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By H. Dudycz, A. Skoczylas, P. Stefaniak, P. Pyda

In the era of Industry 4.0, technologies such as Big Data (BD) and the Internet of Things (IoT) play a key role, especially for multi-site manufacturing companies. In such companies, the challenge is to collect and process massive amounts of data from industrial devices and extract key information from this data in real-time for ad hoc decision-making. The ability to analyse data from industrial devices translates directly into streamlined production processes, cost optimisation, prevention of unplanned events, and safety during operation. In this context, particular attention should be paid to Big Data Analytics (BDA), whose main source is the Industrial Internet of Things (IIoT). The purpose of this paper is to propose an IT system architecture incorporating BD and the IoT for a mining company. The paper presents results from a literature review focusing on available BD and the IoT solutions for industry (mining in particular) for the purposes of the acquisition, integration, and advanced analysis of data. The advantages and disadvantages of the different solutions were indicated and gaps in the accessibility to dedicated functionality are identified. Based on the analysis of a multi-site mining company, the main challenges faced by such companies planning to implement BD and IoT solutions are identified. Also, a proposal for an IT system architecture incorporating BD and IoT for a mining company is described in the paper. The contribution of the article consists of the identification of the challenges faced by mining companies planning to implement BD and the IoT solutions, and the proposal of an IT system architecture that allows BDA whose main source is the IIoT.

Sep 1, 2021

"Chairman: Dr W. S. RAPSON Rapporteur: Mr J. W. WILSONPapers:Computer applications in rock mechanics by F. H. Deist, E. Georgiadis and J. P. E. Moris Rock mechanics in the design of mine layouts by K. Hodgson and N. G. W. Cook Automated regulation of mine ventilation by P. NiskanenThe rock mechanics papers, because of their complementary nature, were presented in succession and discussion on both followed directly. The paper on automated ventilation control at a mine in Finland was then presented and the session was closed with several contributions to this paper.By and large the papers and discussions which followed in this session showed how a classic tie-up had developed between the use of computing techniques in important fields of mining, and their practical application. In fact, the dis-cussion following the rock mechanics papers showed clearly that without the aid of high-speed digital computers the rate of progress in applied research in deep-level hard-rock mines, would have been severely hindered. Furthermore, it became apparent from the comments made by several contributors that the rock mechanics techniques and computer progress described in Deist's and Cook's papers could be used to provide useful data in the solving of rock mechanics and design problems on mines other than flat dipping deep tabular deposits.The paper by Niskanen, which described an automated ventilation control system at a mine in Finland, showed how effective computers could be in areas where the reversal of mine ventilation occurs due to severe seasonal temperature ranges. Although the system described in the paper could not be introduced easily in complex underground mines, several contributors gave examples of similar ventilation problems that could be solved mechanically,In introducing his paper, Dr Deist said that the purpose of the paper was to give a brief account of some of the programs designed by himself and his co-authors to aid in the solution of rock mechanics problems,The first system presented by Dr Deist was known as MINSIM in the South African mining circles. This system was designed specifically to aid in the solution of rock mechanics problems in the South African gold mining industry. It was particularly designed to handle tabular deposits at great depth but it has been used satisfactorily on a number of occasions to obtain at least approximate solutions in other mining situations. Dr Deist said that the principles embodied in the programs were easily extended and, in fact, there was a project in progress at that time which was aimed to do this. He said that the principles could easily be extended to shallow-depth mining at steep or very steep inclinations."

Jan 1, 2014

By Millard M. Gilkey

This Bureau of Mines report presents results of a detailed study of water usage in the Wyoming mineral industry along with projections for the future In 1964, the mineral industries of Wyoming used 20 billion gallons of new water, nearly all self-supplied, and reused 72 billion gallons, a total usage of 92 billion gallons. Consumption amounted to 2.8 billion gallons. About one-half of the 20 billion gallons of new water was obtained from [srface] sources and the rest from ground water. Reported costs, covering power and maintenance, for the self-supplied new water at mineral industry operations ranged from less than 1 cent to 20 cents per thousand gallons and aver-aged 8 cents. At one mineral-related operation, water was hauled by truck to supplement a well supply. The cost was $2.00 per thousand gallons delivered. However, the supplemental requirement was only 10 gpm. Cost figures for the recirculation of water, covering power and maintenance, averaged 2 cents. In terms of water usage, the value of product for the entire industry was $25 per thousand gallons of new water intake and about $180 per thousand gallons consumed. The study revealed that Wyoming has a water deficiency but that the shortage is less severe than in the arid Southwest. Projection of the water needs of the Wyoming mineral industries indicates that the demand for new water will increase from the 20 billion gallons used in 1964 to 25 billion gallons in 1980, a 25-percent increase. The projected new-water requirement for the year 2000 is 40 billion gallons, a 100-percent increase compared with the 1964 figure.

Jan 1, 1967

By Serhat Baycan, Mikias Yohannes

"Kuala Lumpur Karst is a complex limestone formation that is characterized by presence of cavities, solution channels, pinnacles and floaters. Basement excavations in such geological formations are usually challenging, mainly owing to the unpredictable rock head depths and potential for groundwater inflow. Any excavation support system should have adequate robustness and water tightness. Traditionally, Secant Bored Pile walls (SBP) with struts are the preferred option for karst ground. This paper discusses a cost effective and innovative alternative solution for a particular site – using Deep Soil Mixing (DSM) and using Contiguous Bored Piles (CBP) together with Ground Anchors (GA). The site, located around one of the busiest areas of Kuala Lumpur, is a 5,700 m2 commercial and residential development. A 16.0 m deep excavation was needed for four levels of basement and excavation support along the 275 m perimeter of the development. Within the site, the depth to rock head varied from 6 m to 19 m. The basis for each solution and conditions for its suitability are discussed in detail. Some design considerations and construction challenges are also presented. The performance of the two retention systems during excavation are presented, together with comparisons versus design predictions. Suggestions for future development are also given. Advantages of this approach compared to other traditional approaches are highlighted.1. INTRODUCTIONThe geology of Kuala Lumpur is among the most complicated and geotechnically challenging formations in South East Asia. The majority of the city falls into the Kuala Lumpur Limestone formation; which is a thick, highly-weathered and cavernous limestone. This formation is pure calcitic to dolomitic in composition, having infrequent schist and phyllite interbedding (Gobbett et al., 1973).The KL limestone has a highly karstic topography dotted with cavities, ravines, interconnected subterranean channels, pinnacles, overhangs, floaters and slump zones (Tan, 2006). This results in erratic bedrock profiles even within short distances. It is not uncommon to see a precipitous rock head incidence within short distances in the same site. In most parts of the City, the bedrock is typically encountered ranging from very shallow depths to about 30.0 m. The exception to this is at the heart of the City, where Kenny Hill formation prevails above the KL limestone. In such cases the limestone bedrock can be encountered much deeper. The erratic rock head profile and the highly karstic nature of the KL limestone makes it a geotechnical challenge requiring careful consideration of suitable engineering solutions.1.1 – Site DescriptionThe site, located in downtown Kuala Lumpur, is abutted by a busy street on the North. Before development, the site previously served as a car park. To the west an access road separates the site from an empty lot; while on the east, the lot is bounded by light weight residential and commercial buildings. On the south side, the site is bordered by a road that separates it from a prominent Shopping Mall in the City. A layout plan and an artist’s impression of the finished development is shown in Figure 1."

Jan 1, 1900

By M R. Davidson, M P. Schwarz

A model for column bioleaching is investigated to identify and understand aspects of bacteria in bioleaching applications, which have implications in heap bioleaching operations. The model is used to simulate scenarios that would otherwise be time consuming to perform experimentally. This study uses a model of bacterial transport and attachment/detachment to ore particles, with a bioleaching model for the depletion of a copper-sulfide, also accounting for liquid and gas flow and gas/liquid oxygen mass transfer. The model includes aspects such as oxygen and ferrous ion consumption, coupled with leaching of a copper-sulfide via the shrinking core model. The model is used to investigate how the rate of leaching is affected by the bacterial concentration in the columns, by the bacterial regeneration of the leaching oxidant ferric ions. The model is also used to assess the impact of oxygen limitation and inoculation method on the copper leaching. Some comparison of the model with experimental data will be shown.

Jan 1, 2004

By Elena Chiriotti, Federico Valdemarin, Jan Cenek

"SUMMARY The “28 May Station” is the only transfer station between the existing Green and Red metro lines in Baku. As part of the huge development strategy of the metro network, the complete separation of the existing underground lines has been planned at this location, in order to simplify the operation of the future metro system. The extreme challenge of the project is represented by the need of achieve the separation of such lines over a breakdown of the operation of just five weeks. The lack of direct access from the surface, a complex geology with artesian water layers, a congested underground space and sensible buildings represent additional constraints. The chosen design solution consists in creating a complex steel pipe jacking frame around the operating tunnels and then excavating under such frame two large caverns where the separation of the existing lines and the construction of the new metro tunnels will be achieved. Soil treatments have been conceived to mitigate the geotechnical risks and to reduce possible impacts on the existing structures. The paper illustrate the challenges of this extraordinary project, one of the most complex underground structures under study, the design solutions and the risk management approach used to manage the complexity and to design the mitigations measures. INTRODUCTION The metro network in the capital of Azerbaijan is rapidly growing together with its metropolitan area. The beginnings of the existing metro system started in Baku in 1967 in Soviet times. To date, only two lines (Green and Red) are in operation with a total length of 34 km, including 23 stations. The future network will be much wider: besides the construction of three completely new lines and the extension of two existing lines, the whole metro project includes the development and modernization of the existing metro sections. A consortium formed by Systra (leader), Mott MacDonald (Praha) and Saman (Korea) awarded the contract for the preliminary and detailed design of infrastructures for the extension of Baku Metro Network. This extension consists in 83 km of new lines and extension of existing lines. As part of this modernization project, the connection of the Green Line at the 28 May / Cefer Cabbarli Stations, focus of this paper, represent also it’s ""Achilles' heel"" given that the already very congested system have only one transfer station."

Jan 1, 2016

By Zhao Guangwen, Wu Tan, Qiuzhan Tian, Duan Shuzhen

"A thorough study of lost currents in bipolar cells has been made for the development of the great potential of bipolar cells in energy saving. A proper equivalent circuit for bipolar cells has been found, and mathematic methods for computing lost currents at all kinds of polarization have been developed.At linear polarization, the lost currents can be computed by solving either a tridiagonal matrix or an ordinary differential equation of second order. This kind of values can be used to evaluate the minimal lost currents at given conditions. At other kinds of polarization, the lost currents can be computed by the same methods as above if the necessary experiments of measuring the cell voltages of every electrolytic compartment have been made. This kind of values can be used to design bipolar cells at practical conditions.Extensive experiments have been made to evaluate the effects of electrode polarization, emf of galvanic cell for the formation of electrolyzed substance, gaseous products, geometric dimensions of electrolytic cells, special resistance of electrolyte used, and the total and ordinal number of electrolytic compartments on lost currents. It is the first time to make such a systematic research by experiments in the world. Experiments showed that theoretic models were in good agreement with measured data. Experiments also showed that D.C. energy consumption of 0.45 kwh/kg of Pb for lead electrolysis from molten chlorides could be achieved in a cell with 7 bipolar electrodes.IntroductionIt is very promising to apply bipolar electrolytic cells to electrolysis of aluminum, magnesium, lead, zinc and perchlorinates for their great potential of energy saving for example, bipolar cells had been used in the production of magnesium and saved more than 30% of energy, being one of the three main techniques of energy saving in the production of titanium sponge (1)."

Jan 1, 1988

By John P. Capp

After World War II the Bureau of Mines studied methods of producing synthesis gas including a plan to gasify coal in place. Consequently, under a cooperative agreement with the Alabama Power Co., Bureau engineers directed a series of experiments that were carried out on the property of the Alabama Power Co. at Gorgas, Ala. The purpose of underground gasification of coal, regardless of method used, is to obtain the energy contained in the fuel for use on the surface, without mining in the usual sense of the term. Underground gasification can be described as (1) a process where coal, in place, is consumed by partial combustion with air, oxygen, steam, or any combination of these to produce a low calorific value gas (80 to 300 Btu per cu ft) or (2) a complete combustion process in which air is used to produce a gas containing carbon dioxide, nitrogen, and considerable thermal energy.

Jan 1, 1963

By John P. Capp

After World War II the Bureau of Mines studied methods of producing synthesis gas including a plan to gasify coal in place. Consequently, under a cooperative agreement with the Alabama Power Co., Bureau engineers directed a series of experiments that were carried out on the property of the Alabama Power Co. at Gorgas, Ala. The purpose of underground gasification of coal, regardless of method used, is to obtain the energy contained in the fuel for use on the surface, without mining in the usual sense of the term. Underground gasification can be described as (1) a process where coal, in place, is consumed by partial combustion with air, oxygen, steam, or any combination of these to produce a low calorific value gas (80 to 300 Btu per cu ft) or (2) a complete combustion process in which air is used to produce a gas containing carbon dioxide, nitrogen, and considerable thermal energy.

Jan 1, 1963

By Y L. Ma, M Chen, W Bruckard

With the extensive exploitation and gradual depletion of high-grade copper reserves, the mining industry is paying more and more attention to the hydrometallurgical extraction of copper from lowgrade and arsenic bearing copper ores. Hydrometallurgical processing, such as heap leaching, column leaching and bioleaching, provide a viable alternative to the traditional pyrometallurgy due to its harmony with the environment, moderate capital investment, and low operating costs. However, the slow leaching kinetics of enargite (Cu3AsS4) and chalcopyrite (CuFeS2) remain problematic for commercial leaching practice. The formation mechanism and the nature of the passivating layers during leaching is still a matter of debate in hydrometallurgical research. In this study, the dissolution mechanism of enargite and chalcopyrite in sulfuric acid solution was investigated using a range of electrochemical and spectroscopic analysis methods. Electrochemical oxidation of enargite demonstrated an obvious passivation region from 500 to 750 mV (Ag/AgCl). The formed passivation film was found a n-type semiconductor behaviour, which is different from the original enargite with a p-type behaviour. The results of X-ray photoelectron spectroscopy (XPS) suggested that a nonstoichiometric film Cu(3−x)As(1−y)S4 (x>>y) accumulated on the electrode surface, which accounted for the obvious decrease in current density in the passive potential region. For chalcopyrite, three important potentials of 550, 680 and 730 mV which are related to the formation and dissolution of passivation film were observed based on the cyclic voltammetry (CV) and potentiodynamic polarisation. Raman and X-ray absorption near edge structure (XANES) spectra studies of the chalcopyrite electrodes after being treated under these three potentials indicated a metal-deficient sulfide of Cu1−xFe1−yS2 (y>>x) might be responsible for the passivation phenomenon. Hence, it is concluded that the passivation of enargite and chalcopyrite are similar which are caused by metaldeficient sulfide surfaces although the compositions of the metal-deficient sulfide are different.

Aug 24, 2022

By V. G. Papangelakis, M. Cheung, M. Dry

The high pressure acid leaching of laterite was modelled and simulated using a combination of two commercially available software packages, namely Aspen Plus 11.1 and the OLI Stream Analyzer. New kinetic parameters for the acid-controlled metal dissolution and precipitation reactions at temperature were first determined from previous experimental data on the leaching of limonite. A grain model with cylindrical pellets was used to model the solid-liquid dissolution reactions. Precipitation reactions were modeled via aqueous equilibrium chemistry. A dedicated thermodynamic database previously developed at the University of Toronto was used in conjunction with the OLI software to model the solution chemistry and calculate the concentration of hydrogen ions in solution at the leaching temperature. Mass balances were handled by Aspen Plus. The simulation gave good predictions of nickel dissolution under industrial and laboratory conditions, for the dissolution of limonite and limonite/saprolite blends. Computational

Jan 1, 2005

By Kenneth Holmnerg

About 100 million terajoule is used annually worldwide to overcome friction and that is one fifth of all energy produced. The largest quantities of energy are used by industry (29%) and in transportation (27%). Based on our recent studies on energy use in passenger cars, trucks and buses, we concluded that it is possible to save as much as 17.5% of the energy use in road transports in the short term (5-9 years) by effective implementation of new tribological solutions. This equals to annual energy savings of 11.6 exajoules, fuel savings of 330 billion liters and reduction in CO2 emission by 860 million tonnes. In a paper mill, 15-25% of the energy used is spent to overcome friction. The electrical energy used by a paper machine is distributed as 32% to overcome friction, 36% for the paper production and mass transportation, and 32% is other losses. In paper machines, 11% of the total energy used to overcome friction can be saved by the implementation of new tribological technologies. This would result in electrical energy savings worldwide of 130,000 terajoule, economic cost savings of 2 billion euros and CO2 emission reduction of 11 million tonnes annually. An overview of the total energy saving potential by improved tribology in transportation and industry is presented.

Jul 31, 2018

By Efstratios Karampinos, John Hadjigeorgiou, Philippe Morissette

"Ground support is a critical element in maintaining the stability of mining drives in deep and high stress mines. In challenging ground conditions, it is necessary to continuously explore ground support strategies that can control the resulting large deformations. It is an objective of mining operations to optimize the ground support by selecting appropriate systems at the time of installation of each reinforcement element. A successful ground support strategy will result in the use of a system that ensures both the structural and operational integrity of the excavations and mitigates the need for rehabilitation.Preliminary ground support design is often based on empirical observations and methods. Once a design is implemented, field trials, observations and in situ pull tests are used to fine tune or improve the design. Although not often employed during this process, numerical modelling can provide helpful insights into the impact of different ground support strategies. In this respect, it is possible to explore the use of multiple options before selecting the most promising ground support system for implementation in field trials. The challenges associated with the numerical modelling of rock support for mines have been described by Lorig and Varona (2013) and Potvin (2017). The employed numerical models should capture all potential failure modes of reinforcement throughout the mining sequence of the excavation. In particular, it is important to emulate the observed in situ ground support performance, as well as the influence of the installation sequence of the support. However, the time and expertise required for this type of modelling of ground support is often not available at mine sites. Even when the expertise is available, it requires a major time commitment and commitment of resources to set up, run and calibrate the sophisticated models capable of explicitly capturing the behavior of ground support.Rock reinforcement is an integral part of all ground support systems used in underground mines. Long, flexible tendons can reinforce the rock mass deeper into the walls and create a thicker reinforced shell around the underground excavation. This article focuses on the optimization of the cable-bolting strategy in squeezing conditions at the LaRonde Mine in Quebec, Canada by integrating the 3D distinct element method (DEM) in the design process. A calibrated numerical model is used to investigate a series of cable bolt configurations and provide recommendations for the ground support design."

Jan 4, 2018

By L. M. Oshinowo

The incorporation of advanced analysis tools, such as CFD, into the process plant design process has become possible through advances in commercially available computational fluid dynamics software and faster computers. Multiphase modeling is now typically employed in the design phase of process plant design at Hatch. The multiphase models include Lagrange-Euler and Euler-Euler treatment of the multiple phases. Additionally, mixture models with interface-sharpening algorithms are applied to the prediction of free-surface flows in complex geometry. CFD is applied to applications where traditional design rules are not applicable. The additional rigor of CFD modeling in 2D and 3D allows process engineers to come closer to realizing true virtual plant design. The objective of this paper is to outline the benefits and pitfalls in the application of multiphase modeling for rigorous design. Several application examples in the hydrometallurgical field will be presented.

Jan 1, 2005

By J. E. Gebhardt

Progress is reported on capturing the effects of gangue chemistry in the context of a comprehensive stockpile heap leach model for leaching copper sulfide ores, employing leading edge computational fluid dynamics (CFD) technology. The stockpile is a complex multi-phase process, comprising of a solid porous media, with complex fluid flow, gas and liquid phases, competing solid-liquid reactions, dissolution of minerals and transport through the heap. The model accounts for many of the challenging physical and chemical features of the heap, including transport and reactions kinetics for the important copper and iron sulfide minerals, ferrous oxidation, bacterial effects, thermal energy, acid and sulfate balances. In this contribution, the model has been extended to incorporate dissolution of various species from gangue reactions and precipitation of hydronium and potassium jarosite, ferric hydroxide, alunite, and gypsum. The effect of aeration on the simulation of a copper sulfide heap leach is provided as an example.

Sep 1, 2012

By A. Heriba

Cyanide is highly toxic to humans and other organisms. Concentrations of RCN as low as 0.05 ppm can be lethal to fish (Scott and Ingle', 1981). In wet climates and in colder climates where natural degradation is slow, it is becoming mandatory to destroy cyanides in effluents before they can be discharged. The disposal of spent gold ore as tailings from cyanide heap leach processing facilities is a matter of concern to the public, the mining industry, and regulatory agencies. South Dakota mining laws and regulations require that spent ore be neutralized to a suitable level with respect to cyanide before disposal (Durkin, 1990). To safeguard the environment and protect ground-water and surface-water supplies adequately, a reliable test is needed to determine the amount of cyanide in the solid spent ore.

Jan 1, 1993

By Shu Yan

The high resolution resistivity method (HRRM) is developed specifically for detecting underground cavities and tunnels. HRRM has a special feature in that it can recognize and cancel static shift, which makes it different &om the high density resistivity method (HDRM). In searching for various means for detecting underground cavities, we found that the detecting depth of the transient electromagnetic field method (EM) depends mainly on the measurement duration, not the loop area. In addition, TEM can also be used to locate the high-resistivity bodies. In order to use them for local working site conditions, we combine HRRM with TEM to become a combined electromagnetic method. Since the late 1980's this method has been used to locate abandoned mines and air passages and burning centers of mine fires with great success. This paper cites case studies for which this technique was successfully used.

Jan 1, 2005

By Edward L. McHugh, Charles Sabine, David G. Long

While less than 1% of reported mine accidents are associated with slope stability problems, slope failure accidents were responsible for about 15% of U.S. surface mine fatalities between 1995 and 2003. Small rockfalls, which may involve hand-sized rocks weighing only a few pounds, can cause fatal injuries to workers away from the protection of large machinery. Massive highwall failures containing a million cubic yards of material or more can be fatal even for heavy-equipment operators. As part of an ongoing study at the Spokane Research Laboratory, several remote sensing technologies are being evaluated as tools to assess slope stability and monitor slopes for hazards. An interferometric radar device capable of detecting very small displacements on slopes has been assembled and tested. Radar techniques can provide new tools to augment current methods for monitoring ground control hazards in mines.

The value of domestic raw nonfuel mineral output in 1985 was estimated at $23.7 billion, 2% above the 1984 value of $23.1 billion. This crude mineral output was the basis for approximately $244 billion worth of processed materials of mineral origin. [ ] A U.S. company permanently closed its alumina plant in St. Croix, U.S. Virgin Islands, reducing domestic alumina capacity by 10%. Another U.S. company sold its 26% interest in an alumina plant in Jamaica to its two U.S. partners. On completion of the purchase agreement, the two remaining partners promptly closed the plant for an indefinite period, citing a world oversupply of alumina and unacceptably low prices.

Jan 1, 1986

By Thomas S. Jones

This report discusses processing and use of the principal forms of manganese. The focus is on trends in the United States in the 20th century and specifics of domestic manganese material flows as of about 1990. To protect proprietary data, quantitative assessments are limited to the iron and steel industry, which accounts for about 90% of consumption. Nonmetallurgical uses are considered qualitatively. Approximate disposition of a U.S. cumulative consumption during 1901-90 of an estimated 69 million st of manganese is estimated to be iron and steel slag, 69%; nonmetallurgical uses of a dissipative na¬ture, 10%; iron and steel scrap, 9%; National Defense Stockpile, 3%; unidentified and/or including items in service, 10%. In slag from iron blast furnaces and steelmaking, manganese is present as a minor, relatively im¬mobile component, which so far has been uneconomical to recover. Construction and road building are main applications for these slags. Steel slag contains the greater amount of manganese. Studies by others of global manganese fluxes and the effect of human activities on them also are discussed. One source concludes that the main effect of human activities, via deforestation and agricultural activities, has been to increase the rate of transport of manganese to the oceans.

Jan 1, 1994