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By Noel C. Joughin

In making judgements on tolerable levels of risk in industry, and in all spheres of life, it needs to be understood that every action gives rise to risk. Without risk, nothing can be done. Without risk, no economy could be advanced. There is a strong tendency to emphasize the risk at work, but persons who are not working are exposed to a different set of risks. Often persons who are not working face greater risks than persons who are working. Simply, in being alive, one is exposed to the risk of an accident, the risk of contracting a disease, and an extremely diverse variety of other risks. According to the Health and Safety Executive of the UK, it is not possible to have a state of zero risk, because ?a state of zero risk does not exist?. Because zero risk is a physical impossibility, it is not possible to design for a state of zero risk in all engineering design. While the strategic target of achieving zero risk is laudable it does not provide any practical guidance to engineers as to what acceptable limits of risk should be. This causes a significant and real problem in the design for and the management of risk. Without meaningful guidelines, engineers, managers and the authorities often find themselves in disagreement. Thus, it has become essential to establish criteria for tolerable levels of risk and unacceptable levels of risk in order to design and manage engineering systems properly.

Jan 1, 2011

By N. M. Stubina, P. J. Lind

Barrick Gold is in the process of building several new mines and implementing new processes at existing mines for which metallurgical technology is of key importance. The roles of the company's Strategic Technology Solutions team and the Barrick Technology Centre are discussed within the context of their responsibilities within Barrick's Operations Support group. The paper will present an overview of the development of the technology centre from the former Placer Dome Research Centre to its current form supporting strategic technology, capital projects, and operating sites. Novel approaches to research and development will be presented as well as an overview of some of the technologies developed from bench-scale to pilot-scale, and beyond.

Jan 1, 2011

By Alex Doll, Derek Barratt

"There is a number of comminution tests commonly used in the mining industry. Many of the tests are used for a particular grinding model or mill sizing program and are incompatible with other tests of different models. This paper provides an overview of the commonly used grinding and crushing tests, which models (or practitioners) use a particular combination of tests and draws some relationships between the incompatible tests based on the DJB Consultants Inc. database of projects.Case studies will demonstrate similarities and differences between major mining districts with some comments about homogeneous and heterogeneous behaviour within the grindability results.INTRODUCTIONThere are a number of bench-scale grindability tests in use for sizing and predicting throughput for grinding circuits. Part of the reason for this variety is there are a number of different grinding models in use in the Industry, and those models operate using incompatible test results as input (Doll and Barratt, 2008).By using the database of testwork in the DJB Consultants, Inc. (DJB) Millpower 2000 database (see Table 1), some of the more commonly used tests are compared and relationships will be drawn."

Jan 1, 2011

By J. Bouchard, A. Desbiens, M. Maldonado, R. del Villar

ABSTRACT: Despite many years of practical applications in mineral processing plants, the potential of column flotation has still not been fully exploited. The challenge in measuring some key variables is certainly an important contributing factor to this situation. Reliable online measurement of varibles, such as the froth depth, bias, gas hold-up, frother concentration, bubble surface area flux, and bubble size distribution, provides opportunities for the application of various advanced control strategies and real-time optimization based on an economic criterion. For several years, Université Laval’sLaboratoire d’observation et d’optimisation des procédés researchers have been working on these opportunities. This paper describes the most recent advances and current research trends.

Jan 1, 2011

By Tapiwa Chenje, Victor Olivas, Peter Radziszewski

"Ore breakage and grinding media wear have always been considered and determined separately in laboratory tests. However the two processes are linked with the ore broken down in any comminution device being responsible for the majority of the steel wear experienced. The Comminution Dynamics Laboratory (CDLab) successfully developed a test methodology that can more accurately predict grinding media wear in tumbling mills than the Bond Abrasion test. This paper looks at the possible application of the abrasive wear methodology to determine breakage parameters of the same ore used in the abrasion test. Results indicate that breakage parameters comparable to t10 can be determined using the Steel Wheel Abrasion Test (SWAT), while using significantly less ore than standard breakage tests.BACKGROUNDThe Rubber Wheel Abrasion Test (RWAT) is an internationally accepted and widely used method for determining the abrasion wear behavior of materials. The abrasion wheel test was developed to primarily utilize a steel wheel (Brinell, 1921). Haworth (1949) criticized using of the steel wheel by arguing that increasing the contact area size in the steel wheel test causes a change in the wear rate with time. He suggested that the use of a rubber wheel instead eliminates this problem, leading to the adoption of the RWAT which was standardized in ASTM G65 (2004).Radziszewski (2002), however, found that the use of the Steel Wheel Abrasion Test (SWAT) was more applicable for wear testing in the mining industry for two critical reasons. Firstly, the major cause of wear in a ball mill, the most frequently used comminution device, is ball-ore-ball contact and also ball-ore-liner which both are metal-ore-metal contact. Therefore, using the steel wheel has the advantage of providing a similar abrasive environment to the one that takes place in a real ball mill. Secondly, the SWAT creates the potential of running experiments at much higher force regimes that are closer to what happens in actual mills, unlike the RWAT which is a low stress test."

Jan 1, 2011

By Robert Hopler

SECTION 9.---BORING AND BLASTING.*155. Blasting is the operation of bringing down and detaching from its bed or position masses of material by means of explosives.

Jan 1, 2011

By Aiden Carey, Jim Kennedy

During December 2007, Lake Cowal Gold Mine located in New South Wales, Australia experienced a significant pit wall failure. The wall failure resulted in the deposition of a large quantity of saprolite consisting largely of clays and lake bed sediments to the bottom of the Phase 1 open pit mine. This wall failure ultimately buried two loaded blast patterns.

Jan 1, 2011

By A. Elsayed

Lightweight metals such as magnesium show potential in replacing aluminum alloy castings for engine cradles, cylinder heads and transmission cases. Unfortunately, magnesium alloys are susceptible to entrapping oxides and other impurities during casting that hinder strength and ductility. The current study examined various filter sizes and configurations with the aim of improving the mechanical properties of permanent mould cast AZ91E. The unfiltered casting had a yield strength, tensile strength and ductility of 93.3 MPa, 153.3 MPa and 2.2 % respectively and increased to 96.5 MPa, 167.0 MPa and 3.1 % with the use of a fine mesh filter within the well of the mould. The increased strength and ductility was likely due to the filtered castings containing fewer inclusions on their fracture surfaces as compared to the unfiltered castings.

Jan 1, 2011

By H. Y. Sohn, Haitao Wang, Moo Eob Choi

"A novel ironmaking technology is under development at the University of Utah. This technology produces iron directly from iron ore concentrate by gas-solid suspension reduction. Hydrogen is the main reducing agent for high reactivity and for the elimination of carbon dioxide release in this ironmaking process. The direct use of concentrates allows bypassing the problematic pelletization/sintering and cokemaking steps in the steel industry.Intrinsic kinetics of the suspension reduction of magnetite concentrate particles by hydrogen has been measured. Experiments were carried out in the temperature range of 1423-1673 K, other experimental variable being hydrogen partial pressure, the amount of excess hydrogen and particle size. Under most experimental conditions, 95% reduction was attained within several seconds, which presents sufficiently rapid kinetics for a suspension reduction process. The reaction kinetics followed the nucleation-and-growth equation, and a rate equation that contains all the effects of the experimental parameters has been obtained.IntroductionWith the rapid increase in steel production, it is critical to control CO2 emissions which is the main greenhouse gas. It is inevitable to release a huge amount of CO2 when coke and/or coal are used as the main reducing agent in producing iron. As one of the methods to reduce the CO2 emission from ironmaking, the utilization of the gaseous reducing agents and fuels, including hydrogen, has been investigated [1-6]. The use of such gases forms the basis for a new ironmaking technology under development for producing iron directly from fine concentrates by a gas-solid suspension technology. This technology would reduce energy consumption by about 40% of the amount required by the blast furnace and drastically lower environmental pollution, especially CO2 emission, from the steel industry [4]. This is accomplished by adopting H2-based reductant and bypassing pelletization/sintering and cokemaking steps. Unlike other gas-based alternative ironmaking processes using shaft furnaces or fluidized-bed reactors, the suspension reduction technology is a high-intensity process because it will not suffer from the problems that other processes do when operated at high temperatures mainly from the sticking and fusion of particles."

Jan 1, 2011

The mining and minerals extraction industries have often been demonized by the public as industries that put profits and production before people. It is true that the inherent danger of the work has led to more fatal accidents than anyone associated with the industry would care to remember. But, in stark contrast to what has often been said, the truth of the matter is safety is now the top priority of every miner, from the face of the longwall to the executive boardroom. Without safety, nothing else matters. This message was told and retold by representatives from some of the world?s top mining and petroleum companies from Oct. 11-13 during the inaugural Safety and Reliability in the Mining and Resources Industries Conference in Calgary, Canada. The meeting was hosted jointly by the Canadian Institute of Mining, Metallurgy and Petroleum (CIM) and the Society for Mining, Metallurgy, and Exploration (SME). It was the first of a series of conferences to focus on these important topics. Next year, the conference will be held in Minneapolis, MN from Nov. 13-15.

Jan 1, 2011

By Siqing Liu

A low-grade cassiterite-magnetite ore from Sichuan province, China, is finely disseminated, assaying 0.39% Sn and 23.20% Fe, respectively. Mineralogy studies show that the fine-sized cassiterite is mainly disseminated in iron minerals and gangue. Moreover, the embedded size of cassiterite is very fine and must be ground to -0.01 mm to achieve a degree of liberation of about 90%. Therefore, fine grinding needs to be conducted to get a high quality tin concentrate and a great loss of tin cannot be avoided when treating the ore by gravity concentration. Based on the above facts, a two-stage separation, with a low intensity magnetic separator and a shaking table, was selected to test the ore. Compared with other similar plants, a relatively good separation has been achieved. Three acceptable products for smelters were obtained as following: iron concentrate assaying 61.69% Fe with a recovery of 75.09%, tin concentrate assaying 27.21% Sn with a recovery of 56.97% and a sulfur concentrate assaying 40.86% S with a recovery of 32.03%, respectively.

Jan 1, 2011

By John Brennan

Necessity, they say, is the mother of invention. Certainly that sentiment held true during the early stages of explosive engineering. While seaside forts were concerned over static ignition of their black powder caches in the 14th century1, the mining industry in the 1800s were plagued by accidents surrounding the ignition methods for their black powder blasts.

Jan 1, 2011

By Tony Lipiec, Chris Fleming, Larry Urbanoski

In 2009, the Canadian Mineral Processors (CMP) became aware that Canadian securities regulators were amending the contents of National Instrument 43-101. NI 43-101 is a set of regulations which establish how ore resources and reserves are presented to the investing public. The documents produced under NI 43-101 are central to the ability of many companies to raise financing for their projects. With the increase of metallurgical complexity, and decrease of head grades encountered in new deposits, the role of the Qualified Person (QP) in determining process performance has become increasingly critical in determining the classification category of resources and reserves. Given the challenges confronted by those involved in defining the concentration and extraction of minerals and metals, there is a need to provide support to these QPs. To address these concerns, the CMP established a sub-committee in 2010 to create a set of guideline documents to assist the QP involved in process matters as to what should be included at the various levels of study supporting the establishment of resources and reserves in NI 43- 101. The results of the sub-committee work are presented and the considerations in the writing of the documents are discussed.

Jan 1, 2011

By S. O?Connor

When one looks back and does assessments of what has been the key ingredient in achieving success in our safety efforts, there are many issues that spring to mind and cover a wide array of elements. One does not know which has the ultimate maximum effect. In his presentation yesterday, Alan Peers, our SHEQ leader, covered a lot of detail with the way we are managing safety at Modikwa. I have attempted to identify some of the key essentials in making the mine safe. Passion Safety is addressed with a passion that is unbelievable at times. When I get phoned because an incident has occurred and in reporting the incident, there are already action plans being put in place to prevent re-occurrences, you understand the commitment to put employees? safety first. You hear the disappointment in your subordinates? voices when they have to share the fact that an incident or accident has occurred.

Jan 1, 2011

Joy Mining Machinery has developed a new generation of ultra-heavy shields for Anglo Coal Australia?s Moranbah North Mine in the Bowen Basin region of Queensland. These are the largest two-leg longwall shields yet produced by Joy. The longwall at Moranbah North posed a number of challenges, among them a thick, inclined, sometimes undulating seam with increasing depths. The result of this was the need for larger, heavier, more powerful roof supports. Knowing that future longwalls would be going deeper, mine management determined that shield yield ratings of at least 1,750 t (1,930 st) was what would be required.

Jan 1, 2011

By Frank Field, Randolph Kirchain, Elisa Alonso, Richard Roth, Nathan Fleming

"High material prices and price uncertainty can be harmful to manufacturing firms. Increased use of recycled materials, industry-wide, can lower both material prices and price variability; moreover, increased recycling decreases the use of primary material, which mitigates price increases due to scarcity effects. These stabilizing and price lowering effects are explored using an Aluminum industry model. We show that (a) increased recycling leads to smaller price fluctuations in the presence of a primary metal supply perturbation, and (b) that the more substitutable the secondary metal is for the primary metal, the lower the overall material price is.IntroductionThe price of an industrial metal is expected to be a function of both the marginal cost of extraction and its scarcity[l-2]: where scarcity can be defined as the degree to which anticipated demand exceeds the known supply. Recycling end-of-life metal increases the apparent supply of the metal, or-in a functionally equivalent, but alternative conception-lowers the demand for primary metal; this lowers primary metal scarcity and should, theoretically, reduce its price. To the extent that this theoretical prediction holds true, recycling can provide benefits to consumers of industrial metals in the form of lower prices.Using a platinum industry model, prior work by Alonso[3] has shown that increased industrywide recycling can reduce metal price volatility because the secondary metal production (a) offsets virgin metal depletion, and (b) responds to supply-demand balance fluctuations more rapidly than the primary market. However, Platinum is not a typical industrial metal in the sense that secondary metal is perfectly substitutable for primary metal: Both primary and secondary platinum metal are functionally equivalent and have a common price. Other metals, such as secondary aluminum which is used as an example case in this study, contain varying degrees of other elements that were either intentionally added, or were inadvertently mixed in with the metal during the scrap recovery process. Consequently, different grades of scrap exist that have different profiles of elements in their composition. Depending on their particular profile of elements, more or less of a given grade can be used as a mass fraction of the final alloy-the secondary metal is not perfectly substitutable for the primary metal. For the purposes of this paper, the aluminum mass fraction of the final alloy that can be made up of secondary aluminum is termed the secondary substitutability of that grade in that alloy."

Jan 1, 2011

By Maxime Tacher

BRP (Bombardier Recreational Products) designs and commercializes recreational vehicles such as watercrafts, sport boats, snowmobiles, ATVs... The Spyder roadster is the last product in the Can-Am product family lineup. To remain at the forefront of innovation, a hybrid motorization version of the Spyder is being developed in order to reduce fuel consumption and emission of greenhouse gases. But, the addition of electric components (e-motor, lithium-ion battery... ) raises the issue of added weight and volume. This article deals with the mass reduction of this Spyder by optimizing its frame.

Jan 1, 2011

By J. L. Viljoen

t has long been the drive of the industry and all operations to create an environment that is free of injury and illness. We have come a long way; the leaders, executives, managers, supervisors and workers are to be commended for relentlessly driving to create, what I call a ?White Flag Day Every Day?. Yet I am also aware of the huge shift we still need to create in the industry, on the operations and in the workplaces to have them free of injury and illness. Keywords People, values, care, trust, belief.

Jan 1, 2011

By T. G. Joseph, E. Lampard

ABSTRACT: Surface mining operations must manage variability from within their operations as well as variability imposed upon them by external forces. A framework to manage both internal and external variability through the continuous review and adjustment of a mine plan during active mining lifetime operation is introduced, to minimize lost production and maintain operational safety. The observational approach of “observe, evaluate, interpret, predict, and adapt” is employed as the backbone of this approach. Although written with a surface mining operation in mind, the framework outlined in this paper would be equally applicable to any mining or processing operation.

Jan 1, 2011

By F. Sorensen

ABSTRACT Electricity production by the Electricity Supply Commission of South Africa (Eskom) is the most important beneficiation process for South African coal. As one of the world’s lowest cost producers, energy-intensive industries such as ferroalloys and aluminium were introduced. However the poor were neglected. The white paper on energy policy (Department of Minerals and Energy, 1998) sought to redress this. Also, chasing economic growth to generate jobs resulted in high electricity demand and interruptions. Lifespan estimates of South African coal reserves based upon peak theory vary widely. Approaching peak, coal production in the future will be more expensive and, thus, contribute to more expensive electricity, which could inhibit industrial development unless South Africans work smarter.

Jan 1, 2011