sludge thickening in many downstream metal industries with the underflow often dewatered in a belt filter press. Such low cost, high capacity thickeners could also be used instead of conventional thickeners at smaller mines. The simple and reliable continuous washing upward flow (CWUF) sand filters have been used for treatment of waste water from coal preparation plants and steel works as well as in the worldwide production of potable water. The filtered waste water from mining processes can then either be reused or discharged from site. Other installations include cleaning mine water to prevent the blocking of dust suppression spray nozzles.

Jan 1, 2006

By Bill Morgan

This paper discusses the economic zones of application for several different types of earthmoving equipment: dozers, wheel loaders in load-and-carry applications, wheel tractor scrapers, articulated trucks, rigid-frame trucks and wagons. Only the medium to large pieces of equipment were considered. From this chart (Figure 1), you can see the size range, in tons of carrying capacity, of Caterpillar equipment and the specific models analyzed.

Jan 1, 1994

By Rachel De Lucas

Current methods of hydrogen storage are an impediment to the transition of our energy infrastructure from a hydrocarbon to a hydrogen base. The transportation, handling, and storage costs of hydrogen gas account for a majority of its selling price. Magnesium hydride slurry is a safe, environmentally friendly alternative for hydrogen storage. If this form of storage is to be adopted on a large scale, a cost-effective method for recycling the enormous amounts of magnesium hydroxide byproduct must be identified. The solid oxide membrane (SOM) process can be used to recycle the magnesium hydroxide byproduct into magnesium metal, which can be reformed into magnesium hydride and reused for fuel storage. Conventional magnesium extraction/recycling technologies require a great deal of energy and create byproducts that are harmful to the environment and human health. The SOM process poses none of these detrimental effects and requires less energy and feed preparation. The economic viability of a facility that utilizes the solid oxide membrane process for the direct reduction of magnesium must be examined in more detail if industry is to consider it. Cost analysis data related to the commercial viability of a scale-up will be compared to two standard industrial processes: current magnesium production techniques including electrolytic and metallo-thermic processes. We have shown in our cost comparison that the SOM process is cheaper than these traditional techniques and that it is also comparable to aluminum's Hall-Héroult process in cost but with none of the environmentally harmful byproducts.

Jan 1, 2006