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By R. E. McIvor, Brian Cornish, J. A. Finch, Yue Tan, Claude Gagnon

Fred C. Bond is recognized throughout the mineral processing world as the father of comminution equipment applied science and engineering. The Bond Work Index became a universal standard, and is the most widely used measurement tool for comminution energy consumption. This biography is the story of his lifetime of study, work experiences, experimentation, analyses and findings. His numerous published writings are reviewed. His legacy is one of comminution process engineering that will be used in perpetuity.

Feb 1, 2024

By Jurgen Hahn

The paper reports on both, the design and decision making for the filters in a backfill plant in Europe as well as more then 10 years of operation and maintenance experience of the vacuum disc filters installed. It begins with the first step, the filter sizing based on a sample provided by the customer, followed by the commissioning of the filter units and reports on the development of the filter performance during the following 10 years of operation. Based on the physical properties of the sample and the process targets of the client for the backfill plant, the paper shows the logic steps taken in the laboratory to ensure the target moisture, determine the required filtration area and filter size as well as the selection of the ancillary units and the formulation of the performance guarantee. The paper discusses some issues with filter operation during the commissioning phase and the actions taken. Finally, the paper concludes by highlighting the gradual change over the more than 10 years of operation and how this change affected filter performance and operating costs.

Feb 1, 2024

By Angelina Anani, Nathalie Risso, Gail Heath, Dean Riley, Nilufer Akbulut, James Werner, Víctor O. Tenorio

Implementing a Digital Twin at the San Xavier Mine Laboratory (Sahuarita, AZ), requires a network redesign with a robust architecture. The goal is to create an ecosystem in where all personnel and equipment can be monitored in real-time from the University of Arizona campus, visualizing the site in a digital terrain model. A wireless mesh will help to test robots with autonomous features. Expected outcomes include data retrieval and analytics, the evolution of communications and safety protocols, tele-operation, and an innovated approach for managing the site with new supervision challenges. A timeline with expected commissioning benchmarks is also included.

Feb 1, 2024

By Milan Yekich, Emanuele Cauda, Justin Patts, Cody Wolfe

A worker’s personal exposure to respirable dust in occupational environments has traditionally been monitored using established methodologies which entail the collection of an 8-hour representative sample that is sent away for laboratory analysis. While these methods are very accurate, they only provide information on the average exposure during a specific time period, generally a worker’s shift. The availability of relatively inexpensive aerosol sensors can allow researchers and practitioners to generate real-time data with unprecedented spatial and temporal granularity. Low-cost dust monitors (LCDM) were developed and marketed for air pollution monitoring and are mostly being used to help communities understand their local and even hyper-local air quality. Most of these integrated sensing packages cost less than $300 per unit, in contrast to wearable or area dust monitors specifically built for mining applications which have been around for decades but still average around $5,000 each. At the National Institute for Occupational Safety and Health (NIOSH), we are leveraging the power of high-volume data collection from networks of LCDM to establish baseline respirable hazard levels and to monitor for changes on a seasonal basis as well as following any application of control technologies. We have seen the effective use and advantages of monitoring live data before, during, and after events like shift changes, operational changes, ventilation upgrades, adverse weather events, and machine maintenance. However, many factors have prevented a systematic adoption of LCDMs for exposure monitoring: concern for their analytical performance, the complexity of use, and lack of understanding of their value are some factors. This contribution outlines a one-year case study at a mine in Wisconsin USA, covering the installation, maintenance, data visualizations, and collaboration between NIOSH researchers and the industrial hygiene professionals at the mine.

Feb 1, 2024

By H Arvidson, Rondinelli Sousa, Nic Pollock, Cesar Carrasco, Boz Elloy

Global public mineral reporting codes have driven strong governance of public disclosures of minerals information. Recently, we have seen an increase in disclosure of information related to Environmental, Social and Governance (ESG) issues, and governance of ESG information in mining companies has arguably reached a similar level of governance and diligence afforded mineral reporting. We define Resource Governance as the conjunction of environmental, social and minerals governance. A modern systems approach to Resource Governance, which combines mineral and ESG information, would provide not only reporting and governance capability, but also has the potential to sense/respond, predict, and manage ESG risks.

Feb 1, 2024

By Connor Meinke, Shaihroz Khan, Kevin Erwin, Rajiv Chandramohan, Muhammad Usman Siddiqui

High-quality sample selection for metallurgical test work is essential to a geometallurgy study, but the large multidimensional dataset makes sample selection a daunting task, as classifying the dataset while respecting its heterogeneity is difficult. This paper presents a streamlined approach for sample selection, utilizing custom-built tools in Python to standardize the methodology, saving time and costs. This approach uses the cumulative sum method, principal component analysis, and k-means clustering method to elegantly cluster the data and select representative samples. A case study is used to demonstrate the effectiveness of the methodology by selecting 40 samples for flotation test work.

Feb 1, 2024

By M. Portal, L. Goicochea

This study is carried out in the Zenit mining concession, which is located in the city of San Pablo in the department of Cajamarca in Peru. The Project has 33 mineralized structures and according to laboratory analyzes we have the presence of gold and silver. The geostatistical evaluation provides an analysis on the distribution of precious metals in the vein. This information is used to improve the efficiency of metal extraction and to reduce costs. The general objective is to evaluate the polymetallic veins (Au and Ag), for which the classification of resources (measured, indicated, and inferred) has been carried out, taking into account the parameters of minimum distance from the composite, corresponding volume and tonnage calculation. In addition, an inventory of estimated geological resources was carried out with the block grades obtained to generate the tonnage-grade curves.

Feb 1, 2024

By C. Cardoso, G. Bermudez, A. Jalili

Bigger flotation cells can result in larger froth surface areas and longer froth transport distances, this has been credited to impact froth recovery. Thanks to recent advancements, the newer flotation machines can be designed with different launder and crowder arrangements to enhance froth management. Nevertheless, lower head grades, complex ores and even larger mechanical flotation cells can lead to insufficient froth collection, even if the cell is equipped with the most recent flotation advancements like the center launder design. Aforementioned issue can become critical at the end of the flotation row. Increased crowding has been proven to be a solution to overcome inadequate froth recovery. However, scaling-up crowders for larger flotation cells can rise challenges, particularly in terms of structural limits and design for service. This paper presents the development journey for the Spider Crowder Upgrade, an advancement to improve froth collection in large flotation cells that are already equipped with center launders.

Feb 1, 2024

By Jason Clarke, Glen Trainor

As the mining industry faces increased challenges with declining ore grades and harder to access deposits, operating mine sites in an environmentally responsible and economically viable manner will require innovations that improve efficiency in energy logistics, and automation. Technological advancements in mining have been successful primarily because of the willingness and capability of these solutions to share information with one another, for example OEM payload systems sending information to Fleet Management Systems, and in turn Fleet Management Systems interfacing to ERP systems. To promote and facilitate the sharing of data, there has been a push towards open standards with initiatives led by organizations like ISO, ISA, EMESRT, and GMG. These efforts are aimed at creating a more collaborative and interoperable environment within the sector. However, when it comes to implementing autonomous solutions, a different trend dominates— closed-stack solutions. These closed stack solutions not only prohibit a mine site from selecting best-of-breed solutions, by blocking the competition from entering the market, they also risk slowing innovation that could help overcome the challenges the mining industry faces. Open Autonomy, an internationally published standard that allows any FMS to work with any Autonomous solution, breaks this closed-stack approach and invites competition from other industries. This competition comprises of autonomous suppliers from other industries and manufacturers of smaller, civil-sized haul trucks. The availability and capabilities of these smaller-sized autonomous haul trucks will help tackle the challenges of responsibly and economically mining lower quality ore grades and mining harder to access deposits.

Feb 1, 2024

By Jacob Bouke, Jason Janisch, Erik Vlot

The use of conventional tailings deposition methods has been the standard for decades. With the need to reduce the impact of mining, alternative methods are considered when expanding or upgrading tailings handling systems. Converting an existing tailings management system to a more sustainable deposition method during the operation of a mine may incur considerable operational and financial risk, and when assessed more traditionally, does not provide significant advantages. As a result, most mines choose to continue their current technology and add an additional pumping stage or pumpstation to their tailings line in case of a pipeline extension or Tailings Storage Facility (TSF) expansion. This also often involves raising embankments. Changing pumping technology is traditionally assessed by comparing the energy efficiency of current and prospective pumping technology. Despite a reduction in absorbed power, this traditional assessment does not include possible savings in water and the carbon footprint. With the consideration of all these three aspects, alternative pump technologies, such as Positive Displacement (PD) technology, become more economically feasible, providing increased sustainability and enable a site to future-proof their operations. Project feasibility may be affected by the high capital investment required for PD pumps. The benefit of applying PD pumping technology could be enhanced by reducing the volumetric throughput of the pipeline by dewatering the tailings to 65% solids concentration by weight. It was found that despite increasing capital expenditure, the improved reclamation of water will have a positive effect on the direct and indirect cost of fresh water intake to mine operations. This paper seeks to illustrate that in many applications the long-term benefits of investing in sustainable tailings management are optimized when more efficient PD pumping technology is combined with tailings dewatering when upgrading or expanding the tailings handling system.

Feb 1, 2024

By Venkata Aneesh

This paper examines the desired blast fragmentation results associated with mining fleet performance at Sidney Quarry of Pike Industries, A CRH Company by reducing cycle times and hauling less oversize material generated from the blast to the crusher to increase the overall plant throughput. We are constrained with blast patterns due to the poorly sorted and fractured seams in the quarry, which is angled at 35° NE and dipping at 80° and runs parallel to the Interstate-95 highway on the east of the quarry boundary about 600 ft, making it challenging to alter the blast patterns for optimal yield. We evaluated multiple relationships between blast patterns in conjunction with loader diggability. Results analyzed include the digging hours, fleet cycle times, and the fragment size with the optimized blast design through 3GSM software to arrive at the optimal yield to maximize the crusher throughput. Our primary objective is to focus on safety with efficient cycle times and clean floors & clean face generation for better operational efficiencies. Secondly, to optimize the crusher yield which is an integral part of quarry operation. Further, this paper provides the utilization of 3GSM blasting techniques in quarry applications with computer vision fragmentation analysis and VizaLogix, a fleet management software to analyze the cycle times sampling.

Feb 1, 2024

By Paul Schmidt, John Barber

This paper discusses the determination of cutoff grade (COG), including all revenue and cost factors and how to apply the COG in the world of engineering studies and mine planning for underground mines. It provides the engineer with important considerations and practical methods to establish COG and methods of using the COG in the work of mine planning, including the application of Mineable Stope Optimizer (MSO) software which is available on several 3D mine planning packages.

Feb 1, 2024

By Sean Warren, JOSEF BOURGEOIS

The potential of rockfall at open-pit mines presents a continuous hazard to mine workers and is typically mitigated by designing catch benches at empirically determined widths. The National Institute for Occupational Safety and Health (NIOSH) is working in conjunction with industry and academia to revisit and update current catch bench guidelines to better match acceptable risk tolerances for modern mining practices. To begin this process, a rockfall testing program was designed to gather empirical runout and bench catchment data at partnering mine sites in the Western United States. This paper presents a detailed description of each component of the rockfall testing program, including scouting and safety plan development, equipment requirements, synthetic rock development for uniform testing across varying bench configurations, local rock collection for testing of mine-specific geology, data acquisition during testing, and data processing. Additionally, this paper describes how the program has been updated over time according to lessons learned during initial rockfall testing.

Feb 1, 2024

By Kevin Erwina, Rajiv Chandramohana, Connor Meinkea

This paper explores prevalent operational challenges encountered globally in SAG mills, including suboptimal throughput, liner wear, excessive energy consumption, and SAG mill load stability. The paper delves into the root causes behind these issues, such as ore variability, poor operating strategy, or inadequate process control. Drawing on industry experience and case studies, the paper highlights the significance of addressing these challenges to enhance overall mill performance and efficiency. It underscores the necessity of tailored strategies, encompassing improved monitoring, optimized liner designs, and refined control techniques to mitigate these challenges and promote sustainable SAG mill operation.

Feb 1, 2024

By Casandra Gamez Gonzales, Angelina Anani

Copper, the newest addition to the critical mineral list, is an essential metal whose electrical and heat conductive properties label it as a vital mineral for the creation of renewable energy sources and the reduction of Greenhouse Gases (GHGs). However, despite copper’s leading role in the transition to sustainable energy and mining practices, the mining industry has faced various battles in the extraction of this valuable material. These challenges are based on mining’s negative reputation and extensive impact on the environment, nearby communities, and human rights. To ensure the survival of mining in the future and achieve mineral demands, an emerging topic that has initiated the revolution of the traditional sector into a more environment- friendly and transparent industry, is Environmental, Social, and corporate Governance (ESG). ESG has motivated companies to seek growth opportunities and standardize risk accountability and transparency based on its collective framework that creates, modifies, and implements local, national, and international standards. These standards focus on improving environmental, social, and governance issues faced by companies and their projects. ESG has served as a guideline that investors utilize to assess companies and promote sustainability, responsibility, and disclosure to create positive and balanced relationships with stakeholders and the environment. Nonetheless, concerns have been rising which state that ESG is negatively impacting the mining industry by targeting what fuels the industry and world: ore deposits and their resources. Therefore, this research focused on answering the following research questions: what are the impacts of ESG on the copper supply chain and how will stricter ESG standards affect future copper production?

Feb 1, 2024

By Todd Minoski, Matthew McElhinney, Mark Mazzella, Morgan Sears, Craig Compton

The National Institute for Occupational Safety and Health (NIOSH) is staffed with Engineers, Geologists, and Field Technicians conducting a variety of ground control research. The mission of the ground control teams within the Mine Systems Safety Branch (MSSB) is to eliminate ground failures leading to mineworker injuries and fatalities. Advancing the science behind ground control relies heavily on conducting mutually beneficial research at participating mines which is detailed in specific references throughout the paper. The ground control teams have several types of field instruments at their disposal to measure the ground response in underground mines. These include borehole pressure cells (BPCs), vibrating wire stress meters (VWs), hollow inclusion cells (Hi-Cells), roof and rib extensometers, load cells, and convergence meters. These instruments are used to measure changes in pressure, strain, and displacement within the underground environment. Instrumentation data is collected automatically using intrinsically safe or MSHA permissible dataloggers if required. Information is transmitted to the dataloggers using approved cable to distances of 200–1,000 ft. depending on the type of datalogger being used. Once mining is completed, the dataloggers are retrieved and brought to the surface, providing in-mine data to mine management and engineers for the conditions currently being encountered in a particular mine. This data, in conjunction with geologic data and stress mapping, can be used to validate numerical models. The practical application of these models is extremely important for mine management and engineers, particularly when faced with more challenging mine environments. Insight gained from applying these models can be used to make better engineering-based judgments for areas that will be mined in the future. The impact of such applications can result in a reduction of ground-fall accidents and injuries as well as generally safer working conditions.

Feb 1, 2024

By Dan Brunner, Scott Thomson, Ben Lyddall, Duncan Thomson

Geosensing is used in oilfield drilling in conjunction with geophysical tools to support characterization of rock properties, geology, and reservoir conditions. This technology is now available to the mining industry and has been successfully applied to underground in-seam directional drilling in Australian coal mines for geologic exploration and methane drainage. The system utilizes a range of drill rig and wellhead mounted sensors which, combined with analytical software, produce real-time data from which 3D spatial features can be accurately modelled significantly in advance of mining. This innovation greatly expands on the information obtained from current in-seam directional drilling practices and provides for improved characterization of coal seams, including soft and weak zones, locations of geologic discontinuities, and analysis of formation flow. This paper provides a description of the geosensing system and the interpretation of actual data from long in-seam directionally drilled methane drainage boreholes at mines in Australia, and discusses how this system increases the value of directional drilling as an exploration tool for the coal mining sector, and the evaporite and hard-rock mining sectors where directional drilling is also applied.

Feb 1, 2024

By Andrew McGrath, Geraldine Lyons, Sarah Barcelona

In the dynamic and challenging modern industry landscape, understanding and unleashing the true role and contribution of technical teams is crucial to business success. The cyclical nature of industries has led to shifts in the technical professional’s place within the organization and the technical skills that are desired most. This paper reframes the pivotal role that technical professionals play within complex operating assets to maximize value and realize full potential. This investigation focuses on the Rio Tinto Kennecott Technical group’s cultural journey, which is underpinned by an investment in its people. The conflict between legacy industry beliefs and the necessity for cultural change emerges. This is illustrated by a deep dive into the evolving case study of Kennecott’s Bingham Canyon Open Pit Mine Technical team. Here, a multi-faceted approach to cultural change is helping to unlock the team’s contribution to the life extension of an aging asset. Guided by a vision and strategic roadmap, this approach is part way through a 5-year implementation period and is yielding encouraging business outcomes.

Feb 1, 2024

By Terence P. McNulty

Gold-bearing outcrops were discovered in 1862 by Union soldiers garrisoned at Needles, CA, near the northwest corner of the future State of Arizona. Sporadic mining began several years later, but engineered shaft sinking and mill construction were not adopted at Oatman and the neighboring camp of Goldroad until about 1900. Geological interpretations in 1915 enabled major production during the next decade. In the late-1930s, USSR&M built a new mine and mill in Gold Road and the District flourished until closure by Federal Order L-208 in October 1942. For about a decade, Oatman’s mines were among the largest gold producers in the American West.

Feb 1, 2024

By Bruce D. Hebb, Shahin Shadlou

Fiber Reinforced Polymer (FRP) is an excellent material choice for a broad spectrum of corrosive fluids and, in many cases, offers the best value per dollar. FRP Flanges present the greatest design challenge of all standard piping components. The theory underlying the design of flanges is very complex. In addition, due to the nature of FRP material, proper fabrication of the flanges is as critical as the design. In this review, the challenges of making FRP flanges along with the design techniques and best practices of fabrication that will lead to a high-quality flange will be discussed.

Feb 1, 2024