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By J. Alatalo

Autogenous grinding is a process of reducing the particle size distribution of an extracted ore by using the ore itself as the grinding media. It is a process that is difficult to control and there is a lack of knowledge of the events occurring inside the mill. To find out more about how the mill behaves under different processing conditions, a full factorial test was performed with iron ore in a pilot-scale pebble mill at the LKAB R&D facility in Malmberget. To complement this work, a strain gauge detector was embedded in one of the mill?s rubber lifters, the Metso Minerals continuous charge measurement (CCM) system, and was used to get more information about the charge dynamics. The data from the experiments has been analyzed. For production purposes, an increase in the number of particles smaller than 45 µm can be regarded as a probable increase in the production rate. The analysis shows that there will be an increase in fines at 65% of critical speed, especially when the mill is 45% full. This setting will also increase the power consumption, but improves the grindability of the ore even more. The deflection of the lifters is smaller for lower critical speeds. A higher degree of filling also gives a smaller toe angle and a higher shoulder angle as expected.

Jan 1, 2011

By Kati Tschöpe

Cathode wear has become an increasing challenge in the aluminum industry due to the use of more graphitized materials. Today, there exist no standard laboratory methods for measuring cathode wear where different commercial materials can be ranked. The typical average wear rate in an electrolysis cell is quite small. The aim of this work was to design a test method where the wear could be accelerated compared to industrial cells. It was focused on polarized tests where the cathode is exposed to electrolyte, which gives higher aluminium carbide solubility. The cathode materials were characterized by microscopy and image analysis.

Jan 1, 2011

By Grover Wallace

At is important for today?s mining executives and leaders not to underestimate the fact that, while the recent downturn in the economy did take its toll on balance sheets and productivity, factors such as emerging countries, aging workforces, globalization and individual knowledge growth did not lay dormant while the economy was in a lull. It is key for mining leaders to be proactive in their talent strategies. Successful mining companies are developing a clear, concise and communicated strategy and placing a high priority on recruiting the right talent in global markets that parallels their business strategy. They are focused on placing the right people in the right jobs.

Jan 1, 2011

By G. W. Evatt

This paper presents the scientific framework underpinning the Resource Valuation and Optimisation Model (RVOM). The RVOM is a Real Options software package, which helps mine owners optimally plan their operations, understand their project risks, and make defensible valuations. This is achieved in the presence of both financial and physical uncertainty. The three key outputs from the RVOM are: Valuation, Optimal Decision and Probability of Decision, where a decision can include any combination of: normal operation, expanded operation, care and maintenance, and abandonment (and variants thereof). This paper presents a clear example of the RVOMs usage to a case-study gold mine.

Jan 1, 2011

By V. C. Kelessidis

The interaction between rock and drill bit during drilling has been modeled for many years, but a complete understanding of the phenomena occurring has yet to materialize. Successful models will allow the prediction of rate of penetration in a given environment and optimal selection of drill bit and drilling parameters, thus minimizing exploration costs. In most rock-drilling models the value of the unconfined compressive strength of the rock (UCS) is used in the predictive equations, within the concept of specific energy, and the value of UCS is the percentage of the value of the stress applied on the drilling bit in order for the bit to advance. While the exact percentage depends on the model used and it is not known with certainty, good knowledge of UCS is nevertheless required before any decent prediction can be made on rate of penetration. Determination of UCS, normally done via destructive testing, requires not only the availability of sound rock core samples but also expensive testing and significant time for the test, which frequently are not available for routine drillability predictions. Hence, a multitude of methods and techniques has been proposed for estimating UCS from various indirect and/or non-destructive measurements, or combination of measurements with neural networks, such as point load index, block punch index, unit weight, and apparent porosity, water absorption by weight, sonic velocity, and Schmidt hardness. The many proposed approaches are critically reviewed and the results are compared, and what becomes apparent is that after many years, not only in mining but also in oil-well drilling, accurate indirect determination of UCS is still an elusive goal. An equation to predict UCS from sonic velocity data is suggested based on several data sets reported in the literature. Use of the specific energy equation with UCS or sonic data and utilization of drilling data allows an estimation of the efficiency of energy transfer from the bit to the rock and of the friction coefficient. Analysis of data reported in the literature, both from laboratory and field studies, has shown that this approach is sound and enables the determination of energy transfer efficiencies and friction coefficients, which for the cases studied range between 15 and 30% and 0.15 and 0.30 respectively. Thus, the suggested data analysis approach allows drillers to focus on inefficiencies and optimize drilling practices in future campaigns. Keywords Rock drillability, unconfined compressive strength, prediction.

Jan 1, 2011

By Andre Thess, Jurij Kolesnikov, Christian Karcher

"During the motion of molten metal under external non-homogeneous magnetic field the induced electric currents produce Lorentz body forces in the opposite direction to the flow, causing deformation of velocity profile, vortical structures, and adding a pressure drop across the magnetic field. The same Lorentz force acts on the magnet system. We analyse these phenomena in metallurgy, namely, at molten metal pumping, stirring, continuous casting, and in contactless Lorentz force flowmeter (LFF). Experiments with liquid metal alloy, including direct measurements of Lorentz forces, velocities, and flow structure visualization were conducted. Based on this study the industrial prototypes of LFF systems were designed, built, and tested in a secondary aluminium production. A molten metal flow at high temperature (700°C-850°C) can be effectively measured. The LFF technique method allows measuring precisely the volumetric and mass flow rates linked with Lorentz force, and the mass accumulated within production process.IntroductionThe present work demonstrates the development of a non-contact electromagnetic system for measurement of a liquid metal flow. Our approach embodies the Lorentz force velocimetry [1-6] technique which is physically based on a measurement of the force acting on an external magnet system the field of which interacts with the flow. This force is exactly equal to the braking Lorentz force induced in a flowing conducting fluid. In what follows a measurement system based on the Lorentz force velocimetry principle. For monitoring and controlling the production process it is desirable to measure continuously the mean velocity of the liquid metal in order to deduce the mass-flux and volume-flux from it. The form and dimensions of the magnet system are in agreement with geometry of the operating channel. We consider here a version of magnet systems in a composition of permanent magnets.The LFF possesses a number of advantages which make it attractive for the measurement of flows in hot and aggressive melts. The relation between the measured force and the desired volumetric flow rate is often linear (for closed channel or at a constant liquid metal level in open channel). For the converting of the measured force into volumetric and mass flow rate we should know the calibration factor. The calibration factor is independent of the viscosity and density of the liquid metal and depends only on the magnetic field magnitude, the electrical conductivity of the liquid metal and the geometry of the channel in which the liquid metal flows. In aluminium production, for instance, there exists a number of standard alloy compositions having welldefined conductivities for which the calibration factors can thus be tabulated. We consider below consistently effects in liquid metals arising under influencing magnetic field, construction principle of LFF and measurements of metal flows at industrial conditions."

Jan 1, 2011

By W. L. Saunders

RBH Note: In the early days of drill & blast tunneling the jobs utilized large crews of drillers and muckers. Advance per round was limited (typically around four feet) but two rounds per 8-hour shift were expected, around the clock. The scene after a shot must have been chaos, with the muckers expected to quickly make space for the drill setup. Makes one wonder how much time was allowed for the smoke and fumes to clear. Note the headgear of the tunnelers.

Jan 1, 2011

By G. Van Weert, O. Wang

ABSTRACT: When exposed to microwaves, rocks containing sulphides adsorb energy preferentially over barren gangue and quickly become warmer with minimal energy consumption. This effect makes subsequent machine sorting of ore from waste rocks or overburden possible using infrared sensing. This paper reports on the 2450 MHz microwave response of a variety of sulphide minerals by mesh size and spatial distribution, as they might occur in ore rocks. The implications for infrared ore sorting are discussed.

Jan 1, 2011

By R. P. Townsend

It is a widely accepted "fact" that a Koepe friction hoist is generally the best solution for production hoisting when compared to a double drum hoists. This would appear to be true if one looks at the initial capital cost of just the hoist, and also if one compares the size of the motors selected for the duty. But is this the whole story? What are the longer term costs involved in the hoist's operation, and what are the relative efficiency's of the two designs? Perhaps the Koepe hoist design enjoys a better reputation than it deserves.

Jan 1, 2011

By Bryan Ulrich

Knight Piésold and Co. hosted its annual roundtable discussion on March 17, 2011 at the Stockman Hotel and Casino in Elko, NV. The theme for Roundtable 2011 was, ?High density tailings, paste, and filtered tailings,? although the topic may well have been subtitled, ?Don?t prematurely rule out any technologies before they are given their day in court.? Bryan Ulrich, Knight Piésold?s local representative, as well as Tom Kerr from Knight Piésold?s office in Denver, CO, were on hand to help facilitate the discussion. Ulrich and Kerr are senior vice president and president of Knight Piésold?s U.S. practice, respectively. The event played host to more than 30 attendees from several western states. Attendees included personnel from a dozen mining properties and various corporate offices. There were also attendees from manufacturing and specialist consulting firms who have been providing services to various high-density tailings, paste and filtered tailings operations worldwide. It may be noted that the term ?filtered tailings? is used in this discussion. Alternative terms, such as ?dry stack? or ?dewatered tailings,? should be avoided whenever possible, as such terms tend to give a false sense about the nature of the material since these materials typically still retain a significant amount of moisture.

Jan 1, 2011

By Rob Farnfield, Ben Williams

The A5 road in the United Kingdom forms an ancient and well-used route through the hills and mountains of North Wales. In the 1990?s a programme of work was conducted to upgrade the road to modern standards. As part of this work a new cutting was constructed to bypass a portion of road routed through a gorge close to the village of Ty Nant. This new cutting was formed by drilling and blasting and included much pre-splitting and extensive rock bolting. This operation caused much concern to local residents relating to vibration, air overpressure and flyrock.

Jan 1, 2011

By Mohammed Sakr

The use of helical piles as a deep foundation option has considerably increased in the recent years to support a variety of loads, from small loads for several applications such as residential housing, solar farms, utilities and retrofit projects, to large loads for many applications such as commercial, power transmission lines, oil facilities and industrial applications. Therefore, it is necessary to qualify and quantify their axial capacities and performance characteristics. This paper presents the first full-scale axial compression and tension (uplift) testing program executed on large capacity helical piles installed in cohesionless soils. A total of eleven pile load tests using either single or double-helix piles with shaft diameters that varied between 324 mm to 508 mm (12¾ in to 20 in) were carried out, including seven axial compression tests and four tension (uplift) tests. The results of the axial compressive and tensile pile load tests as well as field monitoring data of helical piles installed in dense sand are presented in this paper. Based on the results of this study it was found that helical piles have developed significant resistance to axial compressive loads up to about 2920 kN (656 kips) and tensile loads up to 2900 kN (652 kips).

Jan 1, 2011

By Neal Lee

Often the effects of wet boreholes are not taken into consideration when designing a blasting program to exhibit a certain amount of explosive energy per unit of rock such as design by powder factor, expressed in lbs./bcy (pounds explosives per bank cubic yard) or kg/bcm (kilograms per cubic meter), often the effects of wet holes are not considered. This paper examines different methods of loading wet holes and the effects they have on actual explosive quantities/unit of rock. In particular, we are looking at the amount of water trapped within the explosive column (bulk loading from the collar), or the annular space left void of explosives product around and between cartridges (wet-bags) with many of the current wet hole loading methods in use. We will focus on the effect this has on actual powder factor relative to “as designed” dry hole loading values, as well as the effect on performance of the explosives.

Jan 1, 2011

By Rodney Trevor Jones, Arthur Robert Barnes

Anglovaal Minerals acquired the Nkana slag dump from Zambia Consolidated Copper mines (ZCCM) in 1998 and embarked on an ambitious project to pioneer the recovery of cobalt from slag using DC smelting technology. Anglovaal Research Laboratories performed initial pioneering smelting tests in a 250 kW DC furnace over a 3-year period before engaging Mintek for three piloting campaigns at the 1.5 MW level. Mintek had previously developed a reductive smelting process, patented in 1995, using a DC arc furnace for the recovery of cobalt from slags. The results of the pilot-plant test campaigns were used as the basis for engineering the commercial 40 MW operation installed at Chambishi Metals plc in Zambia in 2001. This paper traces the development of understanding of the metallurgical fundamentals ultimately used to predict furnace performance, reviews some of the extreme technical challenges faced, how solutions were identified and highlights some of the critical issues identified during piloting and how these impacted both positively and negatively on the final commercial operation.

Jan 1, 2011

By Michel Ruel

"PID loops – also known as base layers or regulatory controls – form the foundation of any plant’s control layer and it is generally accepted that PID loop health has a direct impact on the plant’s bottom line. Keeping these thousands of control loops in good health has a direct impact on the plant’s bottom line: it reduces variability, improves quality and throughput, and decreases energy costs and raw material usage. This has been well proven and documented in many articles. In the last ten years, technology has evolved: control engineers can now keep track of control loop performance and link it to the root causes of variability. However, they lack industry-wide best practices and criteria for determining what can be considered as excellent, good, fair, or poor performance. To ensure that PID control loops continue to perform well and meet their objectives, control engineers need a combination of (a) an appropriate monitoring technology and (b) best practices for doing the maintenance of base layer controls.Most plants have limited resources and operate with an increasing number of constraints; therefore, using the right tools and including reports in daily workflow is key for success. This paper suggests roles and responsibilities of key players needed to work toward control performance best practices and discuss organisational changes to succeed.INTRODUCTIONAlthough PID controllers are reliable workhorses in the process industry, they are often underrated. Since the 1980’s, computer control has evolved and the control algorithms used by control engineers have become increasingly complex. However, PID controllers still handle over 90% of the control loops in operating plants. Table 1 shows the savings that can be realized by achieving best-practice in several different process control categories (Brisk, 2004). The savings are expressed as a percentage of production costs."

Jan 1, 2011

By L. Mercier, R. Narendrula, F. Desmarais, L. Amaratunga, A. Aledresse

Thiosulfate is recognized as a promising alternative lixiviant to cyanide for the extraction of gold from ore bodies. Gold thiosulfate ([Au(S2O3)2]2), however, is not well-adsorbed by activated charcoal, making industrial scale use of thiosulfate for gold leaching impractical at present. Because of their high specific surface areas (500-1000 m2g-1) and uniform open-framework nanoporosity (pore channel diameters in the range 3-10 nm), functionalized mesoporous silicas are widely recognized as highly effective materials for the selective, rapid and high capacity uptake of mercury, gold and platinum group ions. In the present work, the efficient and rapid adsorption of gold thiosulfate by thiol-functionalized mesoporous silica (hereafter designated MP-HMS) is demonstrated, whereby the thiol groups in the materials bind with the gold complexes by ligand displacement. The adsorbed gold could be leached out using cyanide, regenerating the adsorbent for further uptake cycles. Functionalized mesoporous silica is thus a promising candidate for the preconcentration of gold from thiosulfate leachate solutions.

Jan 1, 2011

By M. Rufli

Until not so long ago most ring geared mills were operated with fix speed motors only. By using the latest generation of medium voltage frequency converters, new possibilities have arisen to improve the grinding process. Beside all the direct and indirect advantages, several dedicated functions have now been implemented for ring geared grinding mills in the minerals industry. The sophisticated operational functions ensure a smooth, safe and reliable operation with minimum stress for the mechanical equipment and therefore utmost availability of the mill. Several papers have already been presented concerning the benefits of using this state of the art technology for mill drives. Now this paper is focusing on the experiences gained with this kind of sophisticated ring geared mill drive system rather than only show and explains the operational benefit of the different functions. Several measurements of different operating conditions, starting, frozen charge remover, controlled roll back, backlash, etc., made on an installed and commissioned 2 x 5 MW dual pinion ring geared mill drive system will be shown and discussed. The accuracy of the load sharing between the two 5 MW motors during starting, normal operation and stopping will be demonstrated using real measurements from an operating system. Finally the inherent features of these drive systems are briefly discussed.

Jan 1, 2011

By T. D. Chatwin

While new jobs and taxes are major incentives for support of mining, stakeholders must also be assured that current jobs, resources and environment will be protected. Mining companies can help achieve stakeholder support by frankly addressing Acid Rock Drainage CARD) issues. To prevent ARD, miners must begin early in the mine life-cycle to develop an ARD management plan and integrate it into the mining operation. As this proactive preventative program is initiated, mining companies also need to engage and collaborate with stakeholders to insure that their expectations and needs are met. Stakeholder engagement is enhanced as mining companies emphasizes the value of clean and available water for current and future generations.

Jan 1, 2011

By Brad Bockey

Whether you are a driver, blaster, or are in charge of filing, you must recognize the importance associated with DOT-required recordkeeping. As various agencies become intertwined with rules governing the explosives industry, the records we produce must be as accurate as possible. The time is right for reviewing your paperwork process from start to finish.

Jan 1, 2011

By John Norton

"This presentation will cover the physical properties of waste heat recovery. It is a two part presentation. The first deals with actually recovering the heat with new state of the art heat exchangers and applying that heat to the furnace combustion and the second part will cover what other processes you can enhance with this ""free"" heat. It will also talk about converting it to steam, hot air or electricity to be used or sold back to the utility company. The economics of various schemes will be reviewed. A brief discussion on State and Federal grants and subsidies will be presented.IntroductionThere are large quantities of wasted heat in the usual aluminum melting process. And, there are several techniques for reducing and/or using some of that wasted heat as you have seen. Any technique that can make use of wasted heat is a form of recovery. This can range from simply preheating aluminum billets prior to melting, to more complicated processes like air-to-air heat exchangers using the boiling and condensing characteristics of special fluids in “heat pipes.” The objective of this type energy recovery process is to move the wasted heat from the hot and dirty exhaust gas stream into some useful process.Waste Heat Recovery in the Aluminum Melting Furnace.There are considerations, of course:1) What might the value be of the recovered energy?2) Can the recovered energy be used within the process? Within the plant? Or by theneighbors?3) What is the capital cost?4) Is the recovery process complicated?5) Will it take additional staff?6) Will it cause additional downtime on the melting line?7) Will the operations staff need to be licensed?Ideally, the process will be simple and inexpensive, the recovered energy will be very valuable, and the whole effort will cause little distraction to the aluminum melting process itself. These would be ideal."

Jan 1, 2011