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The state of sampling practice in South African minerals industry must be appreciated in the context of the changes that the country has recently lived through. These include the entrepreneurship and investment in local mineral developments, the 'unbundling of mineral assets', the rising foreign control of South Africa's mineral assets, developments in the regulatory environment, and the training that has come to the industry through international experts. In terms of their financial contribution the five most important commodities in the South African mining industry include gold, platinum, non-ferrous metals, ferrous metals, and coal. International Organization for Standardization (ISO) standards form the basis for international trade in two of these commodities and have had a steadying influence on sampling practice over the years. The contribution of the minerals industry to the economic well-being of South Africa and the strong financial links between good sampling practice and minerals marketing, has acted as a driver for improved sampling practice. The state of sampling practice at mining operations of the five main commodities was found to be quite widely divergent with 'pockets of sampling excellence' in each of the commodities. The stages of mineral development at mines for each of the commodities have been described in terms of the sampling sites, sampling mechanisms, and associated problems at different stages of mineral production from exploration, through face sampling, blasthole sampling, and in-mine grade control, ore processing and handling, metallurgical subsampling, process subsampling, and subsampling in the laboratory. In each case the principal errors were identified and their potential impact on value erosion was estimated. In the final analysis it is evident that the greatest problems arise in the early stage of mineral development, and that ferrous metals and coal are particularly susceptible to loss of value through poor sampling practice. Several examples of value lost through poor sampling at the marketing stage that arise from breaching contract specifications, either in terms of grade or sizing, are described. The conclusion is that larger companies with larger ore deposits and greater human, financial, and capital resources are probably more compliant with 'best sampling practice' than smaller companies. Finally the message that equipment suppliers are sending is that business is booming and the awakened awareness of the issues around sampling practice are translating into rands and cents spent on improved sampling equipment.

Mar 1, 2010

At Cliffs Natural Resources Ltd (CNR) crushing and shipping sample stations, precisions are estimated for the sampling, preparation and measurement stages of iron ore sampling in accordance with ISO 3085 (2002). In this Standard, gross duplicate samples are prepared at each of the three stages, yielding eight measurement assays. Appropriate calculations of the differences between assay pairs are then made to estimate precision of each stage of sampling. The International Standard for checking precision in iron ore sampling, ISO 3085 (2002) prescribes a method for identifying outliers that is ambiguous and possibly inappropriate. The procedure also makes an unnecessary implicit assumption, that the differences between assay pairs are normally distributed. The Anderson-Darling statistic is used to demonstrate that in some cases the assay pair differences have distributions significantly different from normal. When applied at CNR as specified, the Standard leads to precision estimates well below the expected values, thus overestimating the sampling method's capability and limiting the opportunity for real process improvement. This paper suggests an improved method of estimating sampling, preparation and measurement precision. A bootstrap procedure is used to estimate confidence limits for the calculated precision estimates. The proposed method would be suitable for testing blasthole precision. The discussion is supported by extensive simulation modelling of realistic data.

Mar 1, 2010

A good blending system is one that ensures that a plant can cope with the amount of grade variation that it will encounter. Prediction of amounts of variation that will be encountered on time or tonnage scales that are important should be regarded as an essential part of the planning of mines and plants. In some cases, the natural amount of grade variation when ore is mined and handled in the cheapest way will be acceptable. In other cases, it is necessary to understand the effects that various ore-handling processes have on amounts of grade variation at various scales and to design a blending system with considerable care. Blending tends to matter more when plants are sensitive to many aspects of grade. It can be very difficult to find the best compromise between capital cost and the amount of grade variation. In these cases it is important that ore blending options be considered carefully as part of the planning of mines and plants. Failure to make plans that consider likely amounts of variation can be very expensive.

Mar 1, 2010

Computational models are very useful for studying many of the physical mechanisms which can cause sample bias. Within such models we can predict the trajectories of all individual particles and thereby make observations which are not possible for physical systems. Physical mechanisms highlighted include congestion at the cutter aperture, particles bouncing over the cutter aperture, air drag on fine particles, waves of material being bulldozed off the belt by the upstream side of the body of square cutters, and particles being thrown by the leading edges of cross-belt cutter blades. Having identified relevant physical mechanisms for an existing cutter, we can estimate the extent to which they are likely to result in unequal representation of portions of a stream of material and thereby estimate the maximum likely sample bias.

Mar 1, 2010

In practice a sampling solution is a compromise of many requirements: the sample should be representative; the sampling system should also be reliable, less than 95 per cent availability restricts the use of the assayed sample for process control purposes; no sample is the worst sample, and investment costs and installation space/layout are frequently a restriction. For instance, online X-ray analysers for process control introduce a delimitation error by the nature of X-ray physics. Thus only in special cases a relative accuracy better than three per cent relative, as one standard deviation, is achieved. A sampling system for process control needs not to be, as representative, for so many sample properties, as one for composite laboratory analysis samples. Sampling system maintenance is also an important issue. There are many sampling systems in the industry which have been difficult to maintain and are in disuse for lack of resources or incentives to keep them running. Pierre Gy developed the most generally accepted sampling theory. One of the main principles is that all particles in a one-dimensional process stream should have equal chances of being included into the sample. A correctly designed and operated transversing cutter comes close to this goal but has limitations in temporal representativity. For slurries an acceptable solution in many cases is to use a fixed vertical cutter(s) in a position where the slurry is well-mixed by turbulence and other means. For online analysis, reliability problems are mostly related to faulty design or installation of the piping system to the analyser. Properties of material processed, process flow sheet and piping details before and after the sampler have to be taken into account when deciding on which sampling arrangement is appropriate. Guidelines and some solutions to these issues are presented in this paper.

Mar 1, 2010

Successful evaluation and exploitation of resources and reserves relies on the collection of high quality sample data. The quality of the sample data must be maintained through the application of a robust quality assurance and quality control (QAQC) program, including documentation of sampling procedures, training of sampling personnel and the regular monitoring of control samples. However, the application of QAQC programs in the minerals industry is often poor and the purpose misunderstood. It is all too common to have good quality control data collected, but no analysis work carried out until after drilling is completed. In a lengthy drill program, this can lead to problems not being discovered and corrected as they happen. Moreover, rectifying problems afterwards will be costly in terms of time and money, if not impossible. The consequences of poor quality sample data are many and include such effects as over- or underestimation of block grades, misclassification of ore and waste, and lower confidence in the resource/reserve models. The purpose of this paper is to highlight, using case studies, the importance of good QAQC practices to monitor the quality of sampling and laboratory sample preparation and analysis.

Mar 1, 2010

Incremental sampling is defined as a solution to fight segregation, the theory is demonstrated and theoretical and practical aspects are discussed. The number of increments necessary for successful sampling is discussed. As an application, riffle splitter division is reviewed.

Mar 1, 2010

This paper discusses the implementation and potential limitations of the method for estimating sampling and analytical errors of multiple source mine output blended into a shipping product, described by Everett and Ziegelaar (2010). The practice of quality measurement varies between iron ore miners. The common objective is to monitor effective resource utilisation and control of product quality to customers. A flow diagram is given presenting the various options used by iron ore mine operators and the merits of the different options are discussed.

Mar 1, 2010

Blasthole cone samples are used for grade control in most of the iron ore mines of the Pilbara of Western Australia. This method of sampling is straightforward when the target sampling interval matches the mining bench height but is problematic when the blasted bench is 'flitch' mined in two or more passes. Crucially, the sampler needs to decide which part of the blast cone represents the upper and lower flitches to be mined. This sampling selection decision is usually made by assuming a certain proportion represents the subdrill component of a sampling face in a blasthole cone and the two flitches are split equally from the remaining portion. In this study of a West Australian channel iron deposit, sampling experiments were carried out to determine the actual proportions of a sampling face in a blasthole cone by spray painting the blast cones at flitch and subdrill boundaries during the drilling process. Measurements were then taken to assess the differences between assumed sampling face proportions and actual proportions. A set of paired samples was also collected from a number of blastholes with one set using the assumed proportions of each flitch for each sample, while the other set sampled the actual proportions, which were identified from the cone painting process.

Mar 1, 2010

Past arguments advocating reverse circulation sampling against blasthole sampling are reviewed to present the debate under a different light. The advantages and disadvantages of each drilling method are compared, and the choice is presented as an informed trade-off between them.

Mar 1, 2010

There are many compelling reasons why correct sampling schemes should be standard practice in the mining industry, yet there are numerous examples where poor sampling practices are known to exist in the business yet permitted to continue. It is not just technical issues that can be ascribed to the reasons for the continued use of incorrect methods. This paper proposes non-technical reasons why incorrect sampling practices continue, and identifies potential ways to overcome them.

Mar 1, 2010

The Marvel Loch Operations (MLO) plant was treating ores from up to six MLO sources and in addition needed to blend externally sourced ores with its own ores. This presented a metallurgical accounting dilemma, which was subsequently addressed by the design, implementation and testing of an automatic sampling system. The MLO automatic sampler was well designed and has been the subject of previous internal and external reviews. The sampling action is fully automated and the unit is essentially self cleaning particularly when sampling primary ores. The purpose of this paper is to document the rationale behind the design, the specific details of the sampling station, its use for ore purchase purposes and an assessment of the sampling system to meet the needs of the operator.

Mar 1, 2010

Bauxite Resources Limited is grade drilling in its Western Australian Darling Range tenements to firm up resource definition and to develop mine plans. The Darling Range bauxite is generally in shallow deposits with minimum overburden. In the northern tenements, the ore is characterised by a higher silica layer which may extend from 0.5 to 1.5 m below, which high grade bauxite is found to a depth of four to 7 m. When grade drilling samples are taken, every 0.5 m and the recovered sample is weighed, logged and bagged. To eliminate splitting errors, the whole sample over the short interval is pulverised. Twinning holes variations are observed when using various drill rigs. Diamond core has been shown to give close to 100 per cent recovery and grades have been verified by digging bulk samples. As such, diamond core is used as the reference. It is intended to include sonic drilling as an alternative to diamond cores. This presentation details and attempts to explain the reasons for the observed variations in the various drilling methods used by Bauxite Resources Limited. This is an ABSTRACT ONLY no paper was prepared for this presentation.

Mar 1, 2010

Once and for all, the debate on the exponent in Gy's formula is pushed to its limit. It is explained why an exponent of 2.5, obtained when using a square root of nominal size d to adapt the value of a calculated liberation factor to a different comminution size, will rarely be encountered in practice, if no arbitrary decisions are made.

Mar 1, 2010

By John A. Breslin

This publication provides an historical overview of research undertaken by the U.S. federal government over the last 100 years to improve the health and safety of our nation?s miners. Federal research efforts began with the establishment of the U.S. Bureau of Mines (USBM, or the Bureau) in 1910. They have continued over the past century, even after the Bureau?s closure in 1996. It is hoped that this publication will give the reader an appreciation for the work of mining health and safety researchers over the past century, and of the miners served by this research. Although not a comprehensive history, this report highlights the key organizational changes made within the Bureau and the federal government that affected mining safety and health research. Some mention is also made of Bureau research not directly related to mining health and safety. Note that the work classified as safety and health research has varied over the last century. For example, before 1970 the Bureau separated mining research and safety and health research. At that time, mining research included ground control and methane drainage because they had direct implications for mine safety. Explosives research was also reported separately from health and safety, even though permissible explosives research was obviously related to safety. Therefore, where budget figures from the Bureau are mentioned in this report, it is often not possible to separate safety and health research from other types of research. This history is generally chronological, with a few exceptions. Because of their prominence and direct links to Bureau research, most of the Public Health Service mining studies completed before 1970, when NIOSH was established, will be discussed in a single section, even though the work spanned many decades. Likewise, for convenience, the brief histories of the Bureau?s mining research centers are located in one section.

Feb 1, 2010

By Charles Rubin

Mining is a capital- and labor-intensive business, and profitability often depends on the ability to squeeze maximum efficiency out of every piece of equipment to achieve safe production. This means keeping every mechanized drill, loader, truck and bulldozer operating at all times, and having a system to coordinate the movements of people and personnel. Mines often use wireless radios to connect equipment with management systems. But growth and changes in a mine?s profile over time can require upgrades to the wireless network. In its openpit gold mine near Carlin, NV, Newmont Mining Corp. has recently upgraded to microwave radio systems to increase bandwidth while maintaining round-the-clock uptime on its wireless network. For many of its operations around the world, Newmont uses Minestar, an operational control software system that allows administrators to dispatch equipment operators and use GPS to track the precise position of every piece of equipment in an operation. Each of the approximately 150 pieces of equipment at the mine has a radio on board. These radios connect to a network backbone that carries information between the equipment and the mine?s operations center. When traffic began to bog down on this network, Newmont upgraded to Exalt microwave backhaul systems to carry dispatch, inventory and control information throughout its operation.

Jan 4, 2010

Beneath some of New York?s most iconic buildings ? The Met Life Building, the Helmsley Building, the Waldorf Astoria ? crews are busily at work on the Metropolitan Transportation Authority?s long-awaited East Side Access (ESA) project. In fact, it is 14 floors beneath the famed Grand Central Station where one of the centerpieces of the project, the new Long Island Railroad (LIRR) station terminal, is being blasted and carved into shape. When completed in 2016, the $7.3-billion ESA project will increase LIRR?s capacity into Manhattan and significantly relieve congestion at Penn Station. Currently, 37 LIRR trains per rush hour roll into the crowded Penn Station where many riders must then transfer to subway trains to complete their commute. When completed, the ESA tunnels will bring an estimated 160,000 riders directly to Grand Central Station, saving those riders 30 to 40 minutes. Studies have found that more people work within walking distance of Grand Central than Penn Station. ?The benefits of the project are tremendous,? MTA Capital Construction President Michael Horodniceanu told more than 340 industry professionals attending the UCA of SME?s George A. Fox Conference in New York on Jan. 26. ?The ESA is the first expansion of the LIRR in 100 years. It will increase the East River tunnel capacity by 50 percent and will help support job growth around Grand Central.?

Jan 3, 2010

By Liming Yuan

To reduce fire hazards from spontaneous combustion of coal in longwall gob areas, a series of computational fluid dynamics (CFD) simulations were conducted by the National Institute for Occupational Safety and Health (NIOSH) to model the spontaneous heating of coal in longwall gob areas. The previous modeling results demonstrate that spontaneous heating of coal usually occurred behind the longwall shields and along the face with a bleeder ventilation system. Assuming a stationary longwall face, the spontaneous heating could turn to a spontaneous fire in several days for the most reactive coal under favorable conditions. When the longwall face advances, the spontaneous heating process will be significantly affected. In this study, the effect of longwall face advance on the spontaneous heating in the gob area is investigated using the CFD model developed in previous studies. One longwall panel with a bleeder ventilation system is simulated. The width of the panel is 300 m (984 ft), while the length of the panel is changed between 1,000 to 2,000 m (3,280 to 6,560 ft). The same permeability and porosity profiles are used for gobs with different lengths. The spontaneous heating first develops in the gob when the longwall face is stationary. Then, the face advances at a certain rate. The face advance is simulated as a series of discrete movements, and the effect of the face advance on the maximum temperature developed during the face stoppage is examined.

Jan 3, 2010

Scattered north and south along a 161-km (100-mile) stretch of Interstate 80, Newmont Min¬ing Corp. owns four active mining properties in Nevada?s northern high desert ? Carlin Trend Operations, Midas, Twin Creeks and Phoenix. Among the four, there are nine openpits, five underground mines and 14 processing facilities. While gold is the predominant ore, silver and copper are also produced. And in a move to hold down energy costs, Newmont built and owns the 200-MW (net), coal-fired TS power plant. This plant provides about 65 percent of the power used for Newmont?s own operations, while the rest is sold to NV Energy, which services Nevada and northeastern California. Bringing the Phoenix Mine ? Newmont?s newest in Nevada ? on-line presented many developmental and operational challenges. Located about 19 km (12 miles) southwest of the town of Battle Mountain, the general area had been home to prospectors and other mining companies since the 1860s. But any profitability in developing the lower grade gold, copper and silver deposit at Phoenix proved elusive, with Battle Mountain Gold being the last company to make an attempt. When Newmont acquired Battle Mountain Gold and its Phoenix reserves in 2001, the lower grade of ore was not a deterrent. Newmont found Nevada-wide cost savings synergies for maximizing profit during the depressed gold market of the late 1990s. The new property was aptly renamed the Phoenix Mine, a nod to its rising from the ashes of the dreams and efforts of previous mine owners.

Jan 2, 2010

Already one of the premiere suppliers of mining equipment in the world, Bucyrus strengthened its position when it signed a definitive agreement to purchase Terex?s mining equipment business for $1.3 billion. Bucyrus? acquisition of DBT in 2007 made the company one of the leaders in the field of underground mining equipment to go along with its already solid standing as a surface mining equipment supplier of draglines and electric shovels. The acquisition of Terex mining will make Bucyrus a comprehensive supplier of mining equipment above and below ground. With the acquisition of Terex, the Bucyrus product portfolio will now comprise walking draglines, electric rope shovels, hydraulic excavators, haul trucks, a full line of drills (surface and underground), highwall miners, underground longwall, room-and-pillar and transport machinery, and belt systems for all mining applications. Bucyrus said its ?unmatched suite of surface and underground mining equipment will be paired with its superior parts, consumable products and after-market support throughout the world.?

Jan 2, 2010