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By S. Poirier, J. -M. Facteau

The gold mine sector is presently facing low gold prices as well as technological challenges. Its competitiveness and survival will depend on new mining methods and equipment to improve ore extraction. In 1999, Natural Resources Canada has invested new funds over a period of three years at CANMET’s Experimental Mine to establish the Narrow-Vein Mining Project. A team of engineers and researchers specialized in mining, mechanics and electronics engineering are working to meet the critical need of ore-extraction technology. CANMET’s programme in mechanization and automation for narrow-vein mining had, prior to 1999, realised several important achievements, many in co-operation with a consortium of mining companies(Soredem). The investment of new funds in this area will contribute to develop technologies to improve the productivity, as well as health and safety conditions of the narrow-vein mining industry. Several important impacts of this project will be monitored. In particular, a database of methods and equipment used in narrow-vein mining is being developed. A key thrust is to identify operators’ needs with respect to the development and automation of mining methods and equipment. Based on those needs, research and development projects will be created. The paper will present the objectives of the narrow-vein mining project and some of the results, including the web site developed to present the results of the project.

Sep 1, 2001

By L. Raaths

This paper outlines the process of improvement utilizing performance monitors and GPS systems on an opencast strip mine. Its primary focus is to maximize coal exposure by draglines and secondly to improve on those processes impacting directly on the dragline operation. The Aquila (DM2/5 system) navigation and monitoring systems were installed on the overburden drills. Their main function is to eliminate manual staking and positioning thereby ensuring a regular pattern being drilled. Holes drilled to planned depth reduce drill metres and it minimizes coal losses and contamination at the coal interfaces. The CAES (Computer Aided Electronic System) will be installed and evaluated on the Caterpillar D11 dozers at Optimum. This system ensures a correct dragline pad elevation through the use of planned elevations and GPS technology to achieve the optimal pad elevations for draglines consistently. The draglines are equipped with a Dragline & Operators Performance Monitor. This monitor allows the operator to control his own performance. It reports on all productivity, method and poor operating techniques. These monitoring systems send critical operational information back to the office. This source data resides in central databases from where it is converted and integrated into management information. To manage an operation means that you as a manager must be able to set objectives and targets and to achieve your goals the activities involved must be measurable.

Sep 1, 2001

By J. M. Zhuang

Lignosulfonates, by-products of the sulfite pulping process, have been utilized in a process [1, 2] to treat acidic rock drainage (ARD). This process is referred to as the LignorTM process. In the present study, lignosulfonates were found to protect lime from developing an external surface coating, and hence to favor its dissociation. Further, the addition of lignosulfonates to ARD solutions increased the clotting and settling rate of the formed sludge. The capability of lignosulfonates to form stable metal-lignin complexes makes them very useful in retaining metal ions and thus improving the long term stability of the sludge against leaching. The LignorTM process involves metal chelation with lignosulfonates, ARD neutralization by lime to about pH 7, pH adjustment with caustic soda to 9.4 ? 9.6, air oxidation to lower the pH to a desired level, and addition of a minimum amount of FeCl3 for further removal of dissolved metals. The LignorTM process removes all concerned metals (especially Al and Mn) from the ARD of the Britannia Mine (located at Britannia Beach, British Columbia, Canada) to a level lower than the limits of the BC Regulations. Compared with the high density sludge (HDS) process, the LignorTM process has many advantages, such as considerable savings in lime consumption, greatly reduced sludge volume, and improved sludge stability.

Jan 1, 2003

By J. E. Gebhardt, J. A. Herbst, K. Y. Lee

Benefits of proper control of reagent usage in flotation circuits are typically improved metallurgy and savings in reagent costs. Improved metallurgy can mean more consistent product quality, i.e., final concentrate grade, better recovery of product values from the feed, or higher plant throughput at existing target recovery, and grade values. Flotation performance is sensitive to a variety of process disturbances which occur in operating plants, such as changes in flow rate, percent solids, size distribution. flotability of mineral species, etc. A way to handle these variations is to fully understand the dynamic flotation responses to disturbances and to implement a suitable control strategy to compensate for these disturbances. Depending on the objectives of the control system, various types of control strategies are available which employ different levels of refinement to achieve the desired performance. Typically, variables such as collector and frother dosages and reagent addition points can be manipulated to affect the performance of the circuit. In the case of sulflde mineral flotation, manipulation of the process electrochemical potential, in flotation and in grinding, offers another degree of process control. Because of the complex and interactive nature of flotation process variables, optimized reagent control requires consideration of all, or at least the most important, interactive variables of the flotation circuit. Model- based optimizing control provides a framework to handle the complex and dynamic nature of flotation reagent process control.

Jan 1, 1994

By Charles N. Speltz

The cost of transportation of industrial minerals frequently is higher than the cost of the product. When a mine, industrial-mineral plant, or customer is served by a single railroad, because of the lack of competition, that railroad may in- crease rates and/or reduce service so that the economics of that mine, plant, or customer are affected adversely. Transloading of industrial minerals from rail-to-truck or truck-to-rail to improve economics and sales of product is not a new concept. However, transloading to create competition and reduce freight costs or to improve service is a relatively new concept brought on by the recent mergers of many of the main-line railroads, both in the eastern and western United States. For example, in 1998, with completion of the Burlington Northern/Santa Fe (BNSF) and the Union Pacific/Southern Pacific mergers (UPSP), the western United States has only two main-line railroads. The industrial-mineral producer, to reduce the cost of transportation or increase the level of service, must evaluate potential transloading opportunities in light of higher prices and reduced service brought on by reduced railroad competition. This paper discusses industrial-mineral transloading and examines the case history of the Tucker Hill perlite project in southern Oregon. The Tucker Hill project is a classic study of industrial-minerals transloading where the project would have failed without the transloading.

Jan 1, 1999

By Jennifer Pakula

Productivity improvements in underground mining are becoming harder to find. Most mines quickly identify deficiencies in their processes and then struggle to make productivity gains beyond that plateau. One way to increase productivity in this situation is to modify existing methods of operation. Vale?s Stobie Mine has been in operation since the late 1800?s employing a variety of mining methods. Many mining advances have been incorporated over time. With the advent of mechanized rubber tired equipment, sublevel cave mining was introduced to allow economic extraction of a large low grade area. Additional productivity gains were seen in the sublevel cave area with the introduction of preloading production drill holes. In preloading, the holes are loaded with bulk emulsion ahead of the production cycle and then primed for blasting as needed. The introduction of preloading, although giving the Stobie sublevel cave process an overall productivity gain, saw an increase in oversize due to the collar priming technique employed. Handling oversize material prohibited the operators from handling additional units of optimally sized material. Prepriming, adding detonators at the toe and midcolumn of the production holes during the preloading process, was identified as a change that could reduce the formation of oversize. This paper describes the introduction of prepriming to the sublevel cave mining method and focuses on the process Stobie employees followed to ensure a safe transition to this productivity improvement.

Nov 1, 2011

By S. A. K. Forson, Newton A. Amegbey

In order to investigate production decline in Tarkwa Goldfields Ltd., located in a tropical rain forest, amongst other areas, a health survey was conducted with the aim to see 1. The health status of the workers. 2. Which parameters carry the most information about the health situation and which of them can be applied easily during screening programmes. 3. What steps could be taken to improve the situation. In all 249 workers were investigated. A non-invasive method involving taking of body weight and arterial blood pressure was used. All subjects were required to answer a questionaire. Emphasis was placed on the history of malaria and diarrhoea within the last six months. Both management and workers co-operated fully. Another set of 110 workers from a neighbouring tyre factory were also investigated for control. Among the underground workers, the percentage body weight loss during a shift increased with decreasing body weight. Dehydration levels could be as much as 4 to 5% of body weight. This could be attributed to the fact that workers took insufficient or no water during the shift. The health status of the mine workers was generally poor and in our opinion malnutrition combined with malaria severely threatens the health and well-being of the workers. Hypertension is also a problem. An improvement in production is intimately linked with the well-being of the workers.

Jan 1, 1989

By T. Yalcin

It is well recognized that machine type and machine characteristics play vital roles in the successful application of froth flotation in mineral processing. Since the early 1900s, a multitude of machine designs have been and are still being introduced in an attempt to improve flotation efficiency. Machines based on mechanical agitation have been the most dominant in industrial practice. However, in recent years there has been a growing interest in pneumatic flotation units because of their claimed simplicity, low cost, high throughput and good metallurgical performance. This work was carried out to assess the effectiveness of pneumatic flotation on a magnetite ore. The method was applied using a prototype pneumatic flotation device that utilized a suitable nozzle for bubble generation. Important variables of the process were examined and optimized, including the nozzle size, air flow rate and froth thickness. Further tests were conducted to determine the influence of frother dosage and to explore the improvements that could be made on concentrate grade and recovery by cleaning and scavenging. Under the best test conditions, an iron concentrate was obtained with a grade of 66.4% Fe and a recovery of 97.7%. Particularly, the recovery was superior in comparison to that of mechanical flotation. This was attributed to the ability of pneumatic flotation to create and maintain a relatively thick froth layer.

Jan 1, 2002

By Sergio Castro, Janusz Laskowski

In the flotation in highly concentrated electrolyte solutions not only ionic strength but also chemical composition, flotation pH and mineral properties play an important role. As a result an improvement or depression may be observed. A strong improvement in the floatability of hydrophobic bituminous coals and other inherently hydrophobic minerals is characteristic for the "salt flotation process", which is carried out in concentrated electrolyte solutions at natural pH and without addition of any flotation reagents. However, pH is a key factor when saline and hipersaline waters with hydrolyzing metallic ions are used as process water. In the case of flotation of Cu-Mo sulfide ores in seawater, molybdenite is strongly depressed by the Mg2+ hydrolysis products when pH is raised to depress pyrite. Process water with a high content of Mg2+ and Ca2+ ions, and this also includes seawater, have deleterious effect on the anionic flotation of industrial minerals with fatty acids. The flotation of potash ores is carried out in NaCl-KCl saturated brine (6-7 mole/L of NaCl and KCl) with the use of long-chain amines. Such a high electrolyte concentration changes dramatically the amine Krafft point making the collector insoluble in brine; its mode of action entirely differs from that in conventional flotation processes.

Jan 1, 2014

By Frank Sames

A recently developed model is used as a tool to optimize blast designs based on the continuing combination of full scale blast assessment and performance prediction. The use of this tool has allowed to evaluate present blasting practices and proposed designs through a better under-standing of the influence of the various blast parameters. The empirical model has a modular structure covering all aspects of blast performance including 30 fragmentation, potential rock damage and 30 muckpile profile prediction. The modules are assisted by a terrain model which is compatible to most mine mapping systems, and a blast design editor. The evaluation is summarized in a blast management module. Various studies have recently been undertaken using the model to qualify and improve blast designs with respect to wall stability, optimized fragmentation and muckpile distribution, as well as to the control of the environmental effects such as blast vibration and airblast overpressure. To verify the predictions of the modeling, full scale blast assessment techniques were used to qualify blast geometry, explosives and initiation performance, rock movement, muckpile distribution, near- and far-field vibration levels and airblast ovepressures. The model provides a tool to gain an improved understanding of blasting and blast control. The modeling results are presented in a visual form which allows simple comparisons of proposed blast designs. Additionally, the model can be used for detailed analysis and blast management.

Jan 1, 1996

By G. M. Wilemon, B. J. Scheiner

The Bureau of Mines conducted investigations on extracting phosphate values from fine-particle wastes generated during the mining and beneficiation of phosphate ore by leaching dried wastes using a H2SO4-methanol mixture. Although phosphatic clay waste contains up to a third of the phosphate originally present in the ore, recovery of these values represents a significant challenge due to the fine grain size of the material, the particles averaging less than one micrometer in diameter. Waste samples obtained from two Florida producers yielded phosphate extractions of 71 and 84 pct, respectively, when leached under ambient conditions and at a stoichiometric acid ratio of 1.4:l. Elevated temperatures did not improve the amount of phosphate extracted. Undesirable A12O3, Fe2O3, and PlgO impurities were largely rejected; higher grade wastes gave acids that meet established industry impurity standards and lower grade samples yielded acids that marginally fell short of the standard. Separation of the crude acids from the insoluble residues was accomplished via vacuum filtration through either filter paper or commercial filter cloths. Both filtration rates and solids retention were improved by the addition of 0.5 lb/ton of poly(viny1 acetate) (PVAc) or poly(ethy1ene oxide) (PEO) to the methanol-acid slurries. These results show potential for substantially increasing the reserves of an important domestic resource.

Jan 1, 1989

By F. Rosenblum, P. Spira

"A correlation has been established between the oxygen demand of Brunswick Mining and Smelting ore and flotation results at the bench, pilot plant and operating plant scale. A method of dete""1llining the aeration requirement of sulphide ores on the basis of this correlation is presented. It is shown that abraded iron from grinding media plays an important role in aeration and flotation. Laboratory grinding must therefore be conducted under controlled conditions with suitable grinding media in order to obtain the true aeration requirement of the ore.A method of evaluating aerator efficiency, also based on oxygen demand measurements, has been used successfully at Brunswick Mining to design pilot plant and full-scale aeration systems.1. IntroductionPre-flotation aeration of sulphide pulps has been practiced in the Noranda Group for many years to help in the depression of pyrite and pyrrhotite and to promote chalcopyrite and/or galena. Recently, two out of three parallel circuits at the Brunswick Mining and Smelting Corp. Ltd. concentrator have been converted on a test basis to a new flowsheet incorporating aeration as a basic step. Among other benefits, a substantial decrease in the middlings load has been achieved as a result of improved pyrite rejection. There has been increasing interest in other organizations in the potential advantages to be derived from' aeration in terms of improved metallurgy and/or decreased reagent consumption."

Jan 1, 1978

By P. Saari

The Talvivaara deposits are located in Eastern Finland, within the Kainuu Schist Belt. These polymetallic sulphide deposits are of relatively low grade, but bioheapleaching enables economically profitable nickel extraction from the ore. Zinc, cobalt, and copper are also produced. Talvivaara?s production process begins with large-scale open-pit mining and four crushing stages, followed by stacking of the ore in bioleaching heaps. The ore is first leached for 13?14 months on the primary leach pad, after which the leached ore is reclaimed, conveyed, and re-stacked on the secondary heap pad. After secondary leaching, the barren ore will remain on the secondary heaps permanently. In the metals recovery process, the metals are precipitated from the pregnant leaching solution. Construction of the process was begun in spring of 2007 and first metal sulphides were produced at the plant in October 2008. The development of the bioheapleaching process was begun in a 17 000t on-site pilot heap operated during 2005?2008 and has continued in the industrial heap. At industrial scale, the development measures have focused on improving the permeability and aeration of the heap. Challenges with crushing and aerations systems at the beginning of industrial-scale leaching delayed the increase in metal recovery, but after the first two operational years the leaching results have improved significantly and the process is performing as targeted.

Jan 1, 2012

By Wong KY, Woodcock JT

Previous results have shown how con- trolled-potential sulphidization (CPS) can give improved metallurgy during rougher flo- tation of mixed oxide-sulphide copper ores. Results in this paper, using different samples and different equipment, confirm the previous results and extend the application of CPS to cleaner flotation. By using CPS, faster flotation of copper minerals (chalcocite and malachite) from clay was obtained in roughing and cleaning, and improved concentrate grades and recoveries were achieved over those by conventional manual control. The optimum sulphidizing potential (i.e. the potential of a sulphide ion-selective electrode versus a saturated calomel electrode) was -500 mV, and could be controlled to ¦5 mV, during four rougher- scavenger and three cleaner-re cleaner stages. This optimum gives the best balance between copper recovery, concentrate grade, and sodium sulphide consumption. Five cleaning circuits and five ore com- posites of different composition (0.55-1.50 per cent Cu) were examined as well as the effect of feed size and pulp density. Better results were obtained at 20 per cent solids in a Denver cell than at 33 per cent solids in an Agitair cell; this may have been related to the high clay content of the ore. Commercial equipment for pilot plant or full-scale plant application of CPS is cur- rently being developed.

Jan 1, 1986

By D Beck

Open access to forecasts of mine geotechnical performance in the form of open databases of model results has been considered risky in the past, with a concern that the results will not be understood or will be misused. However, some modelling techniques allow very high similitude modelling of mine deformation and the results can be presented as deformation, damage and other parameters which are unambiguous and which all engineers can be more easily trained to understand. With some effort, sufficient reliability and quantifications of error are possible to overcome many of the issues.Allowing more members of the planning team to have direct access to forecasts of mine deformation will promote awareness of geotechnical issues and will act as a mechanism for improving mine designs. The models will also be more easily integrated into quality assurance programs, by providing a framework for understanding measurement results.The sufficiency requirements for undertaking simulation aided mining engineering will be presented, included some conclusions about requirements for training, quality standards and software development.

Mar 21, 2011

By K Blay, C McCamley, P Petrucci

The Newmont Boddington Gold (NBG) processing plant was designed for 35Mt/y with ball mills expected to deliver a combined new mill feed rate of 4837 tonnes/hr. Since beginning commercial production in late 2009, the plant has steadily increased throughput to meet design capacity in 2014 and reached 37 Mt/y in 2015. Through improved efficiencies, changes to the milling circuit have taken place since commissioning to take the plant beyond its design to an actual throughput of 39.0 Mt in 2017 and a budgeted throughput of 39.4 Mt/y this year.The NBG milling circuit has four parallel ball mills, each consisting of a 7.9 x 13.4 m ball mill with twin 7.5 MW fixed speed motors in closed circuit with twelve 650 mm cyclones. Each mill is fed by two wet screens with the undersize gravitating to a mill discharge hopper where it is combined with the ball mill discharge and pumped to hydrocyclones for classification. The cyclone underflow is re-ground to a target P80 of 150 µm.This paper will focus on process improvements made to the NBG milling circuit which include cyclone reconfiguration, fine screen panel redesign, implementation of an expert control system, mill power draw increase and grinding media changes to take NBG beyond its design throughput.CITATION:McCamley, C, Petrucci, P and Blay, K, 2018. Going beyond design at Newmont Boddington Gold, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 497–508 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

By A. A. Brant

"Improving geological and geophysical evaluation should serve to reduce the early-stage risk assessment and there-by contribute to exploration expenditure stimulation. The limitations of present-day methods are reviewed, particularly as to anomaly causes, depth penetration and quantitative physical interpretative abilities. Some of the problems now under study are discussed. Future developments expected include the treatment of quantitized geologic and geophysical data, as well as continuing attempts toward computerized interpretation."

Jan 1, 1967

By T Raynlyn, R J. Holmes, J R. Manuel, A Poliakov, L Lu

The prediction of sintering performance of iron ore fines and the possibility of targeted optimisation of specific sinter properties are very important for both the iron ore industry and related research organisations. Physical pilot-scale sinter runs require large amounts of raw materials and are expensive, so it is critical to target large test work programs with many different sintering parameters effectively. To predict values for sintering performance parameters such as tumble index (TI), low temperature reduction disintegration index (RDI) and productivity, a comprehensive database of pilot-scale sintering experimental results has been established and empirical modeling conducted. Similarly to earlier work, physical, chemical and mineralogical characteristics of the iron ores have been considered. However, in contrast to the previous work where only one textural parameter was taken into account, namely the proportion of dense haematite ore texture, the current model includes the abundances of several different textures which were combined into different textural factors corresponding to different sinter properties. Coefficients for the variables within specific regression equations can provide a better understanding of the effect of the variables on the corresponding sintering performance. The modelling results have also been used for predicting the sintering performance of mixtures that were not part of the database used for establishing the models. Comparison of experimental and modeling results for the verification test data is also reported in this paper.

Jan 1, 2009

By O. Bazhko, F. D. L. Uahengo, Y. R. S. Hara

Although the conventional acid-reductive leaching method effectively extracts copper (Cu) and cobalt (Co) from Cu–Co oxide ores, efforts to enhance hydrometallurgical performance are ongoing. This study evaluates the influence of sulphuric acid (H2SO4) and sodium metabisulphite (Na2S2O5) on metal extraction from Zebesha Cu–Co oxide ore using ferrous sulphate heptahydrate (FeSO4·7H2O) and ferric sulphate (Fe2(SO4)3) as lixiviants. Ore samples (<150 μm) were leached at ambient temperature for two hours, and metal concentrations were determined via X-ray fluorescence analysis. In the FeSO4·7H2O system, Co, Mn, and Ni recoveries increased w=ith Na2S2O5 concentration, reaching a maximum of approximately 80% Co at 150 kg/t, while Cu recovery remained below 5%. Conversely, with Fe2(SO4)3, Cu recovery peaked at 88% at 50 kg/t Na2S2O5, then declined to 79% at 150 kg/t. The addition of H2SO4 improved metal recoveries in both systems. Notably, 60 kg/t H2SO4 yielded 92% Cu extraction in Fe2(SO4)3, while Co, Ni, and Mn remained below 40%. However, in FeSO4·7H2O, Co recovery improved from 40% to 84%. These findings suggest Na2S2O5 is more effective for cobalt extraction with FeSO4·7H2O, whereas H2SO4 enhances copper extraction in Fe2(SO4)3.

Oct 24, 2025

By Sedat Esen

"This paper presents a critical review of the fragmentation data obtained from some large open pit copper and gold mines. Database ncludes 35 mines with Uniaxial Compressive Strength values ranging from 19 MPa to 227 MPa (2756 psi to 32923 psi). Variation in the fragmentation data and the causes are discussed in detail. Quality assurance/quality control (QA/QC) in drilling and blasting was shown to have significant impact on fragmentation. In addition, controllable blast design parameters including drill pattern, powder factor, blast timing, stemming length, etc as well as the large blast sizes havesignificant potential to improve fragmentation. Feed size requirements of crushing and grinding circuits were discussed in detail. The paper discusses the effects of different size fractions (top size, 80 %passing size and % passing 10 mm (0.5 in)) on the downstream processes and the role of the fragmentation model in the mine to mill process. Blast domains based on rock strength and structure canbe established by using a fragmentation model which is calibrated using measured fragmentation data. This allows the blast engineer to compensate for changing rock characteristics and stabilize the ROMfragmentation size and result in increased crusher and mill throughput. Two case studies were presented to demonstrate the benefits achieved in downstream processes. Main benefits were reduced downtime at crusher circuits, improved mill throughput as well as reduced total operating cost. A simple relationbetween uniaxial compressive strength and powder factor was proposed using the database for the optimized mines as a guideline to allow site engineers to compare their sites against the other sites."

Jan 1, 2017