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By S. D. Logan

This presentation describes a lightweight automobile body structure concept developed at DaimlerChrysler to support a high fuel-efficiency vehicle project. This body structure consisted primarily of large thin-wall magnesium castings and resulted in a more than 40% weight reduction with a minimal cost increase over a conventional steel structure while achieving significantly improved structural performance as evaluated through CAE simulations. One concept vehicle was built for the purpose of demonstrating concept feasibility. Several slides showing the prototype build process are presented. The presentation also describes several large thin-wall die casting body applications that are in current production or have been used in recent production automotive applications and identifies areas where further development could improve the chances of a magnesium intensive body structure becoming a production reality at a later time.

Jan 1, 2006

By D. D. Hamilton

The ISMS program provided for the development and demonstration of equipment modifications in both conventional and continuous coal mining systems. This report describes activities during the demonstration of the continuous equipment and includes machine performance, results of data gathering, system evaluation, and recommendations for implementing improvements.

Jan 1, 1976

By M. C. Radomsky

Approximately sixty, small, surface coal mines in Pennsylvania participated in a program designed to improve safety performance in the workplace. The method involved the use of safety sampling and observation to assess the safe standards of worker behavior and work conditions. Data were collected through the use of operation-specific, on-site safety records covering seven major occupational units. Workplace events observed (acts and conditions) were assigned a hazard classification; feedback, both immediate and delayed was initiated to improve safety performance. The experiences drawn from this pilot project have proven the need to continue to pursue this behavioral approach; however, a stricter methodology needs to be adopted in the collection and analysis of data.

Jan 1, 1987

By Brad H. A Brown, J Paul Tidman

To design a blast, one must give consideration to safety, economics, geometry, geology, production needs, and a variety of other requirements. To compare designs requires the time to develop alternatives, analyze, and then improve on them. A number of tools are available to assist with the first set of requirements, however they are poorly integrated. SHOTPlus is a program to improve the efficiency of blasting operations, by combining measurement and blast design tools, and offers the user the time and means to modify designs and explore alternatives.

Jan 1, 1997

By G. G. Manekar

MOIL Limited (formerly Manganese Ore India Limited), a Government Enterprise, under the Ministry of Steel, Government of India, produces about 1.1 million tonnes (T) of manganese ore annually from three opencast and seven underground mines. The underground operations are mining using an overhand cut and fill method. The orebody is too narrow for the use of larger equipment and the poor to fair rock mass quality limits the size of stable excavations. Prior to the 1990s underground support consisted primarily of timber square sets in tandem with timber chocks and props. As mine production requirements increased throughout the 1990s led to larger opening sizes and more modern support practices. Research was conducted on ground support design based on rock classification and empirical techniques for designing ground support. Based on the findings and field trials, the Company adopted full column cement grouted cable bolts for back support. Instrumented field trials, using extensometers and load cells on the cable support confirmed the support effectiveness. Stope design was based on two and three dimensional stress modeling which resulted in a significant increase in stope dimensions. The rock mechanics studies for safe stope design were carried out using numerical modeling tool in two and three dimensions for the analysis of stresses. Based on the findings, the safe stope geometry with new stoping parameters was introduced. The earlier stope length of 30 mtrs were changed to 60 mtrs with in situ rib pillar at the cross cuts and in situ post pillars to be left-out in the stope. This leads the formation of of panel comprising of three stopes, for production, supporting and filling. For mechanical handling of ROM in stopes Side Discharge Loaders (SDL) were introduced. The above changes have improved the face productivity from 2?3.5 T with manual operation and 9 T with SDL. The above rapid mining operations has improved the stope productivity but reduced the stope life from 6 to 3 years. For the improvement of the stope availability, further studies were conducted by numerical modeling of stress analysis. The related studies confirmed that with the existing supporting system and proper instrumentation, level interval could be increased up to 45 mtrs from the existing 30 mtrs at deeper levels. At present below 12th Level interval is 45 m at Balaghat Mine. For future mechanization program for introduction of Single Boomers, LPDT, Cutting Machines etc for the development headings rock mechanics studies are underway. The paper provides details of rock mechanics studies that were carried out to study efficacy of the cable bolt support, safe stoping parameters and increased level interval for the improvements in safety, production and productivity at Balaghat Mine.

Aug 1, 2013

By Steve Kral

Reducing the cost per ton and increasing productivity are key factors in a mine’s profitability. Mining companies can do little about commodity prices. So to keep a mine operating at a profit, management must reduce costs and improve worker and equipment productivity in every facet of a mining operation. From mining to crushing to processing, mine management is constantly seeking new methods and technologies to improve the way it mines minerals. And it is willing to borrow techniques used by other operators.

Jan 1, 2002

By P. R. Levey, A. van Bennekom

The effects of nitrogen alloying on the corrosion properties of austenitic stainless steels were investigated by a combination of potentio-dynamic and surface analysis techniques. The results indicate that nitrogen undergoes the phenomenon of anodic segregation, affecting both general and localized corrosion resistance. Nitrogen alloying is found to be beneficial to general corrosion resistance in a de-aerated sulphuric acid solution, but to be detrimental in an aerated solution of sulphuric acid This phenomenon is explained in terms of an ammonium-ion polarization effect. Localized corrosion resistance is found to improve dramatically as a result of nitrogen alloying, the nitrogen improving the formation, maintenance, and stability of the passive film in environments that promote pitting various theories that have been proposed to account for these phenomena are discussed.

Jan 1, 1995

By N. M. Raju, S. K. Dutta, M. A. Khan, B. Singh

The paper seeks to present the application of ground control research at Mosaboni Copper Mines to increase the size of stoping areas. Room and Pillar stopes were experimented for increased production dispensing with the conventional breast stoping. The experimental stopes, with spans varying from 10 to 15 m, were extensively instrumented to study the behaviour of wall rocks (chlorite schist) and to determine the optimum span in the workings, dipping at 25° to 45° and 3 to 5 m in height. The observations confirmed that 15 m wide span could be safely worked with 3 m wide rib pillars at 600 to 800 m depth by using rock bolts. Ground conditions improved with the use of full-column cement grouted bolts dispensing with timber supports and the productivity was improved.

Jan 1, 1981

Improvements in mechanisation should not be considered independently of safety and of environmental hazards. The need to keep gas contents within statutory limits may make the time needed to partially drain a gassy seam the effective control on face development times. Dust levels may provide an effective control on coal extraction rates on any one face. The combination of gas and dust on high output longwall faces may make it necessary for each one to be treated as a separate mine in terms of ventilation, and the faceworkers may need special protection. Mechanisation and safety can be mutually beneficial when mechanisation combined with systematic safety assessment reduces accidents, and when a thorough study of how to reduce accidents and health risks indicates the best method to improve mechanisation.

Jan 1, 1988

By J J. Cilliers

The aim of this paper is to give an overview of the FrothSim flotation simulator and to demonstrate its ability to predict the performance of real flotation circuits. Example simulations are presented in which the feed rate to the circuit is varied, followed by simulations in which a cleaner section and recycle loop are added to the rougher bank.The simulator is able to predict both the recovery and the grade produced by the cells at all locations in a circuit and the simulator is shown to produce plausible grade recovery curves. It also demonstrated that the performance of banks of cells improve as the feed rate to the bank increased (improved grade for a given recovery), but that more cells are required to give the same overall recovery.

Jan 1, 2005

By Brett Triffett, Mark Weidenbach, Christopher Treloar

OZ Minerals owns and operates the Prominent Hill copper-gold concentrator in South Australia, built in 2008 and commissioned in early 2009. The concentrator operates via semi autogenous grinding in a thirty four foot ThyssenKrupp Polysius mill followed by a twenty four foot Polysius ball mill in closed circuit with hydro cyclones, designed for an ore throughput of eight million tonnes per annum. The main aspects of designing the circuit are discussed along with the issues faced in the early stages of operation. A review of the optimization strategy applied to the milling circuit such as cyclone optimization, advanced process control strategy implementation and reline management to improve availability is then discussed highlighting areas of significant process improvement that have seen the plant exceed nameplate throughputs above nine million tonnes per annum.

Jan 1, 2012

By Lynn DR, Wadley GB

The Australian gold industry has made large steps forward in the last few years. This progress has been driven by improvements in mining and processing technology, the high price of gold and by a favourable legislative, political and taxation environment. This paper concentrates on improvements in gold project development, process engineering and technology as seen by BHP Engineering, Perth, Australia.The paper describes technical aspects of successful gold project development including metallurgical testwork, feasibility studies, choice of process flowsheet (gravity, heap leach, carbon in pulp (CIP), carbon in leach (CIL) or other routes). It sets out our views on plant design, plant construction, procurement and project management.A case study for a small plant recently completed in the Philippines is presented as a solution to the problems often encountered in treating quartz vein gold deposits.

Jan 1, 1990

By Gary F. Meenan

The industrial practice of froth flotation for upgrading the quality of fine coal is a relatively complex, expensive, and inefficient process when compared to the coarse- and intermediate-size coal cleaning circuits. The differences in cost and process efficiency can be attributed mainly to the lower equipment throughput, the added cost of flotation reagents, and the fact that flotation is typically a manually operated process susceptible to fluctuating feed characteristics that influence the overall operating efficiency. The emphasis in recent years has been on improving the flotation process efficiency and lowering the cost per clean ton. This has been achieved by larger flotation cell designs, implementation of flotation reagent evaluation programs, and improved process instrumentation and control. These developments are reviewed along with other current coal flotation practices.

Jan 1, 1999

There has been some confusion over the selection of discount rates when performing stochastic simulations of a project's net present value (NPV) using risk- adjusted discounting techniques. Some argue that lower discount rates should be used when performing stochastic valuation simulations. This creates higher NPV values and improves the attractiveness of a project. Others argue that the discount rate should not be lowered for these simulations. This paper exposes the source of this confusion. It demonstrates that stochastic simulations do not remove the risk inherent in a project and, therefore-do not improve a project's value to the risk-averse investor. Risk-adjusted discount rates should, therefore, not be adjusted downward when performing stochastic NPV simulations. Stochastic simulations are, however, shown to he useful in several aspects of project valuation.

Jan 1, 1996

"Energy efficiency in mining and minerals processing has attracted considerable public and industry attention because of the significant quantities of energy consumption involved. In this context the question of what are worthwhile targets for energy efficiency improvements ought to be of the highest priority. It is however worth taking a step back to avoid falling in the trap of taking preconceived ideas that have been reiterated repeatedly before as gospel. The aim of this paper is to highlight areas where new or alternative approaches could potentially be the better way forward. Some may come as a surprise to conventional industry thinking. Ultimately any such solutions are attractive to practitioners not just in an environmental but also in an economic sense, and hence should be targeted through applied research and development efforts. This paper highlights key aspects of each group of opportunities and some of the individual approaches to provide an overview of the current status quo.MINING INDUSTRY POWER UTILISATION – WHERE IS THE BIGGEST BANG FOR THE BUCK?The question of where is the biggest bang for the buck when trying to determine worthwhile targets for energy efficiency improvements has not always been reported on broadly enough, typically because industry practitioners operate in specific areas of expertise and comfort zone. Looking beyond the familiar doesn’t always come easy. Any technology or methodology consideration to address energy efficiency needs to take into account the context of alternative opportunities of superior value or risks not achieving desired uptake. The following sub-chapters have been ordered by magnitude of improvement potential as best as is possible, starting with the biggest first, and the smallest last. Some may be a surprise relative to conventional mining industry thinking."

Jan 1, 2016

By G. C. Lindeque

"A downward trend in tyre life on haul trucks at an open pit iron ore mine prompted an investigation into the current tyre management strategy in order to improve tyre life. ‘Best practice’ was compared to the current tyre management strategy at the mine to determine aspects that could be improved. Aspects that showed significant room for improvement included employee tyre awareness, tyre pressure maintenance, and road conditions. For each of these aspects a plausible alternative was suggested.A new tyre management strategy was formulated as a step-by-step guide on how to implement the proposed changes. Each step introduces new initiatives but at the same time builds on the previous step’s success. A sensitivity analyses was performed to determine the impact of the proposed changes, with the variables being the reduction in the percentage of premature tyre failure, and the reduction of the site wear rate.The ‘most likely’ scenario showed an increase in tyre life of 41% for the Komatsu 730 trucks and 105% for the CAT 777 trucks if the entire tyre management model is implemented. This would result in a possible annual saving related to tyre usage of R9.2 million. OverviewThe study focused on the tyre life on the main haul fleet at an open pit iron ore mine. The haul fleet consisted of 17 Komatsu 730 (180 t) haul trucks and 12 CAT 777 (90 t) haul trucks.The haulage operation consists entirely of tyre-based haul trucks. Five per cent of the total mining budget is related to tyre costs. Since 2012 there has been a steady decrease in tyre life as measured in operating hours (Figure 1) due to the high percentage of tyres that fail prematurely. In 2014 a total of 41% of all tyres failed prematurely and 61% were classified as ‘worn out’."

Jan 1, 2016

By V. Sheikhzadeh, M. Saghaeian, R. Hejazi, A. Abazarpoor

Green pellet strength including drop number and green compression is highly depended on particles size and shape. The used grinding method, ball mill or high pressure grinding roll (HPGR), directly vary the particle size and shape. Considering mode of pellet crack, green pellet is composed of particle-binder-moisture system. Different type of forces existed in such a system to create a stable green pellet: solid particle interaction, magnetic, binding and cohesive forces in the interface of particle-moisture. The pellet failure can occur at solid-liquid interface and/or through liquid phase. Pellet crack occurs when crack passed through entirely the plane failure. In this research, the effect of particle size and shape of pellet feed on green pellet strength has been investigated. It was deduced that green pellet strength highly improved by increase of specific surface area. The drop number and green compression strength of pellets prepared by HPGR was higher than ball mill. It was found that the main reason responsible for this difference was the particle shape. Capillary force is responsible for part of pellet force and improves by decrease of particle size. Also more elongated shape of HPGR particles resulted in higher capillary force due to thinner interface layer between particles. The less circular shape of particles lead to improvement of capillary force as can be occurred for HPGR particles. The rougher shape of HPGR particles resulted in higher wettability of particles and better diffusion of water among particles. In fact the rougher particles means lower connection angle. Aspect ratio of particles was of great importance of crack growth because the required energy of pellet failure increases directly. The required energy for pellet failure increases by increment of particle aspect ratio. The relationship among crack failure force, roughness and aspect ratio has been modeled considering 3 shape descriptors.

Jan 1, 2018

By V Salamakha, K Tang, G Si, J Oh, X Wu, Z Yu

The development of machine learning (ML) algorithms has led to promising advances in lithology classification from geophysical logs, which is indispensable in various underground engineering applications. Due to the resolution and availability of logging data, ML models can recognise lithology change in a definitive form at a fine scale (0.01 m). While the results from previous models indicated promising performance in the classification, the robust capability of generalising lithology prediction to unseen data may not be true for those models due to: (1) data bias caused by borehole selections, and (2) logging data mismatches among boreholes. To this end, this paper aims to investigate the generalisability of ML models and seek potential improvements. Four ML models were selected to be trained on single reference boreholes to test the other (as unseen) in the same region, which includes Support Vector Classifier (SVC), Random Forest (RF), eXtreme Gradient Boosting (XGBoost) and Residual Neural Network (ResNet10). The data set involves 11 boreholes from a coalmine in north-western Bowen Basin (Queensland, Australia): density, gamma ray, neutron, and sonic logs are selected as inputs. Additionally, a data adaptation method is applied for better generalisability. The results show that there is an accuracy trade-off between the same borehole and unseen boreholes across the models. It also indicates a 16–43 per cent reduction in model performance when generalising the predictions (in marco-F1 score), while the adapted data sets can contribute to a around 12 per cent improvement. This study provides a fundamental understanding of the model generalisability when using a single borehole, essential for further correlating boreholes for regional lithology classification; the adaptation method can improve the generalised accuracy, and reduces the labour to label lithology, which facilitates the identification of gas storage mechanisms, geological/geophysical modelling, and stratigraphic analysis.

Sep 1, 2024

By Venugopal Bonani, Kumaran M., Thomas John

Liquid storage tanks are usually located in nearshore or coastal regions with soil profiles containing thick layers of compressible soils. These storage tanks are usually of large diameter up to 90m and carry high loads, and the tanks are supported by heavy deep foundations such as piles. These structures are subjected to huge lateral loads due to wind and earthquake, and any damage to storage tanks with highly inflammable liquids leads to disastrous condition. So, it is important that the top layer of soil (up to the fixity depth) should be strong enough to provide the required lateral load capacity to the pile. In a project for constructing LNG terminal in Odisha containing 2nos of 89m diameter LNG storage tanks supported with pile foundation located near to coastal region, for improving the lateral capacity of existing soil, the top 3m was replaced with compacted engineered fill (GSB). The site was a filled-up area with dredged soil from seabed, the top 5m-10m were soft to medium stiff clay with SPT N less than 10. The lateral design load on pile was 534kN under free head condition. Actual lateral capacity for the strata was around 200kN under free head condition which was less than required capacity as per structural requirements. Therefore, for improving the lateral capacity of pile the top 3m soil is replaced with well compacted engineered fill (GSB) in layers of 150mm and the capacity is proved by conducting initial and routine lateral load tests. This paper describes the properties of the engineered fill used and how the lateral load capacity of pile was improved to meet the design requirement.

Sep 1, 2022

By C. Ford, R. E. Salas Rojas, J. P. Contreras Rodriquez, S. A. Pierce

Heightened environmental consciousness has resulted in the development of various international accords dealing with natural resource management. This international awareness is now being translated into regional and local initiatives that proactively implement collaborative environmental management programs. One such program was recently initiated in northern Chile in recognition of the interconnection of Andean salars. Cooperative efforts between industry, governmental agencies and academic professionals have resulted in the implementation of simultaneous environmental monitoring of flora and fauna in the salars of northern Chile. This coordinated effort is leading to an improved understanding of the migratory patterns of South American fauna, as well as improved access to an expanded database for the multiple user groups associated with the Andean salars. The El Abra Mine is actively participating in these coordinated monitoring efforts.

Jan 1, 1999