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By D Kahler

Modern gold production from the Gympie Goldfield commenced in 1995 with the first production from the Monkland Mine. The primary ore target was the 2.5 m wide Inglewood Fault ore zone, which was initially mined using traditional narrow-vein shrink stoping. This manuallyintensive mining method allowed the mine to re-open with minimal capital cost, however the trade off was low productivity and high operating costs. As the mine has developed, access through 100-year-old, timber-lined, small shafts, and the high cost of delineating reserves, has restricted modernisation of the operations. In early-2000 a stockwork lode was discovered adjacent to the existing workings with an economic width of 40 m. In order to maximise the benefit of such an orebody, mining needed to be approached in a new way. This paper summarises the many changes implemented at the Monkland Mine, including the necessary cultural change, implementing long-hole stoping, de-bottlenecking and the application of mechanisation. The result has been a significant improvement in safety performance, higher productivity and a more secure future for all those involved in the project.

Jan 1, 2002

By Nicolin Govender, Pramod Kumar, Raj Rajamani

Mill power models have been used in a variety of ways in industrial practice since power directly equates to throughput and fineness of ground product. We first start with Hogg-Fuerstenau Power Model and show how this model successfully predicted the power draw of many grinding mills in several mining operations. Then, we show how this model was on the verge of being able to predict the influence of lifter design on power draw. Next, we describe the discrete element model and how it overcame the issues faced by the previous power model. Using a DEM software known as Millsoft, we show the influence of lifter design geometry on power draw and analyze the power draw of rubber lifters versus the steel lifters via several case studies. As years passed, the two-dimensional discrete element model imbedded in Millsoft is superseded by three-dimensional discrete element method. Due to the gigantic computational power of graphic processing units, new computational codes that can do the tumbling motion along the entire length of the mill has come about. Here, we show the predictive capability of Blaze-DEM for ball and SAG mills.

By P York

The study commenced in October 2012, to understand the basic ecology of the spotted-tailed quoll (Dasyurus maculatus) and to confirm whether the species utilise previously mined land on the Mt Owen mine site that was rehabilitated in 1996 to 2011, as part of their home range. The spotted-tailed quoll is a widely distributed marsupial carnivore that is listed as rare or threatened in every state in which it occurs. The species is a forest-dependent marsupial carnivore that occupies a wide range of habitat types (Long and Nelson, 2004).The first part of the study involved trapping a spotted-tailed quoll and fitting the individual with a combined global positioning system / ultra high frequency (GPS/UHF) radio-transmitter collar (Telemetry Solution – Quantum 4000E). The benefit of the GPS/UHF collar is that it records locations (or fixes) at intervals programmed by the user. The UHF component allows the researcher to locate the individual at a frequent interval, and the Quantum 4000E also has a remote download function, enabling the GPS data stored in the collar to be wirelessly transmitted between the collar and researcher. The benefit of this new technology is that the animal does not need to be repeatedly captured to retrieve the GPS data.Daytime searches are also undertaken using the UHF receiver to locate the individual and locations of daytime denning and latrine sites. The location of each den site is recorded using a hand-held GPS. Data downloaded from the GPS collar is then imported and mapped using computer software program ARCGIS (geographic information system), to overlay the data points onto aerial photography.Results demonstrate that threatened species will utilise rehabilitation areas post mining. The data presented will be used to develop a greater understanding of threatened species ecology in and around rehabilitated areas, which will assist in the planning and design of native forest rehabilitation areas.CITATION:York, P, 2014. Mt Owen Mine spotted-tailed quoll study, in Proceedings Life-of-Mine 2014 , pp 591–596 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 16, 2014

By D. J. Murdock

Cominco Ltd. has developed a number of innovative technologies for electrowinning. The paper discusses the application of these technologies to the copper industry. Tankhouse and cell design will be discussed in addition to anode cleaning and cathode handling. Specific examples of the application of this technology to the copper industry are cited.

Jan 1, 1987

By C. Joulian, A. G. Guézennec, A. Chmielarz, Y. Ménard, M. Hanke, P. d’Hugues

"The copper concentrate used in this study is produced by flotation of a black shale organic rich ore. This resource is a carbonate-rich, polymineral concentrate. In the last 5-6 years, ore characteristics changed and the concentrate grades degraded. This study evaluated bioleaching of the concentrate in stirred tank reactors as an alternative to the pyrometallurgical technology that is currently applied, and which may no longer be feasible in future given the concentrate chemistry.The first part of the study focused on testing non-traditional operating conditions during continuous bioleaching experiments: high solids concentration (> 20% solids), reduced agitation and aeration rates. For the same residence time, bioleaching performance at high solids loading (25%) was the same as that reached during previous bioleaching experiments at 15% solids. No mixing or microbial issues were encountered. The bacterial consortium used in the experiments demonstrated a high copper tolerance.The second part of the study was devoted to technology development for metal recovery from copper bearing solutions obtained during bioleaching experiments. Due to the high copper concentration of the leachate, solvent extraction prior to electrowinning was not necessary. After iron removal, high quality copper cathodes (morphology and composition) were obtained from the PLS by electrowinning."

Jan 1, 2014

By T. W. Camm

"As engineers, we are trained to use logical, rational problem solving to insure our mines operate at maximum efficiency. We tend to use the same technical approach to design safety into all mining systems. This works well for machines, but not so much for the human component. Recent insights in the field of behavioral economics provide useful ideas for addressing the fact that we are driven by emotions more often than by rational thought. Understanding the nonrational aspect of human behavior is an important piece of any safety system design. INTRODUCTION The most common economic model is based on humans making rational decisions; that given the proper information, we will make a logical, rational decision based on what is best for ourselves (Ariely, 2009, p. xviii). In many cases this is an accurate description of how we make decisions. As an engineer, I was trained to apply the precision of mathematics and logic to solve problems. As an engineering professor, I now teach this approach to bright young minds preparing them for a life of professional effectiveness as practicing engineers. That said, we are not only rational. Daniel Kahneman, winner of the Nobel Prize in Economics, describes a model for how we think (Kahneman, 2011). System 1 is the part of our mind that is fast, intuitive, and emotional; while our logical, slower, and deliberative mind is System 2. According to Kahneman’s model, System 1 runs automatically, most of what you think and do originates in System 1. System 2 takes over when things get difficult, including the application of math and logic, and the resolution (or avoidance) of conflict. As engineers, we would typically assume that we operate in System 2 mode most of the time. This is where the model becomes useful, for Kahneman points out two important aspects of the dynamic between the two systems in our mind. First, System 1 has biases, systematic errors that lead to answering questions with an easier answer (rather than a right answer) before System 2 is engaged. Second, we can be blind to the obvious, and also be blind to our blindness. Complicating things further, System 1 cannot be turned off (Kahneman, pp. 24-25)."

Jan 1, 2015

By S. S. Cole, C. E. Wood, T. L. Joseph

"INTRODUCTION Iron ore containing titanium was first used in blast furnaces over a century ago. It is well known that TiO2 is a slag-forming material that will increase the amount of slag produced by the usual gangue materials, silica and alumina. Increase in the volume of slag due to the presence of TiO2 and a lack of information concerning its effect on the properties of the slag have prevented the general use of titaniferous ore. Also rather com¬mon belief among furnace operators that the bottom of the furnace builds up when ores containing TiO2 are smelted has militated against the use of titaniferous ore. This building up of the hearth has been attributed to the formation of copper-colored crystals of titanium cyanonitride, which have been observed in the salamanders of blast furnaces. Until recently the availability of nontitaniferous iron ore has left little incentive to use ore containing titanium.The presence of vanadium in certain deposits of titaniferous magnetite in New York State has created new interest in problems connected with the use of titanium-bearing ore. It appears that most of the vanadium in this ore can be recovered in pig iron, which can be blown in a converter to produce a slag containing vanadium in amounts suitable for the production of ferrovanadium.The Titanium Division of the National Lead Co. recently erected a largo mill to treat ore from Sanford Hill, in Essex County, New York, about 50 miles west of Port Henry. The ore deposit was acquired from the MacIntyre Iron Co. and is often referred to as Sanford ore. It is one of the largest deposits of Iron-bearing material to be found east of the Lake Superior region and is being mined by open-pit methods."

Jan 1, 1943

By A. Luckita, A. Samtani, R. Barus, J. R. Donald, J. Syarifuddin

In conventional Rotary Kiln-Electric Furnace (RK-EF) laterite nickel processing, management of dust continues to be problematic. A more efficient processing of dust represents an opportunity for energy efficiency, increased production, and productivity. PT International Nickel Indonesia (PTI), together with Vale Base Metals Technology Development (VBMTD), has successfully developed and implemented a novel flowsheet enhancement that capitalizes on these opportunities. In the novel flowsheet, the dust recycle stream is moved forward in the RK-EF laterite nickel smelting process. The dust is injected into the kiln's main burner, as opposed to being recycled to the dryers. A similar treatment of dust is commonly practiced in the cement industry; however, application to nickel smelters has not been fully developed to date. This paper describes this dust insufflation technology, the process through which it was developed for laterite nickel processing, and summarizes the lessons learned. A key conclusion is that successful new technology development requires a multi-disciplinary team involving members from research and development, study management, engineering consulting firms, project implementation management, process technology and operations.

Jan 1, 2011

By A. Saigal

The effect of temperature on the cutting forces during machining of alumina reinforced aluminum composites was investigated, Aluminum 6061, 10% Al2O3 reinforced composite and 20% Al2O3 reinforced composite were tested, A 5/8-inch diameter high-speed steel end mill, a Micro 100 TiN coated single edge endmill cutter and a two-fluted solid carbide insert cutter were used for tooling, The results, in general, showed an increase in the cutting forces as the temperature of the material increased, From the raw data, there are temperatures ranges in which the force data did decrease but they were insignificant with regards to predicting a downward trend. A regression analysis was used to understand which variables had the greatest affect on the forces being generated, The correlation and regression analysis showed that at 600 rpm (velocity: HSS- 98,2 sfpm, Micro 100 cutter - 78,5 sfpm, solid carbide cutter - 192,4 sfpm) the tooling, the workpiece material, built up edge, and temperature were statistically significant factors in the test, Tooling was a significant variable in all testing, The smallest forces recorded during machining were generated with the solid carbide two-fluted endmill cutter, Visually, the solid carbide tooling produced a better surface finish during the testing which made it the tool of choice, In addition, the force data proved that as the cutting speeds were increased, the cutting forces decreased.

Jan 1, 2005

By Satu Strömberg

A single-particle laminar-flow technique was used to study oxidation of two nickel concentrates and a granulated nickel matte (43 wt% of Ni). Experimental conditions were: reaction gas from N2 to N2 + 75 vol% O2; gas preheating temperatures ranging from 500 to 1100°C. The major nickel-bearing minerals in the two concentrates were pentlandite and violarite, respectively. Chemical analysis of the particles was used to determine the oxidation degree of the materials, and optical and scanning electron microscopy were used to detect their morphology and mineralogy. Total desulfurization of the nickel concentrates was achieved under the most oxidizing conditions, while the sulfur removal from the nickel matte was not as efficient, especially with the coarse size fraction. Pentlandite-based concentrate was found to be less reactive than the violarite-based.

Jan 1, 1995

By K. V. Raj, A. Miller

"Workers at mineral processing facilities are often exposed to high levels of dust generated when ores are processed. Crushing, grinding, screening, and other processes generate large quantities of dust, which can exceed the threshold VALUES (prescribed by the Mine Safety and Health Administration (MSHA). Many ores contain quartz (silica), which has been known to cause serious health problems in workers over time. Given the structure of mineral processing plants, the airflow regime is not coherent inside the building, which may lead to multiple recirculation zones. These recirculation zones can trap dust, and concentrations of dust can then rise over time. Therefore, there is a need to understand the airflow phenomenon that occur inside of mineral processing facilities and how these occurrences interact with the dust generation processes to identify zones of potentially high dust concentration. Computational fluid dynamics (CFD) modeling can give a better understanding of the airflow and help recommend designs and methods to mitigate the high dust concentrations in a mineral processing plant. This paper presents the CFD modeling of airflow inside of a mill building to demonstrate airflow patterns that will affect the generation and subsequent dispersion of dust due to crushing, grinding, and other activities. This study was conducted by researchers from the National Institute for Occupational Safety and Health (NIOSH). INTRODUCTION In a mineral processing facility, minerals go through various mechanical processes in order to reduce their size for separation of economic minerals from gangue minerals to produce a final marketable product. This research, conducted by the National Institute for Occupational Safety and Health (NIOSH), focuses on ore mills in metal and nonmetal mining (MNM) operations, but the applicability of the approach will be valid for any large structure where workers are exposed to airborne contaminants. The processes of crushing, grinding, cleaning, drying, and product sizing in these facilities generate a large amount of dust, creating hazardous conditions for the workers in these facilities. This is highlighted by the fact that MSHA sampling data for the years 1997–2012 indicate that 12.3% and 15.9% of the gathered samples were over 100 µg/m3 for silica for metal and nonmetal mills, respectively [1]. Mineral processing operations typically use some type of engineering control to address their most significant dust sources. Engineering controls include such approaches as bag-house-type dust collectors, scrubbers, and electrostatic precipitation [2]."

Jan 1, 2018

By A. M. Gaudin

THE so-called Kick law' is generally accepted to . mean that for each reduction to one-half in particle diameter, in a unit weight, the same amount of work is required. In crushing-efficiency calculations on crushing tests it is customary, when basing the calculation on Kick's law, to assign ordinal numbers to each standard sieve size. These ordinal numbers increase by a constant difference with each successive sieve aperture, because standard sieve apertures are in constant ratio. Minus 200-mesh is generally assumed as equivalent to 37 microns in size. By definition, the ordinal number multiplied by the per cent material of any size is equal to the energy units in the material of that size in a unit weight of sample. The sum of all energy units is the energy units content of a unit weight of sample, whether it be crusher feed or product. The difference between the energy units in the product and that in the feed is the tangible result of the work input per unit weight of feed. From this the amount of work necessary for one energy unit may be calculated. This has been done for a quartz crushing-test made at the Intermountain Experiment Station of the U. S. Bureau of Mines at Salt Lake City, in which the net work going to crushing was carefully measured. The results of this crushing test are given in Table 1.'

Jan 1, 1929

By L. K. Daneshmend

Key issues in managing information systems in the minerals industry will likely continue to be those relating to the integration and interoperability of disparate systems. This paper argues that, in order to harness the promised benefits of information technologies, the mining industry should adopt a set of open systems standards to define data formats and protocols for seamless data exchange. This is in direct contrast to the present situation where mining equipment, software and instrument suppliers rigidly adhere to proprietary standards for fear of losing competitive advantage. Benefits to the mining sector resulting from the adoption of such standards would be: the provision of near-time data for executive decision support, and the freedom to choose best technologies. The principal benefits to the leading mining software suppliers will be increased market share as a result of “captive sites” converting to open systems standards. Examples are given of open systems standards developed for related industries such as the Petroleum Open Systems Corporation (POSC) and the Machinery Information Management Open Systems Alliance (MIMOSA).

Jan 1, 2000

By J. Malone, D. Loth, J. Palmer

WMC Resources' Kalgoorlie Nickel Smelter was commissioned in 1972 at a design capacity of 30,000 tpa of contained Nickel in matte. A series of upgrades and progressive improvements have resulted in a design capacity increase to 110,000 tpa of contained Nickel in matte. The smelter sources nickel-in-concentrate from three Mine / Concentrators and supplies nickel-in-matte to WMC's Nickel Refinery and export customers. The Flash Furnace was last rebuilt in 1999, and is over halfway through the 10-year campaign target. The many modifications over the previous campaigns, including the Integrated Flash Furnace, are reviewed. Recent operation of the smelter and the development of the process during the current campaign are detailed herein. An overview of key interfaces with the Nickel Business Unit Concentrators and Refinery operations is provided.

Jan 1, 2005

By Charles H. Atkinson, Robert T. Johansen

Tremendous volumes of petroleum ( crude oil and natural gas ) at present cannot be recovered economically . The feasibility of using nuclear explosions for production stimulation therefore has been investigated . Data from underground nuclear tests conducted by the Atomic Energy Commission were reviewed , and the physical effects were evaluated for stimulating petroleum production . Calculations of the effect on ultimate recovery of increasing reservoir temperature with nuclear explosives showed disappointingly small increases . Production increases caused by fracturing of massive low- permeability reservoirs appear technically and economically promising . Petroleum reservoirs that might be converted from submarginal to commercial production are being located and evaluated as to potential reserves and as a location for a field test .

Jan 1, 1964

By Louis R. Hodell

WHEN the drilling of an oil well is completed a permanent opening from the reservoir to the surface must be provided. This is done by lining the hole with pipe, commonly known as casing. In the past, all but a small amount of casing has been run in the hole and joined by threads and couplings. Recently, however, in California, Texas, and Oklahoma, there has been a definite tendency 'to adopt -the welded joint for the following reasons: (1) Plain end casing for welding may be bought for 15 per cent less than thread-and-coupled casing; some of this is offset by the cost of welding the pipe in the hole but a respectable net profit remains.

Jan 1, 1937

By Walter K. Utt

The U.S. Bureau of Mines conducted research to develop an accurate, real-time, position monitoring and warning system for the vehicles used in surface mining. The product of this research will be technology to reduce accidents and injuries associated with the operation of surface mining haulage equipment. The position monitoring system should reduce accidents related to vehicle position and also increase the efficiency of haulage operations. This research was conducted in preparation for development of an accurate, real-time position monitoring and warning system, which notifies equipment operators when they deviate from a known safe course and are approaching a fixed hazard. A radar positioning system designed for marine applications was evaluated and a series of tests was run to determine the accuracy of the radar positioning system when used in a land vehicle. The radar position determination was compared to surveyed values. Both static and dynamic (moving vehicle) tests were conducted. The static test results were marginal and the dynamic test results were not accurate enough for the position monitoring and warning system. Although a promising technology, the system tested needs to be modified to meet the accuracy requirements of mobile mine equipment.

Jan 1, 2010

By V. M. S. R. Murthy, Biswaraj Dash, Somnath Chattopadhyaya

Tunnel boring machine (TBM) has been in focus for the last few decades and is currently the most preferred excavation method for metro, hydro and irrigation tunnels. Tunnelling in hard and abrasive rock conditions, in particular, is adversely affected by a very low advance rate coupled with increased TBM disc cutter failures and cutterhead jamming, seeking an in-depth understanding of the design and operational processes of the boring components of the TBM. The cutterhead and disc cutter are the critical boring components of the machine, influencing the boring process significantly. These components directly interact with the rock and hugely influence the machine’s efficiency. This paper encapsulates a review of prior studies related to disc cutter design and the cutterhead design for hard rock TBM tunnelling. A design methodology for designing and selecting a disc cutter and a cutterhead is suggested. The design methodology has been applied for a hard rock tunnelling case, and suitable design specifications for the boring components were arrived at. The disc cutter and cutterhead specifications designed based on the suggested methodology closely match with that of deployed TBM specifications. It may be observed that except for the case of high-strength and high-abrasive rock (greyish quartzite), for the rest of the rocks, the suggested design can meet the desired advance rates.

Jan 31, 2024

By N. H. Darton

In mining coal in the anthracite region of Pennsylvania the general custom has been to leave a large percentage of the coal in place as pillars to support the roof. Evidently any practice that involves partial waste of an important mineral resource is bound to be discarded. It is well recognized that one method of obviating probable waste is to fill the workings with cheap or worthless materials, a process extensively employed in the anthracite and some European mines. At present many of the collieries in the anthracite region of Pennsylvania are utilizing refuse from the old culm banks, which formerly were prominent features in the landscape, and are flushing the fine waste underground so that pillars may be reduced in size or removed. As a result the banks are now disappearing and soon will be gone. The fine culm from the breakers and rock from the mines will continue to be available, but the volume of these materials is insufficient to replace any considerable proportion of the coal removed. The next stage of progress suggested is the use of sand. Fortunately there are available large deposits of this material, much of which can be handled by dredges and pumps. This report is issued by the Bureau of Mines in the interest of safer and more efficient mining methods. I ts purpose is to describe the sand deposits in the northern anthracite coal field in Luzerne and Lackawanna Counties, Pa, Much of the information available is presented in the map, Plate I. Field studies, mostly preliminary, were made in the summer of 1911 to determine the distribution, amount, and character of the larger deposits. It was not thought desirable to make a detailed examination of the region because when the coal companies decide to utilize the sand their engineers will make precise surveys and drill test holes. In preparing the map the various coal companies were consulted; they contributed a large number of facts, especially as to the deposits in the buried valley of the Susquehanna between Pittston and Nan- ticoke, where nearly 1,000 test holes have been bored. The results of these borings were placed at the author's disposal, and have been utilized in drawing the boundaries given in the wide valley area and its extensions up Lackawanna River and NewportCreek. Wyoming Valley contains deposits of sand that are 100 feet thick over a wide area, 200 feet thick in places, and over 300 feet thick in the deep old channel south of Plymouth.

Jan 1, 1913

By Michel Ruel

"PID loops – also known as base layers or regulatory controls – form the foundation of any plant’s control layer and it is generally accepted that PID loop health has a direct impact on the plant’s bottom line. Keeping these thousands of control loops in good health has a direct impact on the plant’s bottom line: it reduces variability, improves quality and throughput, and decreases energy costs and raw material usage. This has been well proven and documented in many articles. In the last ten years, technology has evolved: control engineers can now keep track of control loop performance and link it to the root causes of variability. However, they lack industry-wide best practices and criteria for determining what can be considered as excellent, good, fair, or poor performance. To ensure that PID control loops continue to perform well and meet their objectives, control engineers need a combination of (a) an appropriate monitoring technology and (b) best practices for doing the maintenance of base layer controls.Most plants have limited resources and operate with an increasing number of constraints; therefore, using the right tools and including reports in daily workflow is key for success. This paper suggests roles and responsibilities of key players needed to work toward control performance best practices and discuss organisational changes to succeed.INTRODUCTIONAlthough PID controllers are reliable workhorses in the process industry, they are often underrated. Since the 1980’s, computer control has evolved and the control algorithms used by control engineers have become increasingly complex. However, PID controllers still handle over 90% of the control loops in operating plants. Table 1 shows the savings that can be realized by achieving best-practice in several different process control categories (Brisk, 2004). The savings are expressed as a percentage of production costs."

Jan 1, 2011