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By C. Feng, W. Song, B. Moudgil, P. Zhang, W. Xiao

Separation of dolomite from phosphate is the most challenging problem in phosphate mineral processing. Over 50% of the future phosphate reserves in Florida contains too much dolomite to process using the current industry practice. The FIPR Institute has collaborated with worldwide experts in the field to address this issue. As a result, the industry is now offered with three feasible options. Optional 1 involves crushing and grinding of high-dolomite phosphate pebbles followed by dolomite flotation at slightly acidic pH using a new collector that does not require phosphoric acid as a phosphate depressant, achieving a final concentrate analyzing less than 0.9% MgO at about 87% P2O5 recovery. Option 2 offers three methods for reducing MgO content in the concentrate from the Crago process, including adding a dolomite depressant in the rougher flotation step, dolomite flotation of the cleaner concentrate, and scrubbing the cleaner concentrate in quartz sand. These methods could reduce MgO content in the final concentrate by 20-40%. Option 3 is a gravity separation technique using an innovative separation jig, and may well be the ultimate solution to the problem. INTRODUCTION Magnitude of the Dolomite Problem With the depletion of the higher grade, easy-to-process Bone Valley deposits, the central Florida phosphate industry has moved into the lower grade, more contaminated ore bodies from the Southern Extension. The phosphate deposits in the Southern Extension may be divided into two zones: an upper zone and a lower zone. The upper zone is readily processable using the current technology, but the lower zone is highly contaminated by dolomite. Geological and mineralogical statistics (Hassan and Bogan, 1994) show (Table 1) that more than 50% of the phosphate resource would be wasted if the lower zone is bypassed in mining, and about 13% of the resource would be wasted if the dolomitic pebbles in the lower zone were discarded.

Jan 1, 2019

By Jaana Romppanen, Satu Jyrkönen, Tiina Ranki, Peter Björklund, Markku Lahtinen, Kaj Eklund, Päivi Suikkanen

Outotec is continuously developing our existing process equipment and new equipment solutions to enhance the Flash Smelting process. Thanks to the long operating history of the Outotec Flash Smelting process feedback from the numerous operating references are available and is utilized. The general goals for development work are to improve equipment performance, thus realizing savings in Smelter plant operation costs by increasing the process efficiency and online availability. Digitalization also opens new possibilities for the feeding equipment and furnace operation monitoring. These solutions will improve the safety and performance of the smelter, and provide process and equipment related information which has not been available earlier. INTRODUCTION The year 2019 marks the 70th anniversary of Flash Smelting. The technology was operated on industrial scale for the first time at the Outokumpu Harjavalta copper smelter in Finland in 1949. The Flash Smelting technology, is now owned and developed by Outotec Oyj and the first plant, is now owned by Boliden Harjavalta Oy. The two companies have been evolving throughout history by optimizing the process for various feeds and raw-materials, as well as through developing the equipment and operating practices. Even though sustainability was not a hot theme/topic during the first days of Flash Smelting, it has nevertheless been the key principle in guiding the development. This is well proven by the wide adoption of Flash Smelting for the processing of copper and nickel concentrates, mostly due to its ability to fulfil the economic and resource efficiency criteria demanded by its operators. Along with the process technology development, also development of the equipment has taken place over time. Outotec is continuously working on developing our equipment to better suit the changing need of our customers in the continuously changing operational environment. Orebodies are getting more challenging with lower ore grades and more impurities. Achieving high recoveries for all valuable elements becomes more difficult with high slag quantities and with the need to tackle the high impurity concentrations. There is a need for higher capacities in greenfield and brownfield smelters. The role of the Loss-in-Weight Feeder, the Air Slide and Concentrate Burner is to ensure even feed into the reaction shaft of the Flash Smelting Furnace, and to enable controlling the process well, thereby enabling the best performance for the customers smelter. The design of the Flash Smelting Furnace aims for high availability, long campaign and safe operation.

Jan 1, 2019

By M. G. Beukes

"In South Africa most of the large gold mines operate between 1500m and 4500m below surface where reef is accessed initially through a vertical shaft system then via a network of tunnels and mined in either a longwall, sequential grid or scattered mining configuration. Due to the complexity of the ventilation networks used to ventilate these mines and the potential disastrous consequences associated with underground fires, it is of utmost importance that these mines are managed in such a way that underground fires are prevented. However, if they do occur the fires are managed to firstly prevent the loss of life and secondly protect the infrastructure and viability of the mine. The aim of this paper will be to: • Discuss current SA mining legislation regarding underground fire prevention and control. • Examine these fires from a risk management perspective by means of a bowtie assessment. • List and discuss the major Threats and Consequences as determined by the bowtie assessment. • Discuss the various prevention and consequence controls for deep level underground fires. • Examine how to effectively run an emergency control room. From this, a practical way of designing, implementing and managing an underground fire management system is explored. Lastly, the paper identifies new technology and ways of thinking and how these can be used to combat underground fires. INTRODUCTION The orebodies of South African gold mines are generally narrow tabular structures that vary in thickness between 0.8m and 1.2m with an inclination of between 200 and 700. This, coupled with depths of between 1500m and 4500m, as well as the unpredictable geology, creates unique challenges and significantly impacts on mine designs and mining methods. In general, gold bearing reefs are accessed initially through a vertical shaft system then via a network of tunnels and mined in either a longwall, sequential grid or scattered mining configuration (Figure 1). Mining is very labour intensive with very limited mechanisation opportunities and this increases the risk to human life if an underground fire occurs. On 16 September 1986, one of the worst mining disasters in SA mining history took place when 177 mineworkers were killed at Kinross Mine. An acetylene tank sparked flames that swept through the mining tunnel igniting plastic covering on the wiring and the flames also set fire to polyurethane foam. The burning plastic combined with polyurethane and the toxic fumes that filled the shafts caused the miners death. This incident was a stark reminder of the serious consequence that underground fires can have on human life as well as the crippling financial and asset impact for the mining companies. Over the past thirty years, the SA mining industry reduced the number of mine fires significantly by replacing normal timber support with fire retardant treated timber, alternative support systems such as backfill and elongate support and many other fire prevention initiatives. Although the number of fire incidents and number of fatalities due to fires does not show a direct correlation because of various factors, the controls put in place against fires has had an impact on the number of fire and explosion fatalities (Figure 2)."

Jan 1, 2019

By C. Opoku-Ware, M. Kukay, P. Conrad, F. Inkoom, R. Pal

Researchers at Montana Tech are investigating the potential for developing trees tolerable to degraded un-reclaimed mine site tailings and soils as a solution to re-establishing long-term tree growth on those sites. This project involves growing tree seedlings from seeds planted in the degraded mine tailings and soils in which they will eventually be planted. The outcome of the project is expected to lead to a successful solution for re-establishing tree growth in degraded tailings and soils in Butte, Montana with minimal post-planting human intervention. Work conducted on the project to date has shown successful growth of seedlings in degraded tailings and soils. INTRODUCTION In an effort to improve Butte Area One natural resources, this research project is working to help restore tree growth in the Butte Priority Soils Operable Unit Boundary (BPSOU) (Opoku-Ware, et al 2018). Research by Blicker, et al (2003) found that, the BPSOU, which is part of the Silver Bow Creek/Butte Area National Priorities List (Superfund) Site within and near Butte, Montana has multiple historic mining sites situated entirely within the urban setting of Butte. Mine wastes and mill tailings, accumulated from over 100 years of gold, silver, and especially copper mining are dispersed throughout Butte, posing health risks to human and environmental receptors. Stabilization of tailings sites is needed to control fugitive dust, prevent run-off of toxic material resulting in subsequent sediment deposition in streams, reducing the volume of water seepage through acidic and heavy metal contaminated material, and improving land productivity and aesthetic values (Watkin and Watkin, 1982). If successful, the project will help restore water quality and maintain stream flow in Silver Bow Creek where it flows through Butte Area One. Trees native to Butte are being grown to seedlings in a greenhouse located on Montana Tech’s campus which will be planted in degraded soils located within the BPSOU. Growing trees is expected to help restore vegetative ground cover within the watershed contributing to stream flow in Silver Bow Creek. The trees will prevent soil and tailings from eroding and being deposited in Silver Bow Creek where they could degrade water quality and choke stream flow. The project combines research with tree seedling growth to provide a resource for Butte that could produce thousands of tree seedlings each year adapted to the harsh climate, soil, and tailings conditions that exist in the BPSOU where they will grow. It is anticipated that the trees developed by the project will have the capability for long-term survival and growth because they will be germinated and grown into seedlings in the degraded soils and tailings collected from the BPSOU where they will be planted. Soils and tailings collected for the project have been evaluated to determine if they lack nutrients or contain substances potentially toxic to the long-term growth and survival of the trees. Toxic levels of metals, high concentrations of soluble salts, extremes in pH, nutrient deficiencies and imbalances, surface crusting, high bulk density, low infiltration rates, high surface temperatures, low cation exchange capacity, restricted microbial activity, low water retention, harsh climatic conditions and surface particle movement are some of the traits of mine tailings sites that restrict revegetation efforts (Barth, 1986).

Jan 1, 2019

By Arsenio Enriquez, Adrian Deneys, Ryan Walton, Jenny Esker

NOx emissions at the Rio-Tinto Kennecott Copper (RTKC) smelter, near Salt Lake City, Utah, are regulated to a compliance emission limit at the Main Stack of 15.9 kg/hr on an annual rolling average. The paper discusses RTKC efforts and improvements, particularly related to the anode furnace operations, since the Smelter modernization in 1995 to comply with the air quality approval limit. This includes replacement of gaseous ammonia to Steam-Gas Refining (SGR) system during the copper reduction stage, upgrade anode furnace oxygen-fuel burner from Praxair’s Stabilized Jet (S-J) to Jet Lance (J-L) technology, development and implementation of operational best practices and continuing to investigate and evaluate NOx control technology and strategy in the industry. In early 2016, changes to Praxair J-L Burner technology on both anode furnaces, utilizing wider lance spacing, was adopted and further improved NOx emission levels well below the compliance limit. INTRODUCTION Since the establishment of the Clear Air Act in 1970, the Environmental Protection Agency (EPA) has been regulating emissions of nitrogen oxides (NOx) to reduce impact on public health and the environment (USEPA, CAA, USEPA, NAAQS). As a requirement of the Clean Air Act, the EPA evaluates the standards for NOx and criteria pollutants on a periodic basis and as a result, standards have been revised and ultimately reduced over time (USEPA, CAA, USEPA, NAAQS, UDAQ, SIP). To remain competitive with changing regulations and in conjunction with Rio Tinto environmental standards for continuous improvement, the RTKC smelter has been motivated to research and implement NOx control strategies. NOx health and environment impacts NOx refers to a group of seven compounds including the most common, nitrogen dioxide (NO2). (USEPA, NO2). The EPA enforces both short-term (1-hr average) and long-term (annual average) standards for NO2 to protect against associated respiratory system impacts. Short-term exposure of elevated NO2 concentrations can aggravate respiratory diseases and lead to symptoms such as coughing, wheezing or difficulty breathing while longer exposures may contribute to the development of asthma and potentially increase susceptibility to respiratory infections. (USEPA, NO2) Additionally, NOx is necessary in the formation of ozone and particulate matter less than 2.5 microns (PM2.5). Ozone concentrations can negatively impact lung function and in some cases, contribute to chronic obstructive pulmonary disease. (USEPA, Ozone) The particles associated with PM2.5 can reduce lung capacity and aggravate heart conditions. (USEPA, PM2.5) For all NOx related pollutants, children and the elderly are generally at greater risk for the health effects. (USEPA, NO2, USEPA, Ozone, USEPA, PM2.5)

Jan 1, 2019

By G. E. Sreedhar, R. Kumar

The pockets of high silica blue dust across the entire high grade hematite deposits in the Bailadila sector bothers the excavation activity due their iron content, which is higher than the threshold value specified by the Indian Bureau of Mines and the agony of stacking them separately due to their fragile & powdery nature. The physical nature of blue dust and its negligible alumina content makes these a potential source of hematite, which is a blessing in disguise. As most of the particles are in the form of an independent grain making it appropriately suitable feed for dry magnetic separation and thus the dry beneficiation has turned a bane into boon by enabling to produce concentrate either suitable for using as DSO or amenable for blending. The emphasis on carrying out dry beneficiation studies in the present context serves the purpose of mineral conservation, mitigates the issues of excavation and stacking as well as conservation of water resource. This paper describes the laboratory and pilot scale dry beneficiation studies carried out on blue dust of 48 – 60%Fe and Silica up to 30% at 25 Kg/hour to 400 Kg/hour, resulting in production of concentrate assaying 60 – 65%Fe. INTRODUCTION High silica blue dust (HSBD) is associated with Banded Hematite Quartzite (BHQ) and is available in abundance in various pockets across the Iron ore body in the Bailadila region of Chhattisgarh state. High Silica Blue dust occurs in the form of free granular particles and also as friable lumps. The chemical quality of this falls under sub-grade category (45 – 55%Fe) and as per the guidelines of Indian Bureau of Mines, these are to be stacked and conserved as future resources of Iron if it can’t be utilized in the present circumstances. Due to its friable nature, stacking of HSBD is a challenge and it is also compounding the problem by polluting the air under high velocity wind conditions. Because of its physical nature and occurrence in pockets pose challenge to systematic mining. The existing processing set up of the operating mines is designed to treat either Direct Shipping ore (DSO) or Run-of-Mine (ROM) have grade >60% Fe. The present practice of beneficiating iron ore fines (<1 mm) comprise combination of two or more processes such as desliming, hydraulic classification, magnetic separation and flotation apart from requirement of grinding depending on liberation characteristics. The HSBD which is predominantly occur as free granular particles, is significantly low in its alumina content. This gives us an opportunity to utilize them by exploring a suitable beneficiation process so that the concentrate produced can be used as a sweetener for alumina rich iron ore/concentrate. Thus, in the present study, an attempt has been made to adopt dry high intensity magnetic separation technique to explore the amenability of the high silica blue dust for beneficiation.

Jan 1, 2019

By Marko Lampi, Ross Andrews, Jouni Pihlasalo, Robert Matusewicz

With widespread discussion on reducing carbon, sulphur and other emissions, use of sustainable energy sources and the pivotal circular economy theme, consideration needs to be given to pyrometallurgical operations broadly and more specifically, non-ferrous metallurgy. These themes present a number of challenges in terms of current operations and the view of processing the metals which are largely taken for granted in day to day living. This paper considers how these themes will impact pyrometallurgical flowsheets using the non-ferrous base metals as an example. It will examine the flowsheet chain to offer views on the boundaries of flowsheet optimization and the application of available tools to meet these future goals and challenges. INTRODUCTION The themes of reducing footprint through lowered CO2, S and other emissions, together with process sustainability (e.g. lowered energy) and links to the circular economy are well known to everyone in the metals industries. Whether it is reducing greenhouse gas emissions or analysing the importance of metals recycling in the circular economy, all these themes carry with them the fundamental premise of any change being considered; how can you best optimize a system to meet your aims? Of course, this depends on the available tools and the approach used for optimisation.

Jan 1, 2019

By J. Kretschmann

According to the model of product life cycles, the global coal mining industry is in the stagnation phase. The coal demand of the main consumer, China, has peaked in 2013 and is slowly declining. The Norwegian sovereign wealth fund, the world´s largest, has excluded coal-related companies for ethical reasons. Important players like the UN or the EU have already begun to describe pathways towards de-carbonization. Increasing competition between coal mining companies and the mining regions can be expected worldwide if companies want to keep their positions on the global and national coal markets. Companies will focus on the best deposits. European countries like France, Spain or Germany are only forerunners of this development - their centuries of coal production have been finished. The concept of Sustainable Development (SD) is fundamentally based on a model of progress where ecological, economic and social dimensions should be developed equally and positively. But without the idea of competition, the concept of SD is incomplete. Questions arise, such as: How can SD be realized on stagnating or declining markets without guarantees for companies “to live forever”? How can SD be a corporate goal in a phase of decline? How can declining mining regions sustainably progress into a better future? The German hard coal mining industry´s lifecycle has ended in 2018 after 60 years of stagnation and decline. As of 2019, all hard coal consumed in Germany will be imported, especially from Colombia, Russia and South Africa. What has been done in Germany to handle the coal decline in a sustainable way and the lessons learned from this process is described in this paper. It may be useful for mining regions who will face a similar future sooner or later. INTRODUCTION Principally, mining natural resources is a finite business that reaches its limits once the deposits mined are depleted, the resources can no longer be mined in an economically profitable way, or substitutes are pushing the mined products out of the market. An example for the latter is the increasing replacement of coal with natural gas and renewables in power generation in the USA. (Kok 2017) According to the model of the product lifecycle, the global mining hard coal mining industry has reached the stagnation phase. (Kretschmann 2000) Although the coal mining business is more a multi-regional than a global business the trend is obvious. The peak of coal use is behind us, especially because the coal demand of China is slowly decreasing since 2013. (Shell 2018) China´s government has announced investing $360 billion in renewable energy by 2020 and scrap plans to build 85 coal-fired power plants. In March 2018, Chinese authorities reported that the country was already exceeding official targets for energy efficiency, carbon intensity, and the share of clean energy sources. China’s energy regulator, the National Energy Administration, rolled out new measures to reduce the country’s dependence on coal. (Kejun and Woetzel 2017) Coal consumption in the US is facing a 16 % decline in five years from 800 to 670 million short tons between 2015 and 2019 and - according to the EIA – will not rise again. (EIA 2018) The decline is attributed to complex market dynamics from low gas prices because of the “shale gas revolution” (Kok 2017, p. 3) to federal environmental regulation like the Clean Power Plan. The United Nations´ UNEP Finance Initiative is cooperating with the Portfolio Decarbonization Coalition of institutional investors to implement decarbonization strategies across their portfolio. Amongst these investors is the New York State Common Retirement Fund, the third largest public pension plan in the USA. (UNEP 2017) The European Union has already begun to de-scribe pathways to decarbonization. (European Union 2018) The Norwegian sovereign wealth fund, the world´s largest, excluded coal-related companies for ethical reasons. The oil giants Total S.A. and Royal Dutch Shell, tradi

Jan 1, 2019

By M. Woodie

INTRODUCTION Information such as application review to choose the proper style of vibrating screen, parameters that determine the proper size of vibrating screen, engineering design information that governors proper screen design, review of topics that govern proper isolation from structural steel and other topics that dictate proper screen selection for applications will be presented in this paper. Topics like process and application information review to choose the style of screen and how material size and type influences proper type of screen selection (multi-slope, incline, horizontal, linear incline or dewatering) will also be discussed. Parameters will be reviewed that help size the screen for the application. The total amount of surface area to size a screen is critical to the overall success of a screen installation. Once proper style of screen is determined there is an engineering process that is required to design the screen to operate correctly in the environment it will be used. Finite Element Analysis, Dynamic Modeling, Field Vibration Analysis and other engineering tools will be reviewed to best implement a successful vibrating screen installation. TYPES OF SCREENS Multi-Slope Multi-Slope vibrating screens are used where sizing large amounts of tonnage on surface areas that would be smaller than conventional screening where roughly 6” (150mm) minus material is required to be sized. Occasionally larger particle sizes can be screened on the Multi-Slope machine but the effectiveness of the machine can be diminished with larger particle sizes and larger than 4” (100mm) screen opening. The most common and effective size range of screening with these machines is 2” (50mm) minus material. The Multi-Slope screen is used where particle size is not extremely important. Mineral processing, hard rock mining and industries where exact material size is not critical are best suited for this equipment. Because the aggregates industry requires very specific material sizes, the Multi-Slope screen is not suited for most aggregate screen applications. The key to the success of a Multi-Slope screen is proper material presentation at the feed end of the screen. This allows for the material to stratify quickly and disperse the fines through the screen quickly with a relatively thin bed depth at the feed end which allows the undersize material through the screen quickly.

Jan 1, 2019

By C. Rodriguez, T. BoBo

Comminution, being the energy intensive part of a mining operation receives much scrutiny by cost controllers, CEO’s, investors and others as the mining industry goes “back to basics” to reverse the decline in productivity which occurred during the mining super cycle. Blasting is the first and lowest cost per ton stage in the comminution value chain. The basic principle that effective blast design can optimize fragmentation from the Run of Mine (ROM) ore muck pile to improve productivity through digging, loading and crushing to grinding and increase mine site profits has been well documented. Benefits of controlling fragmentation in the blast include reduced wear on equipment, faster loading, increased truck loads while detecting oversize rocks at the muck pile can reduce the frequency of a blocked primary crusher. A second basic principle is a measure of particle size distribution (PSD) at each unit operation in the comminution cycle allows engineers to manage blast design to produce fragmentation in the ROM ore most suitable to optimize downstream unit processes to improve mine site productivity and profits. Split-Online® systems have measured PSD of rocks on conveyors from the primary crusher to the SAG mill for over 20 years. Split-Engineering partnered with various mining companies to develop Split-ShovelCam® to automatically measure fragmentation from shovels and excavators working the ROM muck pile. This paper takes the reader “Back to Basics” by discussing the use of real time fragmentation analysis at the muck pile as an important parameter to optimize energy factors required for each blast. Case studies are given. INTRODUCTION The basics of mining are: • Explore for and find economic resources of valuable minerals • Mine rocks containing valuable minerals using blasting • Crush and grind rocks to liberate valuable minerals (comminution) • Recover valuable minerals for sale Comminution is an energy intensive process which accounts for a major proportion of mine site costs. Effective blasting can improve comminution and deliver significant reductions to mine site unit costs, (CEEC, 2016). Engineers, scientists, builders and even philosophers have long promoted the phrase “measure to manage”; the premise being “you can’t improve what you don’t measure”. Blast Engineers measure fragmentation in ROM ore for feedback to manage energy input in the design of blast patterns to optimize the ROM product size for downstream operations, whether they be for ROM Leach or feed into the primary crusher.

Jan 1, 2019

By Euler De Souza, Kyle Penner

"Booster fans play an important role in assisting main fans by boosting the air pressure of the ventilation air passing through it. The correct placement of underground booster fans in a mine is a critical decision since it not only influences the mine’s operational capacity in terms of costs and efficiency, but also affects safety and environmental conditions. There are many booster fan installations around mines that are inappropriate, in some cases resulting in system failure (fan stall) or in a major negative impact on mine production. Inadequate booster fan placement has resulted, in some cases, in extensive air leakage which has compromised the economics of the operation and, in other cases, in recirculation of contaminants which has seriously compromised safety. This paper provides guidelines for proper design and siting of booster fans underground, to not only achieve an economic ventilation system but to create safe work conditions and efficient atmospheric conditions. Procedures for the planning, installation, operation and maintenance of booster fans are also presented. A case study illustrating the design and siting of a major booster fan installation in a potash mine, supported by computational fluid dynamics analysis, is presented.INTRODUCTIONIn large underground operations with complex ventilation networks offering high resistances, the never ending increased required quantities of air can almost only be supplied through use of high pressure main fan systems. These fans may, in effect, induce significant leakage losses in the system, having a negative impact on safety performance. In such cases, booster fans can be designed to decrease the main fan pressures and reduce the leakage flows, improve system efficiency and reduce costs. In well designed systems, booster fans can thus be used to redistribute the airflow and assist the main surface fans.When the pressure supplied by the main fans is insufficient to meet the ventilation circuit pressure requirements, booster fans are placed in strategic locations where pressure boosting is essential. Booster fans are typically sited in sections of the circuit offering high ventilation resistance and requiring this form of ventilating air motivation. Booster fans are thus required when the mine expands, and so the resistance of the ventilation network, and the primary fans no longer can supply the required pressure and flow."

Jan 1, 2019

By J. Holtzhausen

"An analysis of operating costs for underground mining operations in the current global economic climate considers the financial burden for a ventilation system to be in vicinity of 30–50%. These operating costs are often overlooked by management teams in the greater scale of things when looking to save money in the procurement phase. This oversight to operational costs can be as little as the effective delivery of ventilating air to the work zone. One of the biggest opportunities for substantial savings and improvements can be realized in the selection of a quality vent duct that is suitable and fit for purpose. The key component to the selection process for quality products is a solid selection criterion that is followed during the tender process. This allows the management team to filter out unsuitable suppliers and products. The case study identifies some of the key components that were considered in the procurement and selection process for lay-flat ducting products. These included the characteristics and strength of the materials. The selection criteria also considered a ducted performance comparison that offers the best aerodynamic performance with some of the following components. • Airflow at Duct Face (m³/s or cfm), Fan Pressure (Pa), Air Power (kW or hp), Assumed Fan Efficiency, Annual Running Costs, K – Factor or Lambda, Leakage Factor, Joining Method and available Duct Lengths with weights. • Critical components considered were the current Testing standards available for: o Bursting Strength AS 4878.5, Mass AS 2001.2.13, Tensile Strength AS 4878.6, Tensile Strength AS 2001.2.3.1, Tear Strength AS 2001.2.10, Tear Strength AS 4878.7 • Other key considerations were: o Warranty Claim, Damage claims, Local storage / operations, community engagement and relationships, current testing data, previous issues, after sales service with technical assistance, etc. Hidden costs associated with product failures and operational stoppages are often not quantified during the tender process. Buyer beware. INTRODUCTION The largest constraint underground mining operations currently face are their operating efficiencies and electrical costs. The overall cost of an operations ventilation system and its components requires more focus to identify what opportunities exist to maximise efficiency and effectiveness. This tender process may not always be clearly understood and it should be broken down into fewer components to achieve quantifiable results."

Jan 1, 2019

By R. C. Gilmore, J. F. Brune

"Pulverized limestone rock dust used in United States underground coal mines to prevent and suppress coal dust explosions must easily disperse by forces of a methane or coal dust explosion. Moisture in the mine environment causes caking of the dust. Colorado School of Mines researchers performed dispersibility tests in a full-size explosion test drift. Tests included conventional, hydrophobized, and rock dust approved for German mines. Conventional and German standard rock dust products partially agglomerate, which may not be effective in suppressing a coal dust explosion, while hydrophobic rock dust retains better dispersibility.INTRODUCTIONA coal dust explosion devastated the Upper Big Branch mine in 2010 resulting in the death of 29 miners, the worst mining accident in the United States since 1972. The explosion propagated through approximately 65 km of active mine workings, but was extinguished in areas that had been properly rock dusted (Page, 2011). Researchers have long studied and established the ability of inert limestone rock dust to suppress coal dust explosions, see Richmond et al. (1975), Cybulski (1975), and Sapko et al. (2000).To be effective, rock dust must contribute to a total inert content of > 80% by weight and 100% of rock dust particles must pass through an 850 µm sieve, while 70% of the rock dust must be finer than 74 µm. This is established in US regulations 30 CFR §75.2. Dry rock dust is a nuisance that prevents mining work downwind from rock dusting activities. To overcome this problem, dust manufacturers have proposed applying the rock dust as a wet slurry or foam. After drying, manufacturers expected the slurry or foam-applied dust to have the same explosion suppression capabilities as dry-applied rock dust.Researchers at the Colorado School of Mines (CSM) designed and built a full-scale, underground Explosion Test Facility (ETF) at the CSM Edgar Experimental Mine in Idaho Springs, Colorado about 20 miles west of the CSM Golden, Colorado campus. To disperse the different rock dust products, researchers produced an air pressure pulse using a mesh array of PETN detonation cord. This method is simpler, more reproducible and safer than other methods considered, including methane-air explosions and a compressed air cannon. The detonation cord blasts produce a wind velocity of 30 to 50 m/s, the minimum velocity at which coal dust explosions can propagate, based on research by Nagy (1981) and Cybulski (1975)."

Jan 1, 2019

By Sangjian Zhang, Zhu Xiao, Lairong Xiao, Rushi Chen, Mei Fang, Zhou Li

The copper-graphite metal matrix composites were fabricated by two different production methods: directly sintering with copper and graphite (Cu-Gr composite), and in-situ sintering with cuprous copper and graphite (Cu2O-Gr composite). During the in-situ reaction sintering, a redox reaction occurs at the interface of the Cu2O particles and Gr particles, resulting in the improved physical and mechanical properties of Cu2O-Gr composites. Compared with Cu-Gr composite, Cu2O-Gr composite has a higher compression strength at any given graphite content due to the improved interface bonding and uniformly distributed fine graphite particles in the matrix. Increasing graphite content decreases the mechanical properties of the copper-graphite composites. The compression strength of Cu2O-Gr composite is 50-100 MPa higher than that of Cu-Gr composite. INTRODUCTION Copper-graphite composites have been widely used in industry due to their low density, relatively high strength and hardness, good thermal and electrical conductivity, arc ablation resistance and self- lubrication ability (Grandin & Wiklund, 2018; Han & Xu, 1999; Huang et al., 2017). Electric sliding contact friction pair in the high-speed railway system and motor brush in electric contact components have a very high demand on electrical conductivity and self-lubrication ability of materials. The electric devices need to bear both mechanical load and high electric current. Copper-graphite composites with good mechanical, electric and self-lubrication properties are the best candidates for application in multifunctional electric sliding contact frication components. The relative sliding speed of friction pair is developing towards 100 m/s or even faster, which can withstand the electric flow of more than 800 A, and it is often accompanied with vibration and impact (Guo & Ding, 2008). Conventional wear-resistant materials can no longer meet the current requirements and this promotes the development of copper- graphite composites with excellent comprehensive properties (Ding, Chen, Zhu, Zhang, & Zhou, 2009; Yasar, Canakci, & Arslan, 2007). There are many ways to fabricate copper-graphite composites, mainly including powder metallurgy method, liquid immersion infiltration method, rapid sintering method and electrodeposition method (Kalin & Poljanec, 2018; Kim, Lee, & Han, 2014; Liu et al., 2018; Wang et al., 2018). Each method has its own advantages and disadvantages, and the powder metallurgy method is the most commonly used one due to its simple process, high economic benefit, and industrial production applicability. The common steps of the powder metallurgy method are as follows (Samal, Parihar, & Chaira, 2013): firstly mixing the copper (copper alloy) powders and graphite with a certain ratio, following by die-forming, and then sintering at the high temperature with or without pressure. The advantage of copper-graphite composites is that the graphite distributed in the copper matrix uniformly and it can form a carbon diaphragm preventing the wear of the composite (Fu & He, 2010). However, the bonding strength of the interface between the copper matrix and the graphite is relative low as the combination between them is mechanical interlocking but not metallurgical bonding (Ma et al., 2008). It is meaningful to develop new fabrication technology of copper-graphite composites with better interface bonding, which could provide guidance for the design of copper-graphite composites with excellent comprehensive properties.

Jan 1, 2019

By V. A. Temeng, M. Owusu-Tweneboah, K. Awuah-Offei

The mining industry has long recognized the value of dispatch systems in open pit mines as they reduce load and haul costs. Over the years, researchers have proposed many dispatch systems with various limitations and advantages. The simplest dispatch algorithms are the so called 1-truck-for-N-shovels dispatch strategy. These algorithms are limited by the fact that their objective functions do not consider all the objectives of a mine and cannot be applied to all possible truck-shovel configurations. They are also myopic in nature. However, they are simple and computationally efficient and do not require occasional updates of the upper stage problem as required in multi-stage dispatch algorithms. In this work, an agent-based truck dispatch algorithm that conceptualizes trucks as intelligent agents that make autonomous dispatching decisions to maximize their utility is proposed. The advantages of this algorithm includes utility functions that encapsulate all of management’s objectives and agent’s with broad situational awareness. They are also more suitable for autonomous trucks. We evaluate the new algorithm against a simple 1-truck-for-N-shovels dispatch strategies using discrete event simulation. The simulation results show that the new utility function has significant advantages over 1-truck-for-N-shovels inspired utility functions. Future work will incorporate adaptive behavior into the model via reinforcement learning algorithm. INTRODUCTION In an attempt to optimize truck shovel operations in open pit mines in order to reduce the cost of haulage operation, which according to (Alarie and Gamache, 2002) is estimated to be about 50-60% of the total cost of mining, several effective and efficient strategies have been developed. Optimizing truck haulage systems in an open pit mine is one of the greatest challenges of mining engineering and has been the subject of many research projects. It is important that haulage systems are designed to be efficient, in order to minimise haulage cost, improve profitability and increase the total mine value. Although optimizing the number of trucks required in the operation of open pit mines can help reduce the cost, an effective and efficient truck dispatching system add value by ensuring that the available trucks are used efficiently. With truck dispatching systems, the trucks are normally dispatched between the crusher and dumping station (e.g. waste dumps and stockpiles), and the shovels in order to maximize the total output, obtain grades targets, reduce fuel consumptions and other objectives. Truck dispatching, which can have one or more objectives, is typically subjected to certain operational constraints such as truck and shovel capacities, empty and loaded trucks speed, among others. The problems associated with truck dispatching was first mentioned by Dantzig and Ramser (1959) after they made an attempt to determine the optimum routes of a fleet of delivery trucks between bulk terminals and a service stations. The problem occurs in several industrial systems besides mining (Alarie and Gamache, 2002; Gendreau et al., 2006; Rego and Roucariol, 1995). The dispatching problem, also referred in literature as the vehicle routing problem, has seen a number of modifications and extensions with Bertsimas and Ryzin (1991) presenting a dynamic and stochastic vehicle routing problem, and Ralphs et al. (2003) also adding to the original concept, the concept of vehicle capacity routing.

Jan 1, 2019

By Esau Arinaitwe

The most extensively used methods and approaches for characterizing and selecting frothers for plant application are based on measurements in clean water in the absence of solids and without consideration of physicochemical factors that are known to influence the properties and behavior of practical flotation froths, and hence metallurgical performance. These factors include aquatic chemistry, collectors, modifiers, particle shape and size, and pH. Understanding interactions between these factors and the role and relevance that they play in characterizing frothers and froth zone properties will greatly aid in the frother selection and evaluation process. Such an understanding will also greatly enhance the ability to create frother solutions that are sufficiently robust to plant variability (such as mineralogical, comminution, operational, physical and chemical). This paper reports results of a “systems approach” study designed to probe ways in which physicochemical factors a) influence frothing and bubble size in 2- and 3-phase systems, and b) confound correlation of fundamental measurements with flotation outcome. The concepts and insights gleaned from fundamental frother studies, together with empirical laboratory flotation tests and a thorough understanding of plant needs and challenges were used to develop and implement customized frother formulation at a Cu-Mo flotation plant. Plant metallurgical data and qualitative assessment of froth zone properties showed that a frother formulation developed using the approach described here provided marked improvements in froth characteristics (mineralization, mobility, stability, persistence). These improvements resulted in better circuit control and significant performance advantages, such as improved coarse particle recovery, without detrimental downstream effects. INTRODUCTION Successful recovery of value minerals of sufficient grade via the flotation process requires selective manipulation of the value minerals to render them hydrophobic using collectors and modifiers. The hydrophobized minerals then attach to air bubbles and the mineral-bubble aggregates are selectively transported through the froth zone into the launder. Frothers play a critical role in froth formation and more importantly in achieving and maintaining desirable froth characteristics (for example, stability, mobility, persistence) that are essential in facilitating the selective transport and recovery of value minerals. Fundamentally, frothers contribute to the transient stability of thin liquid films and so aid in reducing bubble coalescence rates in the pulp and froth zones, thus maintaining the small bubbles required for efficient bubble-particle attachment. Invariably, the action of frothers at the liquid/gas interface in the pulp and froth zones impacts bubble stability, water and solids transport to the froth, which in turn impacts froth mobility, froth carrying capacity, and the concentrate grade. Consequently, selection and evaluation of frothers for flotation plants requires careful consideration of the frother type, though the choice is limited to only two main classes of compounds in terms of fundamental chemistry (short chain alcohols and polyglycols). Even with the selection of what is thought to be the best frother for a given application, practical knowledge of the froth zone and experience in controlling its properties is essential for maximizing metallurgical performance.

Jan 1, 2019

By Christopher Jon Preston, Troy Williams, Daniel Roy

There has been significant progress made with narrow vein gold mines in which a second option for crushing has begun to attract attention. To ensure the profitability of a mine that has based its economics on the absence of a crusher station, more than just best blasting practices are required. Using a blasting operation itself as a primary crusher would undoubtedly save enormous capital costs as well as eliminate some of the costs of crushing ore with the result that considerable savings might be realized. The challenge would be to define the conditions necessary to make this type of operation feasible by providing consistent blasting methods that result in a significant paradigm shift with respect to both blasting and current underground crushing methods. A break model has been developed and applied as a technique in designing blasting patterns based on a unit charge blasting geometry and stress reflection from free faces. There are four components to this model and these are 1) unit charge, 2) thermodynamic/energy, 3) stress reflection, and 4) radial break. Some important changes in timing between holes and rows based on rock properties and the percentage of burden moved were also used. On-site testing at a narrow vein gold mine in Quebec Canada, provided measured parameters for the model. No underground crusher was planned - relying only on the fragmentation profile generated by ring blasting. The specification for muck was that the fragmentation profile needed to be 100% < 400 mm (16 in) with no overbreak - with dilution less

Jan 1, 2019

By G. Bonin, A. Jamal, G. Preciado, S. Gillis

"Accurate, easy to obtain, and reliable methods of measurement are the cornerstone of shaft and tunnel developments - during their sinking, operation and maintenance, or in some cases, remediation. This paper presents a new methodology to capture existing shaft conditions in such a manner that they can be transferred from the field to a digital copy, where they can be stored and used for engineering design purposes in a space not directly affected by the costs associated with schedule and equipment performance. The methodology utilizes basic principles of excavation alignment (plumb lines and survey instruments) while adding modern LiDAR, geolocation and survey control tools that can more completely capture the surrounding environment. The complete cycle of collection, processing, and delivery of pertinent information underground can take under an hour. During sinking, capturing data as a live stream measurement and being able to assess the alignment of the shaft liner can be critical to meeting rigid design tolerances. As sinking progresses, small changes in alignment or liner deviations can be captured and immediately corrected. Likewise, post-construction as-built conditions can be recorded and digitized, which will allow the mine personnel to compare the proper working condition to the actual condition years later. Observed changes can be identified and planned as future shaft repair works. This methodology has been developed and successfully deployed during the on-going sinking works of the two shafts at the Jansen Potash Project in south-central Saskatchewan and is described in greater detail in this paper.INTRODUCTION Light Detection and Ranging (or LiDAR) scans of the BHP Jansen Production and Service shafts during construction identified sections of both shafts where the internal radius of the temporary primary liner was insufficient to accommodate the tolerances of the permanent liner that was to be installed inside the temporary liner. These locations are referred to as “tights”. The “Tights Removal Program” was designed to collect high resolution point clouds of the shaft, using stringent survey control, that could be compared to the design profile to generate a heat map of locations for removal of up to 75 mm of steel-fiber-reinforced, 70 MPa concrete liner. This work was all on critical path, which made it valuable to save time on the schedule. Because concrete removal was a time-intensive task, it was essential to locate and remove only the concrete that would encroach on the planned permanent liner, while attempting to maximize the amount of cutting time. Removal was carried by a road header attached to a Brokk(R) 160, a small multi-attachment demolition machine."

Jan 1, 2019

By S. Kemball-Cook, D. Heinze, A. Kornberg, M. Harmon

Climate change presents risks to mine infrastructure, operations and long-term obligations to protect environmental conditions. Management strategies and design of infrastructure and containment systems based on past or current climate conditions may be inadequate in the future if changes in climate are not taken into account in planning for mine operations, decommissioning, closure and post-closure. Data-driven assessments using climate model projections of the future can be used to quantify: • Changes in site-specific risks to mine structures, access, containment facilities, operations and staff safety. • Changes in vegetation and water balance/chemistry, and potential for acid mine drainage, erosion and design failure. Climate- and weather-related risks are a serious threat to the mining industry, but risk transfer solutions can alleviate these vulnerabilities. Mining companies can protect themselves through bespoke solutions which provide operators, investors and buyers with protection against weather-related disruptions to operations by hedging to smooth revenues. Using risk transfer structures to mitigate climate risks is a mechanism that is available to all types of mining operations world-wide. In this paper, we describe methods for evaluating site-specific climate change impacts and developing risk transfer solutions to mitigate their effects. EVALUATING MINE RISKS FROM CLIMATE CHANGE The best available tool for understanding potential future changes to the earth’s climate system are global climate models (GCMs) (IPCC, 2014). GCMs are computer simulations of the climate system which include the atmosphere, ocean, land surface, cryosphere and biosphere. Because of the computational demands of running a global model for many decades, the spatial resolutions of the GCM grids are necessarily coarse, typically on the order of 100-300 km. GCM data are therefore suitable for evaluating future physical risks on global or continental scales, but may not be appropriate for evaluating location-specific risks (e.g. Kotamarthi et al., 2016). For site-specific, quantitative physical risk assessment, GCM projection data are “downscaled” or adapted for use at the local level using statistical techniques together with observed data (statistical downscaling) or using high-resolution regional climate models (RCMs) that focus on a single geographic region and have spatial resolutions of 10-50 km (dynamical downscaling). Downscaling bridges the gap between the GCM scale and regional/local scale. Through the downscaling process, new information is added to the GCM output from observations and/or RCMs, resulting in patterns for weather variables that are more consistent with local terrain and weather influences. Downscaled climate change projections for the mine site are selected considering mine location and geography, the availability of local observations, and the performance of the downscaling method and global/regional models used to develop the projection in simulating the variable under study. Where possible, we use projections from an ensemble of global and regional model runs spanning a range of future greenhouse gas (GHG) scenarios.

Jan 1, 2019

By Scott Thayer, Michael Murphy, Natalie Cope, Gabriel Esterhuizen, Anthony Iannacchione, Tim Miller, Brent Slaker

"The Subtropolis room-and-pillar mine extracts the Vanport Limestone (Allegheny Formation, Pennsylvanian System) near Petersburg, Ohio. Strata instability problems associated with excessive concentrations of lateral stress caused the mine operator to implement a change in layout design. This mining method has been identified as a stress control layout, which has been used by other underground stone mines in the past with varying degrees of success. Practical experience has shown that entry headings advance in the direction of the principal lateral stress, producing lower stress concentrations with better mining conditions. It is important to minimize stress concentrations along the mining front, so an arrow-shaped advance is recommended. This technique advances more developments (headings) in a “good” direction and reduces developments (crosscuts) in a “bad” direction. As is expected, the stress control layout enhances the potential for shear failures in crosscuts. It is, therefore, important to focus crosscut engineering interventions that either: (a) lower stress concentrations (for example, an arched roof) or (b) enhance strength of the strata containing the shears (for example, rock reinforcement). This study focuses on observing strata conditions on a regular basis and monitoring the response of this strata to changing geologic and mining conditions through 3D Dynamic LiDAR scans.INTRODUCTIONProject AimsThe Subtropolis Mine is extracting the Vanport Limestone in northeastern Ohio. Since the start of mining in 2006, ground conditions have been significantly affected by excessive lateral stress condition. In some other mining districts with this hazard, certain mine layouts have been shown to lessen the potential for unstable ground conditions. The term “lessen” is used to state the realization that stress concentrations are not eliminated but instead occur in less frequency and intensity, and their locations can be projected.The stress-control mine layout, specifically for large-opening room-and-pillar stone mines, naturally evolved at mines suffering from excessive lateral stress problems. These mines will typically experiment with methods to mitigate adverse impacts, thus developing best practices for their conditions. These practices have evolved into a basic framework for the stress control mine layout. For example, Jack Parker was able to write about personal experiences at the White Pine Mine in Michigan (Parker, 1966, 1973). Various researchers at the U.S. Bureau of Mines (USBM), the Mine Safety and Health Administration (MSHA), and the National Institute for Occupational Safety and Health (NIOSH) have studied the effectiveness of stress-control mine layouts over a wide range of geologic conditions (Emery, 1964; Mark and Mucho, 1994; Iannacchione et al., 2003). While the stress control layout design approach has proven successful in many categories, it can be difficult to implement. For example, excessive stress conditions in crosscuts can put the ground control focused intervention at odds with ventilation and haulage constraints, thus limiting optimal crosscut size, shape, and location. Therefore, more information on the effectiveness of this approach is needed."

Jan 1, 2019