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By A. F. van der Merwe, R-D. Taylor, M. Jacobs, F. H. Conradie

Total bound moisture (TBM) is a typical quality indicator of industrial-grade gypsum. This gypsum is comprised of three distinct phases, namely anhydrite, dihydrate, and hemihydrate, of which only the latter is of much industrial use. TBM analysis is a lengthy laboratory procedure, and an artificial neural network (ANN) TBM inference measurement is proposed as a fast and online alternative. An ANN inference model for gypsum TBM based on plant data was developed. The inputs to the network were primarily focused on the plant's calciner, and different network topologies, data divisions, and transfer functions were investigated. Furthermore, the applicability of the TBM value as a quality indicator was investigated based on a gypsum phase analysis. A strong correlation between TBM and the gypsum hemihydrate and anhydrite content was found, validating the plant target TBM of 5.8% as a quality indicator. A network topology consisting of one hidden layer with logarithmic-sigmoid (logsig) and pure linear (purelin) transfer functions showed the best performance (R > 90%).

Oct 3, 2023

By Ehab Gomaa, K. A. El‑Nagdy

Backfilling material such as tailing (mine wastes) mixing with cement or gypsum has grown throughout the world’s underground mines. However, despite their growing popularity, the typical hydraulic and mechanical fill types utilized in many mines still exist. Deep underground mining has increased due to the lack of commercial minerals nearby. Mine wastes were considered the main part of backfilling to prevent environmental pollution, ground subsidence after mine abandonment, and mine collapse during deeper extraction phases. The cemented backfill technique is the principal technique used in underground mines, which include cement with fly ash and/or filter dust, cement with tailing material and fly ash, gypsum with fly ash, and synthetic anhydrite with fly ash and have been reviewed. It has concluded that a backfilling material must be selected based on further goals, available material near the mine site, and economic factors. This paper analyzes different backfill material mixtures to create a technique that will increase safety in underground mining conditions and foresees an appropriate formula that gives high uniaxial compressive strength. The multiple linear regression (MLR) on the collected data from the experimental works to construct the relationship between the uniaxial compressive strength (UCS) of the mixture and the components of the backfilling and the prediction formula for expected compressive strength was obtained. The results revealed that the predicted regression equation was robust and reliable to predict the (UCS) for the new components of the filling (cement (CE), filter dust (FD), water content (WC), and time (T)).

Oct 3, 2023

By Marco Silva

Underground mines are complex environments that require continuous control and monitoring actions in order to have a safe and efficient operation. At Nexa, the goal of achieving "zero harm" promotes the constant search for in its operational processes. Currently, there are manual activities that reduce the agility and precision when working with information from inside the mine, using mostly radio communication and management by sight of badges as an operational standard. This project was born in the context of increasing the operational safety of underground mines, bringing gains to the entire process involving the underground.

Sep 29, 2023

By Marcela Aliaga

Este trabajo propone una metodología para disponibilizar un mapa de calor de riesgos de conflictos sociales, que sirva como instrumento de alerta temprana y de gestión preventiva, pero que también permita comprender cuáles son los factores concomitantes que inciden en la mayor probabilidad de ocurrencia de conflictos sociales vinculados tanto con las prácticas empresariales como con las condiciones socioeconómicas y culturales del contexto. Para elaborar este mapa de calor, se ha construido un índice de riesgo de conflicto social que incorpora 13 variables (7 internas o vinculadas con el desempeño de la empresa y 6 externas o de contexto).

Sep 29, 2023

By Aaron Malone, Lino Morales, Francisco Alejo

Este documento utiliza un enfoque multidisciplinario, que combina las ciencias naturales y sociales, para desarrollar una imagen holística de por qué el mercurio y el cianuro convergen en el procesamiento del oro y con qué impactos potenciales. Mostramos que los factores socioeconómicos impulsan la combinación de prácticas de mercurio y cianuro en la MAPE tanto o más que los factores técnicos.

Sep 29, 2023

By Gabriel Castillo

The global warming and the associated changes in climate variability would increase the risk to the mining industry in both magnitude and frequency. Consequently, extreme climate conditions would disturb the infrastructure, equipment and mine closure strategies in areas that have not consider this potential impact. To cope with these climate-associated risks is critical to understand the exposure and vulnerability with a local perspective. Having a clear knowledge of the current climate risks, the vulnerability of species, ecosystems, and ecological processes in the watershed where the mining operations are is essential to inform how patterns of risks and potential benefits are shifting due to climate change.

Sep 29, 2023

By Fredy Mamani

El objetivo principal de este trabajo es aplicar técnicas de estimación geoestadística multivariables, aprovechando la correlación y relaciones entre variables. Luego realizar un comparativo de las variables estimadas con los resultados obtenidos por métodos tradicionales. Los objetivos específicos están enfocados en realizar el análisis exploratorio de datos para resumir las variables principales asociadas a la estimación multivariable. Luego se realizará la validación de información obtenida de la estimación multivariables.

Sep 29, 2023

By Gabriella Vaschetti, Pascual Perazzo

A paper presented at Perumin 35 in 2022 described the concepts and a state-of-the-art system with extruded curbs and PVC anchor wings, adopted among others at the first four stages of Las Bambas tailings dam in Peru, discussing how upstream geomembrane water barriers can mitigate the numerous issues, including environmental aspects, of tailings dams’ design and operation. This paper, beside presenting a summary of what has been carried out so far at Las Bambas, amplifies the subject, presenting the results by means of the data of the leakage monitoring system, showing that the flow monitoring data at the downstream toe are seasonally consistent, and in alignment with design predictions.

Sep 29, 2023

By Carlos Torres, Albert Cabrejo

For the last 20 years mine slopes have been monitored with slope stability radars. Since 2015 a group of dedicated geotechnical engineers dedicated to remotely monitor radars around the world have detected 2000+ slope failures of different characteristics. A statistical analysis of the information gathered of these failures have been made and the summarized results are presented with some degree of analysis appropriate for the vastness of the database. The analysis considers different types of commodities, countries, mining processes, rock types, and weather conditions.

Sep 29, 2023

By Paloma Camargos, Saulo De Rezende

In the pursuit of sustainable development, the mining industry is constantly evolving, recognizing the importance of utilizing all extracted materials. Nexa addresses waste management in the mining industry, with an emphasis on the adoption of waste as innovative and sustainable raw materials. With a focus on exploring the potential of mining waste, the characteristics of materials from the Vazante and Ambrosia units were evaluated to determine their suitability as aggregates in the construction industry, as well as to identify other possible applications.

Sep 29, 2023

By Alfonso Núñez

The adoption of digital technologies can lower the costs and risks for construction, commissioning, hand-over and transfer to operations eliminate many of the costs and delays associated with handovers and ensure fit for operations deliverables. In Mining, future projects could have 50/30 % less CAPEX/OPEX due to unmanned platforms, remote operations centers, and automated data collection lowering headcount. Additionally, these strategic investments can ultimately become profit centers beyond the traditional ROI paradigm, resulting in a greater return to shareholders/stakeholders for our customer organizations.

Sep 29, 2023

By Caio Moreira, Saulo De Rezende, Nelly Ruíz

The present project sought alternatives for this material through the Mining Lab Beginnings program, which was developed by Nexa in partnership with Escalab to find solutions for the company's highly complex challenges. Through the program, several solutions were evaluated, with additives for the construction market being the most prominent. Tests were conducted to confirm the efficiency of jarosite in the mixture that composes this material. With successful laboratory tests, the technology was tested on an industrial scale, where it also demonstrated its technical and economic viability. The project is now moving into the operational phase, demonstrating that circular economy is the best solution for disposed tailings.

Sep 29, 2023

By Rodrigo Rossi

Evaluating the field of artificial intelligence, it could be seen an increase on video analyses (or computer vision) usage, capturing information that would be difficult to get with other techs and reducing measurement error. After this research, it was presented to operational managers and the idea of applying it to monitor our industrial processes was born.

Sep 29, 2023

By Ting Ren, Jon Roberts, Zhongbei Li, Ming Qiao, Jianming Wu

Spontaneous heating of coal continues to present a health and safety hazard in underground coal mines. The influence of seam gas composition on gas flow dynamics and distribution characteristics in the active longwall goaf has not been studied in-depth, and corresponding effective proactive goaf inertization strategies for preventing potential spontaneous heating from occurring have limited investigation. To advance this knowledge, an 80-m-height goaf model was constructed and developed based on specific conditions of an Australian underground coal mine, and onsite gas monitoring data was collated to verify base model results, which allowed for various scenarios of seam gas composition to be simulated and investigated with confidence. This study involved modeling five different gas composition scenarios for the goaf atmosphere, namely, 100% CO2 (case 1), 80% CO2 and 20% CH4 (case 2), 50% CO2 and 50% CH4 (case 3), 20% CO2 and 80% CH4 (case 4), and 100% CH4 (case 5). Simulation results show that O2 is primarily distributed at the middle and upper part of the CO2- dominant goaf model, while it is mainly layered at the floor level of the CH4- dominant goaf model. N2 is superior to CO2 in the goaf inertization for the CO2- dominant goaf model, whereas CO2 performs better than N2 for the CH4- dominant goaf model. The optimal inert gas flowrates for case 1 to case 5 are 1.5, 1.75, 0.75, 0.5, and 1.0 m3/ s, and the oxidation zone area is reduced by 55.76%, 67.21%, 58.04%, 78.17%, and 81.82%, respectively. The simulation results allow for increased insight and understanding of the gas distribution patterns in the active goaf with different seam gas composition and the development of corresponding proactive goaf inertization practices, thus minimizing potential spontaneous-heating-related hazards and improving mining safety.

Sep 26, 2023

By R Peiffer, L van Wyk

The Port of Port Hedland is the largest bulk export terminal in the world and is one of Australia’s most important pieces of economic infrastructure. BHP is the largest Port user to support the export of iron ore products from mines located within the Pilbara region of Western Australia (WA). BHP’s priority is the safety and well-being of its workforce and the communities where it operates. In a recent regulatory application to increase export capacity, BHP committed to the deployment of wind fences to reduce wind erosion from stockpiled ore. Wind erosion from stockpiles was identified through inverse modelling as the most significant dust source compared to other sources such as stackers, reclaimers, shiploaders and transfer stations. The primary cause of dust emissions from stockpiles is dust lift-off during high wind conditions. BHP proposed the installation of wind fences across its Port Hedland operations, targeted at reducing emissions from wind dependent sources, primarily stockpiles, by reducing the wind speed downwind of the wind fence. Modelling predicts that installation of the wind fence will significantly reduce emissions from stockpiles, particularly at BHP’s western operations (Finucane Island). To be effective in shielding stockyards and reducing wind speeds, the wind fences are located upwind and as close as practical to the open stockyards. BHP’s wind fence design incorporates learnings from other existing installations and has been tailored for Port Hedland’s cyclonic conditions. The wind fence will be higher than the stockpile height, with a mesh porosity of approximately 50 per cent. The mesh porosity allows some of the wind to pass through the mesh. This reduces the wind turbulence downstream of the wind fence, as opposed to a solid wind fence, which increases downwind turbulence, resulting in increased dust.

Sep 18, 2023

By S Hapugoda, H Han, L Lu

Charcoal produced from Syzygium Zeylanicum trees was widely used in ancient Sri Lankan iron smelting practices. Charcoal made from Syzygium Zeylanicum tree trunks, branches and leaves were analysed by optical mineralogy and SEM and found to contain unusually high concentrations of calcium oxalate (CaC2O4.H2O – CaOx) crystals in plant cells. Partial and full reduction tests of a high-P Brockman ore were conducted at several temperatures with coke and coke doped with CaOx and CaCO3. It was observed that CaOx promoted reduction and generated comparatively more metallic iron in reduced samples. Furthermore, CaOx encouraged phosphorous partition into slag phases than into the metallic iron, suggesting CaOx can a potential alternative fluxing material to calcium carbonate for treating high-P iron ores in ironmaking processes.

Sep 18, 2023

By Q Zhou, J Pan, D Q. Zhu, C C. Yang

Oxidised pellets have become an indispensable high-quality charge for blast furnaces (BF) due to their uniform particle size, high iron grade, high mechanical strength, good metallurgical performance, as well as relatively low energy consumption and gaseous pollutant emissions in pellet production. Nevertheless, due to the rapid development of the global steel industry, highquality pellet feeds are becoming more and more scarce. In order to broaden the source of pellet feeds and reduce the production cost of pellets, more and more steel mills are going to use coarse iron ore fines with relatively low iron grade and low impurities for preparation of desirable pellet feeds through a typical wet grinding-settling-filtering process. In this work, the grinding, settling and filtering behaviour of Brazilian and Australian iron ore fines are studied and compared, aiming at finding out the internal relationship between the mineralogical characteristics of different iron ore types and their grinding-settling-filtering performance. The results show that the grindability is heavily dependent on the hardness of iron ores, which is governed by the mineralogical characteristics of the raw materials. Usually the higher the hardness, the more grinding energy is required. Except for Brazilian specularite, Australian hematite-goethite type iron ore fines and Brazilian hematite ore fines exhibit good grindability with a Bond Work Index of about 10–15 kW•h/t. In addition, the settling and filtering performance of ground iron ores are largely affected by the density, mineralogical characteristics of iron ore fines (eg, quantity of clay minerals and goethite and porosity of ore particles), grinding fineness, etc. Generally, iron ore fines with higher density, lower quantity of soft minerals (clay and goethite) and larger particle size give superior settling and filtering performance. For iron ore fines with inferior grinding, settling and filtering performance, applying more energy-efficient grinding techniques, blending with ore types with good settling and filtering performance can reduce grinding energy consumption and improve settling and filtration rates to maximise the productivity of equipment and lower the operational cost

Sep 18, 2023

By E Nunes, R Mendes, D Jacobson, G Cota, T Machado, E Santos, J Almeida, E Pereira9, B Raso

Grinding circuits are known to be the highest consumer of energy used in the ore comminution process, with high operational costs and sensitivity to ore conditions. The mining industry is being encouraged to look for more energy efficient processes while increasing the mass and metallurgical recovery; a specific example is projects with lower iron ore grades, which demands a higher level of liberation and resulting higher energy consumption. This has led to increased usage of high-pressure grinding roll (HPGR) technology as an alternative design within the comminution circuit. A growing use of the HRC™ HPGR technology has been used to generate concentrate through a more sustainable process. In the Brazilian state of Minas Gerais, the readaptation of iron ore beneficiation circuits has been initiated, replacing the traditional crushing-to-grinding flow sheet with circuits using crushing-to-HPGR flow sheets, with the main driver being reduced energy consumption. Utilising results from sampling campaigns and analysis of experimental data collected in an industrial plant, the work herein presents a case study from the JMN Mineração operating plant, where the HRC™ HPGR was used as an alternative to traditional grinding using horizontal mills. The results show that the HRC™ HPGR performance in this iron ore processing plant showed benefits in terms of reduced energy consumption as compared to the projected performance with a traditional grinding circuit.

Sep 18, 2023

By P Donecker

Like all chains, iron ore values chains are only as strong as their weakest link, which in ore processing is often the humble chute. While mechanically the simplest element in the iron ore flow sheet, chutes are often the most problematic and regularly the major cause of unscheduled downtime. Chute designs have remained static for decades, despite the extra demands being placed on them by grade reduction, which impacts chutes in three ways viz: 1. Higher volumetric rates as infeed increases to meet production targets. 2. Higher moisture content as mining goes below water table. 3. Stickier properties as the dilution phase is often clay based. While there is no shortage of ideas and the geometry options are infinite, the fact is that chute design has not kept pace with grade decline and has remained essentially unchanged. One reason cited for this lack of innovation is the difficulty evaluating and de-risking designs. While the power of computers running Discrete Element Method (DEM) models has advanced, the models themselves still need to be ‘calibrated’ with the dynamic properties of the ore. Flow properties commonly measured for bin design are useful for static situations only and were never intended to predict dynamic behaviour as in chutes, a critical qualification lost in the mists of time. So while they always produce a colourful and reassuring animation, DEM models informed by static ore properties often result in wildly inaccurate real world predictions. Responding to this low success rate, many operators are now utilising physical modelling to help reduce risk and avoid the consequences of having an underperforming chute in their value chain. Physical testing, in a dimensionless scale-down of the proposed system (bulk material and chute geometry), addresses the shortcoming of mathematical models designs and when used in combination with DEM is the best option. In the ideal world, the focus of chute modelling should be innovative design concepts aimed at addressing future needs, however in reality the focus is nearly always on modifications to installed chutes that are underperforming even today. This situation can be traced back to design procedures which if informed at all, are based static ore properties. As an industry, we need to break this cycle and become more proactive, which means addressing flaws in the current design process. In 30 years of providing modelling support to the industry, I have looking at hundreds of underperforming chutes in the iron ore industry. This practical experience has led to a unique and unbiased perspective on chute design and their performance in the real world. The knowledge presented in this paper can not only be used to help avoid baked-in problems now, but also help guide and evaluate designs so we can deal with the challenges of our low-grade future.

Sep 18, 2023

By H Haghighi

Haul roads are often permanent unsealed access roads used by heavy haul trucks to transfer minerals. These roads can deteriorate rapidly which results in potholes, deformations and dust. Downer EDI Works has successfully provided efficient solutions to the mining industry to maintain their haul roads. HaulPac as a solution package is a process in which a bituminous emulsion is used to create a stable and durable pavement. The emulsion penetrates the road and binds the particles together, creating a stable base. It also seals the surface and prevents water from penetrating the underneath layers. Bituminous emulsion can increase the strength of the pavement material and decrease the road surface degradation which results in dust suppression. However, the everincreasing price of commodities, the necessity of reducing carbon emissions and the increasing use of autonomous haul trucks have made it vital to invest in novel maintenance solutions that can meet the needs of the mining industry in a cost-effective manner. This paper outlines the benefits of bituminous emulsion in terms of productivity, safety and environment followed by Downer’s approach to evaluate the suitability and to optimise the amount of product. The potential for changing the colour of the treated surface is explored and an initiative that incorporates end-of-life tyres of haul trucks into the pavement is introduced. And finally, an innovative method using artificial intelligence to estimate dust emission is presented.

Sep 18, 2023