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By O Bascur, A Soudek

Large metallurgical complexes are substantial users of energy, water and assets. To improve the effectiveness of energy and assets the quality of the data and events become paramount for real-time operational management. A lack of resources at the local operations and at the enterprise makes it impossible to process the sea of information and many projects have failed. As such, a novel approach for implementation of continuous improvements at the local level and innovations at the strategic level was implemented at all operating plants at Anglo American Platinum. Sixteen concentrators, three smelters and two refinery process systems were integrated to scale the information for manufacturing services at the local and enterprise level. The new capability of an enterprise real-time monitoring and diagnosis software infrastructure was available to implement many business strategies in tandem. Mineral and metallurgical processing knowledge is used to simplify the implementation of the data model. As such, asset monitoring, energy, production and process control management were implemented in an integrated approach reusing the same data but with different context and time horizons to have a standard methodology for local root cause analysis. This paper will highlight a sustainability management approach to change and empower the local and strategic team to collaborate using a new approach for adaptive reporting and condition-based event management and notifications. The results based on the integrated and collaborative team efforts will be presented. OSIsoft Plant Information system was installed and configured to achieve a targeted reduction in energy consumption of 15 per cent by 2015.CITATION:Bascur, O and Soudek, A, 2014. Implementation strategies for energy effectiveness and sustainability – example of Anglo American Platinum, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 101–108 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

By T Tan, C P. Holmes, C E. Hartford

Transportation of iron ore from the mine to the plant is critical to business success. Ore from the mine may have to be transported across states, countries and even continents to get to the processing plant or export facilities, and ultimately to the client. Numerous transportation steps may result in potential logistical difficulties. Companies are continually seeking ways to increase production rates, decrease delivery times and reduce operating costs. Transportation cost is a major component of the total cost of mining iron ore and therefore requires effective use of transport systems.Bottlenecks in iron ore transport systems, due to material handling issues, can result in loss in profit in the order of millions of dollars per hour. Bottlenecks can be seen anywhere in the transport system where the desired flow rate cannot be achieved. These bottlenecks occur for various reasons such as increasing throughput in a transport system originally designed for a lower throughput resulting in plugged transfer chutes, changing material characteristics (eg finer material, increased moisture content), changing to a new type of material or blend that again alters handleability, or changes in operational philosophy due to equipment availability or process utilisation.Stockpiles may have limited live capacity such that an adequate amount of ore may not be readily reclaimed when required (eg to fill a complete train’s railcars). In bins and hoppers, material may discharge through a central flow channel resulting in the formation of a stable rathole, which can then collapse causing material to flood the downstream system and cause significant downtime for clean-up (eg railcars beneath train load outs). In transfer chutes, bottlenecks can be caused by pluggages or downtime required for the change-out of liners due to excessive wear. In ship loading, long settling or de-aeration time, or material exceeding its transportable moisture limit (TML) may result in further bottlenecks. These bottlenecks all have associated costs because of the need to address their causes and because of the lost opportunities for throughput.This paper will discuss how bulk material technology and proper understanding of material flow characteristics can be applied to mitigate bottlenecks. It will discuss how to predict potential bottleneck locations through a scientific method of analysis and evaluation to determine if an increase in throughput of an existing transport system is possible, as well as whether or not a new material will flow reliably through an existing system.CITATION:Hartford, C E, Holmes, C P and Tan, T, 2015. De-bottlenecking iron ore transportation from mine to plant, in Proceedings Iron Ore 2015, pp 393–398 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

By M. M. Kim

As-electrogalvanized coatings of pure Zn, Zn-11% Fe, and Zn-18% Fe coatings were characterized in terms of initial crystal structure and surface morphology. Samples were then subjected to heat treatments simulating the paint bake cycle of automobile manufacturers. Surface morphology changes were correlated with the process variables, and crystallo.graphic changes were interpreted by mapping heat treatment routes on the Fe-Zn phase diagram. The morphology of pure zinc electrogalvanized coatings with heat treatment from platelets to smeared platelets. The zn-11% Fe coating changes with heat treatment from tetrahedral nodules to a mixture of round and tetrahedral nodules, with the Zn-:18% Fe coating always having round nodules. Regarding crystal structure, a critical transformation time can be defined at any selected temperature, below which the crystal structure does not change. This temperature is related to iron content.

Jan 1, 1990

By G J. Wilkie, P A. Revell

The R&D landscape for ore pre-concentration technologies within mining is characterised by the development of individual technologies and point solutions. This presents METS and mining companies with the combined challenge of understanding how to apply pre-concentration technologies to create maximum value, and how to sustainably integrate the technologies into their businesses to maintain the value. The paper will consider the requirements of an integrated pre-concentration system and presents a portfolio of R&D projects that have co-developed and integrated a suite of new precencentration technologies and methodologies across the mining value chain. Focus areas include in-situ orebody characterisation, blast design, real time cross belt mineral sensing, and consideration of how much data needs to be acquired in order to make value based decisions between ore pre-concentration options. An ore pre-concentration workflow is presented to demonstrate how additional optimisation opportunities are enabled both by moving decision points further upstream in the value chain, and by integrating the concepts of pre-concentration into the design of mineral processing equipment. Additionally, several research projects examine the non-technical factors that present barriers to uptake of new technologies within mining companies. Organisational culture, risk management and socio-political factors are discussed and a set of management tools are presented that allow organisations to self-assess their readiness for new technology uptake, along with process models to assist management with identifying and navigating the ecosystem of stakeholders that are decision makers in the use of pre-concentration technologies.

Nov 10, 2020

By Ramazan Comakli, Cemal Balci, Nuh Bilgin, Hanifi Copur, Can Polat, Deniz Tumac

"Application of mechanical excavators for rock excavation in both civil construction and mining engineering fields has increased significantly in recent years. Prediction of the excavation performance of any mechanical excavators – tunnel boring machines, roadheaders, impact hammers, continuous miners and shearers for any geological formation is one of the main concerns in determining the economics of a mechanized mining and/or tunneling operation. A new portable linear rock cutting (PLCM) device was developed in the Mining Engineering Department of Istanbul Technical University and supported by The Scientific and Technological Research Council of Turkey (TUBITAK-112M859). The PLCM is used for cutting small core or block rock samples by a real-life mini disc cutter. The results from the PLCM are compared with the results obtained from the full scale rock cutting tests and theoretical model. It is found that there is reliable correlation between test results obtained from both cutting tests and theoretical model. 1. INTRODUCTION Mechanical excavators are currently the only alternatives to drill and blast due to higher production rate, increased safety, uniform muck size, less roof support, easier ventilation, continuous rather than cyclical operation, and possibilities for automatic control. The most of large civil tunneling and some mining projects are now carried out by mechanical excavators rather than drill and blast methods. Mechanical excavators can be categorized into two main groups: full-face and partial-face machines. Full-face machines such as tunnel boring machines excavate the face in one mode at the size of the cutterhead. Due to their cutting mode, the shape of the face profile by the full-face machines can only be circular. As for partial-face machines, the cutterhead is attached at the end of a boom. The face profile excavated by the partial-face machines can be from circular to horseshoe shape due to the cutting mode of the boom."

Jan 1, 2016

By M. K. Boateng, K. Awuah-Offei

"Mining companies have started using quantitative tools, including computer models of community interaction, to gain intelligence on social risks surrounding their projects. Models of changes in community preferences regarding mining projects over time are useful for evaluating changes in project risk due to changes in the social license to operate. For example, agent-based models that use information diffusion models and social networks are useful for studying those changes due to information diffusion. However, such agent-based models are sensitive to many input parameters including the parameters of the diffusion model and the average degree of the social network. This work evaluates the sensitivity of such a model to diffusion and network model parameters (probability of imitation, probability of innovation, and average degree) using the first order and total sensitivity indices. The results show that the model is much more sensitive to the probability of imitation than the other two parameters. Thus, to reduce uncertainty surrounding the model’s predictions of community acceptance of mining, mines need to obtain accurate estimates of the probability of imitation. INTRODUCTION Mining companies have started using quantitative tools, including computer models of community interaction, to gain intelligence on social risks surrounding their projects. Models of changes in community preferences regarding mining projects over time are useful for evaluating changes in project risk due to changes in the social license to operate. For example, agent-based models that use information diffusion models and social networks are useful for studying those changes due to information diffusion. However, such agent-based models are sensitive to many input parameters including the parameters of the diffusion model and the average degree of the social network. This work evaluates the sensitivity of such a model to diffusion and network model parameters (probability of imitation, probability of innovation, and average degree) using the first order and total sensitivity indices. AGENT-BASED MODEL OF COMMUNITY ACCEPTANCE A few researchers have started using agent-based models to study mining systems (Fujiono 2011; Nakagawa et al. 2013; Bahr 2015; Boateng and Awuah-Offei 2017a, b). Nakagawa and co-workers used ABM to evaluate dynamics of a mining project’s stakeholder networks whereas Fujiono used ABM to study innovation diffusion in the mining industry. Our previous work has presented models and a framework for modeling information diffusion in a mining community and its impact on level of acceptance (a measure of SLO) of the mining project (Boateng and Awuah-Offei 2017a, b)."

Jan 1, 2018

By D. D. Bolstad

This report describes the construction and use of a direct-reading azimuth protractor (DRAP) by the Bureau of Mines for measuring fracture orientations in mines, tunnels, or other excavations having a magnetic environment. The DRAP allows a rapid and simultaneous measurement of dip and azimuth of dip of a fracture plane. The instrument is rugged, lightweight, and easily constructible from standard hardware items. The DRAP can measure dip to within ±0.5° and azimuth of dip to within ±5° of corresponding values obtained with a Brunton compass.

Jan 1, 1974

By H. S. Auvil, J. T. McCartney, J. D. Davis

"INTRODUCTION It is now generally recognized that the small-scale laboratory dilatometer method of test does not give results of much utility in predicting the expansion (or contraction) of a coal in a coke oven. The carbonizing conditions in the laboratory test differ radically from those in the oven; in this test, the charge is heated through the coking range of temperature as a whole, whereas in the oven, coking proceeds by layers parallel to the oven walls as each succeeding portion of the charge goes through the plastic range of temperature and coke formation sets in. The paths of the gases and vapors and the pressures set up are different in the two methods. Furthermore, the rate of heating in the test usually is much more rapid than in the oven. H. Koppers 5/ was perhaps the first to adopt apparatus and procedure whereby the layer coking of the coke oven could be simulated closely however, the heating progressed from one side of the charge only; later he experimented with a small coke oven with a movable wall heated from both sides. It is not clear how well the results in the later oven correlated with those of the earlier small test oven, but in a comparatively recent Koppers publication a modification of the original small test oven heated from one side is recommended 6/ Altieri 7/ was perhaps the first to experiment with the Koppers type small test oven in the United States and Brown- has tested a large variety of coals in a rectangular test oven of his own design heated from the sole or floor. Subcommittee XV of American Society for Testing Materials Committee D-5 is now making a study of the various methods proposed for determination of expanding and plastic properties of coal with a view to standardization. 9/"

May 1, 1939

By Karin Bäppler

"When considering large-scale infrastructure projects worldwide special attention has to be paid to the large diameter tunnel construction projects that were successfully completed in the Southern Hemisphere. The projects that are highlighted in this paper are large-scale infrastructure projects in the sector of transport. In focus are four road tunnel projects that were constructed in Australia and New Zealand using mechanized tunnelling technology. The tunnel boring machines (TBMs) that were reliably applied to these four major projects all exceed the bore diameter of 12 meters. These TBMs are therefore in the range of large to very large diameter TBMs. The technology used demonstrates state of the art technology with tailored tunnelling technology adapted to the specific project demands. Two Double Shielded Hard Rock TBMs (Ø 12.35 meters) were used for the construction of the Clem Jones Tunnel in Brisbane crossing beneath the Brisbane River and these two machines have been reused for the excavation of a 4.3km long two-lane highway tunnel for Legacy Way in Brisbane creating a new traffic artery towards the city centre. Two EPB Shields (Ø 12.48 meters) excavated and lined the twin-tube road tunnel for the Brisbane Airport Link. Excavation diameters in excess of 14 meters, such as the Earth Pressure Balance Shield (Ø 14.41 meters) involved in the Waterview Connection Project in New Zealand, are understood in the tunnelling industry as very large diameters. The machine is customized to the requirements and subsurface conditions of Auckland. The paper spotlights the large to very large diameter TBMs that were used and focuses on the comprehensive solutions developed by the machine manufacturer to provide a system with benefits for the contractor especially for the Waterview Project. INTRODUCTION Extensive large-scale road infrastructure projects like the ones implemented in Brisbane (Australia) and currently under construction in Auckland (New Zealand) show the tendency of today’s infrastructure construction projects. Functional infrastructures need to be put in place to cope with the demand of mobility and flexibility of people living in cities and metropolises. Impact during construction work to people or environment has to be kept as low as possible to ensure the quality of life is not disrupted."

Jan 1, 2016

By T. C. Marshall

A comparison between hydraulic and pneumatic rockdrills by T. C. Marshall, Pr.Eng. (Member) The greatly increased output of rockdrills has placed new demands on booms, carriers, and drill steels and bits. Limited scope for further improvement in pneumatic rockdrills has led to the development of hydraulic rockdrills, which compare favourably with their pneumatic counterparts: they are more efficient, more flexible in coping with variations in the working conditions, more economical in the consumption of drill steel, and less productive of noise and mist. Their disadvantages include a greater need for a reliable power supply, a greater vulnerability to dirt, greater complexity (requiring more skilful maintenance), and the liberation of heat into the working environment. They should be regarded as a complement to, and not as a substitute for, pneumatic rockdrills.

Jan 2, 1974

By Armand Bur, W. R. Reichenstein

Since coal is one of the largest cost items in the production of electricity, its analysis for heat value and composition has been the subject of intensive study. Sampling started with crude hand methods, out of the railroad car or barge or from moving conveyor discharge, and progressed to reliable mechanical in-plant sampling systems. The mechanical system takes its sample from a falling stream of coal such as a conveyor discharge or crusher discharge hopper. But this has a disadvantage in that the identity of the coal is lost. Coal is shipped to the user in train-loads, often made up of shipments from various mines. When the cars are dumped into hoppers and the coal conveyed to the power station, the various shipments become mixed because residual coal remains in hoppers and chutes.

Jan 5, 1959

By Loren R. Anderson

This volume documents the use of the probabilistic slope stability program PROBISH. The probabilistic slope stability program is an interactive program and is essentially self-tutorial. It prompts the user for the required input data as it is needed, and allows the user to correct mistyped data before analysis is initiated. The program computes safety factor probable Width of failing and probability of failure for a given circular failure surface. Four example problems are included to illustrate its use.

Jan 1, 1982

By J M TORLACH

Learning is an iterative process, and we might reasonably expect that after more than a century of mining during an era of sustained technological development, (following a millenium or two of unrelieved hard physical graft), that the more obvious physical hazards could by now be competently managed. It is perhaps a reflection on the perversity of human nature that we have not fully learned our lessons in this exacting environment, and that worse, we have still too often failed to profit by the experience of those lessons. The more obvious underlying factors which impact on this situation are examined briefly, as a prelude to consideration of some outstanding examples of recurrent problems experienced in recent years. Reasons for the continued existence of sub-standard practices are outlined, with a focus on the human element, and finally proposals for appropriate remedial strategies are summarised. This paper therefore seeks to examine and discuss some of our deficiences and to suggest some directions for the way ahead.

Jan 1, 1992

By J. B. Gayle

Both immediate and long-range economic factors are associated with blending anthrafines to produce metallurgical cokes, and they warrant careful consideration of the technology of carbonization of blends containing significant proportions of inert substances in general and anthrafines in particular. This situation has resulted in numerous publications dealing with various phases of the overall problem, particular emphasis being placed on the effects of inert substances on the yields and quality of cokes produced. Because relatively little attention has been given to the expansion behavior of coal blends containing inert substances, an investigation of this problem was undertaken using the Bureau of Mines sole-heated oven. Since experiments in the sole-heated oven do not measure wall pressures directly, a new method of interpretation of sole-heated oven data, which permits estimates of wall pressures, has been proposed.

Jan 1, 1955

By Liu Liu

In the recent 10 years the rapid development of Chinese steel industry has attracted the attention of the world. The technological progress of converter steelmaking has played an important role in this process. First of all, slag splashing has been extensively adopted by Chinese steel companies in various sizes of converters from largest to smallest ones, and even including those using special hot metal containing V and Ti. Remarkable metallurgical results have been achieved. Up to now the average converter campaign life has reached nearly 10,000 heats, and the longest exceeds 30,000 heats in three melt shops. Based on this process, the long-life combined-blowing converter steelmaking technology has been developed. Slag splashing has been used to form a gas permeable "slag mushroom" on the top of bottom nozzles to protect the nozzles. In order to keep the effective bottom blowing, furnace bottom thickness control technique has been developed to prevent the furnace bottom growth. It makes the service life of bottom nozzle the same as the converter campaign life (average 10,000 heats and longest > 30,000 heats). The complete combined blowing was ensured through out the furnace campaign. Concentration product [C][0] is in the range of 0.0023 ~ 0.0030%, the T.Fe in the slag is lowered by 4 ~ 6%, and the [0] in steel is decreased by 100 ~ 250 ppm.

Jan 1, 2004

By John B. Knaebel

Hammer machines are now widely used for underground sampling and exploration. Their application to such work can be divided into two classes - sampling and testing with ordinary drilling equipment to shallow depths of 22 feet or less, and "long hole" drilling with heavy machines and special equipment to depths of as much as 250 feet or more. In the first category hammer drills are employed for either of two distinct purposes: first, as a means of checking the results of grab or cut samples or, in certain types of ore deposits, as a substitute for these methods; and second, as a method of sampling the ground 5 to 20 feet beyond existing faces and thus aiding in the control of stoping operations or in the direction of development headings, as the case may be. The deep-hole drill, in the second category, has proved to be a valuable adjunct to the old established methods of exploring, end developing ore, provided it is employed under natural conditions to which it is suited, handled by men thoroughly familiar with the technique of its operations, and used with its possibilities and limitations clearly understood.

Jan 1, 1932

By Earl C. Herkenhoff

Editor's note: The subject of mining on the moon can generate a wide range of strongly held opinion, from those leaning toward the view that, ultimately, such activity is the destiny of mankind to those who believe that all suggestions for moon mining to date are unrealistic, wildly expensive and in the hands of people who 'know nothing.' MINING ENGINEERING herewith publishes some of the basic pros and cons on the subject of moon mining by writers who are among those holding strong views on the subject, with the hope that some of our readers may be interested in joining this debate. Every mineralogist and most mineral industry people were keenly interested in the examinations of the first moon rocks brought back by US astronauts in 1969. Suffice to say that the examinations revealed nothing exotic in the mineral makeup of the very limited rock samples. The rocks were generally of igneous type, dark-colored and contained some common, Earth-type minerals. There was, in Earth terms, above average TiO2 content, but they contained nothing of commercial significance by Earth standards. Therefore, interest in moon minerals rapidly faded. Years later, on Sunday, May 4, 1986, living in Reno, NV, this author was shocked to read a local newspaper article by the Dean of the Mackay School of Mines, University of Nevada, Reno, headlined, "Moon Mining Not Far Off." Considering that the announcement more or less coincided with a slump in our domestic mining industry, the immediate questions in a reader's mind

Jan 1, 1991

By Jr. Foot

EIMCO Process Equipment Company has introduced the new SmartCell series of conventional flotation cells. The flagship of this new development is the 5000 ft3 cell that is the largest available in industry. This new series of cells includes a cylindrical tank design, a conical draft tube and froth crowder. Optional air control, wash water addition and embedded expert control are available. A discussion of the design parameters, energy efficiency, testing, and commercial plant results are presented.

Jan 1, 1997

By P T. Stoker, A Allman, D P. Carville

Classification of mineral resource estimates is one of the most important responsibilities of the Competent Person. In recent years, classification decisions have been driven more by the detailed block-by-block attributes generated by the now widely applied geostatistical estimation methods, and less by a general geological overview. This is increasingly resulting in æspotted dogÆ outputs, in which blocks of Inferred Resources or unclassified material separate blocks of Measured and/or Indicated Resources, or individual drill holes are surrounded by annuli of Measured and Indicated Resource blocks. Not only are such outputs potentially misleading, since they ignore fundamentals such as continuity of geology and mineralisation between drill holes and the imprecise nature of resource estimation, they can also cause substantial problems for engineers undertaking mine designs and estimating ore reserves, particularly for underground mines. Competent Persons for mineral resources must keep in mind the purpose of their work, and should use their experience and judgement to avoid or smooth out æspotted dogÆ classifications, providing a result commensurate with the level of geological and resource estimation confidence. For their part, ore reserve Competent Persons must understand the resource estimation and classification process, and should question resource classifications that are not consistent with the level of geological and resource estimation confidence.

Jan 1, 2006

By Bern Klein, Givemore Sakuhuni, Libin Tong

The use of continuous discharge centrifugal concentrators introduced in the early 1990’s for recovery of gold associated with sulphides has introduced a novel application niche for gravity concentration which could not be realized with the low mass yield batch and semi-continuous concentrators. A typical application is scavenging gold associated with sulphides from flotation tails which has potential to increase productivity by reducing gold loss to tailings and lower grinding cost by using a coarser grind. However, the full potential of this technology has not been fully exploited partly due to the lack of reliable small sample procedures to demonstrate applicability. This paper introduces a bench-scale procedure developed to characterize the Knelson Continuous Variable Discharge concentrator (CVD) for scavenging gold from flotation tails. The procedure code named gravity release analysis was derived from standard flotation release analysis. It is a modification of the gravity recoverable gold and gravity amenability test in order to best simulate continuous centrifugal concentration. Based on this iterative procedure, a gravity release index similar to the flotation rate constant, for measuring individual mineral gravity susceptibility for an ore is introduced which can be a useful quantitative measure to both predict application of centrifugal concentration and for plant design. The gravity release analysis procedure was tested on a polymetallic flotation plant tailing at Myra Falls, BC, Canada and results show that it can predict CVD performance. The gravity release index for gold was observed to decrease with each successive cleaner stage showing that the initial stages recover liberated gold whilst successive runs recover gold associated with sulphides and or gangue. The difference in magnitude of the gravity release index for different mineral species shows the species separable by centrifugal concentration.

Jan 1, 2014