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By M Allen

Energetics has been in the business of climate change for more than twenty years. This experience has only served to cement the understanding that decisions taken during design define the environmental and economic performance of any project. The 80-20 rule definitely applies, with 80% of a project’s performance being set through the first 20% of design decisions. This in depth knowledge is used for determining energy price forecasts, future carbon markets and carbon costs, current and future energy technologies, as well as giving a thorough understanding of the processes and technologies in place in the mining industry to work out what the most carbon and energy sensitive decisions during design are. Project selection and design is a gated process where decisions are taken in line with the information available at that point in the evolution of the project. Design decisions are, by their nature, dominated by uncertainty. In order to ensure that robust decisions are taken, it is necessary to ensure that the correct information is brought to bear at the correct decision point. This then defines and supplies the necessary carbon and energy information for design decisions to be correctly made. One of the most significant risks facing design engineers and decision makers in the mining industry is the future cost of energy. Part of this risk is associated with a future cost of carbon, however, a significant part of this risk is the cost, and variability in this cost, of the energy itself. This paper investigates the information required to support good decision taking during the design process.Project Managers and MetPlant Operators accept poor quality evaluations because they are generally unaware of what they should expect.The 2010 draft AusIMM ‘Guidelines for Techno-Economic Evaluations’ were collated by a subcommittee of practitioners and are regarded as best practice.They apply directly to projects and metallurgical plant evaluations, including those with a heavy technical basis. They can be applied to technical problem solving where there are no monetary computations.Project Managers and MetPlant Operators should demand that economic models and evaluations follow the six principles. They should become working tools which are easy to understand, fit for purpose, consistent, rigorous, record sources of input data, have key graphs and are rapid to audit.

Aug 8, 2011

By Ali Ekrem Aritan

Exposure to hand-arm vibration (HAV) among the labor force in the mining industry can result in permanent vibration diseases such as behavioral disorders, visual impairment, osteoporosis, pain (mostly in the hands, wrists, and shoulders), circulatory system disorders, and malnutrition. In this study, the vibration exposure of excavator operators working regularly in 25 different natural stone quarries was measured. In addition, the relationship between vibration exposure and rock properties was investigated. Gloved and ungloved vibration measurements were performed and revealed that antivibration gloves reduce excavator operators’ vibration exposure by 7.10–25.95%. Samples from each quarry were characterized with rock mechanics tests. The correlations between the hand-arm vibration measurements and the natural stone physical–mechanical properties (uniaxial compressive strength, Shore hardness, Knoop hardness, apparent density and total porosity) were determined to be over 70%. One finding of the study was that the health risk in excavators cannot be reduced sufficiently by the sole use of antivibration gloves. Furthermore, the excavation of any rock with a Knoop hardness above 121 is associated with an 81% risk of HAV. To increase awareness of the danger of vibration exposure for natural stone miners, training programs should be provided, and technical and operational changes should be implemented.

By J E. Everett

A block model of the orebody is used to plan a mine. The first requirement is to identify ore to be extracted, discarding waste, so as to meet target grade, generally in multiple analytes. Commonly, cut-off values are set for each analyte, so as to distinguish ore from waste. It will be shown that, if more than one analyte is important, this procedure is wasteful of ore and a composite cut-off function is preferable.A second requirement is to sequence the ore extraction so that the variability in ore grade is controlled: failure to do so will result either in low-quality ore being marketed, or excessive re-handling being required to blend the ore to reduce the grade variability.A third requirement is that the extraction sequence should be such as to control the amount of equipment movement required, enhancing the equipment productivity.The overall objective, to optimise the Net Present Value (NPV) of the mined ore, is simply stated but complex in realisation, since so many factors, such as target grade, grade variability, equipment choice, equipment movement, and downstream blending all have alternatives which can be traded off against each other, and all of which contribute to the costs and benefits making up the total NPV.There exist commercial packages for ore selection and mine planning. However, they are often of a ‘black box’ nature, and users are sometimes not fully aware of the criteria being applied. In particular, the treatment of quality as a multidimensional vector may be problematic. The purpose of this paper is to discuss some of the issues involved and to suggest an alternative set of approaches, which should complement existing commercial treatments.The discussion will be illustrated specifically by reference to the mining of iron ore, but the issues are relevant to a wide variety of mining situations

Sep 5, 2011

By Earl M. Woodward

INTRODUCTION Kerckhoff-2 is a 140 MW underground hydro-electric project designed and owned by Pacific Gas and Electric Company and constructed between May, 1980 and May, 1983 by Auburn Constructors. The project is located in the western foothills of the Central Sierra Nevada Mountains, about 30 miles northeast of Fresno, California, and develops the power potential of the lower San Joaquin River and its tributaries between the existing Kerckhoff and Millerton Lakes. The Kerckhoff-2 Project consists of project roads, adits, and access tunnels, service tunnels, power tunnels, powerhouse, tailrace tunnel surge shaft, buss shaft, intake structure, discharge structure, and switchyard. In the 1920s, the Kerckhoff 1 project, consisting of a dam, reservior, tunnel, and 34 MW powerhouse, was built in the same general area as Kerckhoff-2. The tunnel was constructed by conventional methods, and was left unlined. In time, other projects were built upstream, allowing the flow of the San Joaquin River to be regulated. The Kerckhoff 2 project is designed to harness that regulated flow, providing an additional 140,000 ON of power. Kerckhoff 2 will be the primary power plant; Kerckhoff I will produce power whenever the flow rate exceeds 4,800 cubic feet. The new power tunnel is built along the east side of the San Joaquin River between Kerckhoff and Millerton Lakes, parallel to the existing tunnel but extending approximately one mile further downstream.

Jan 1, 1983

By Andreas Jungbauer

Two Arvedi ESP plants going into operation in 2015 will allow a Chinese steel producer to better serve the extremely attractive local and export markets for high-quality, thin-gauge strip products. The energy consumption and the related costs are reduced by up to 45% compared to conventional casting and rolling processes. This also means a major reduction in CO2 emissions. The new plants are designed for an annual production capacity of 2 x 2.55 million tons of high-quality, ultra-thin, hot-rolled strip products with widths of up to 1,600 mm and thicknesses down to 0.8 mm. The project scope also features a comprehensive training and assistance package for plant start-up and operations by personnel from the existing ESP plant at Acciaieria Arvedi SpA, Italy. The plant setup, the trainings and assistance program as well as latest results from the ESP plant in Italy will be presented. While this project is under execution three further ESP lines have been ordered by the same customer summing up now to five ESP lines at the same location.

Jul 30, 2018

By Santiago Faucher

Molten slag from pyrometallurgical furnaces is tapped at high temperature, carrying a large amount of thermal energy. But the common slag dumping and water granulation methods used for slag treatment do not permit energy recovery. Furthermore, water is present in these processes and while operations are designed to minimize risks of steam explosions, from the contact of slag with water, these common slag handling practices have never been inherently safe. Common handling practices do permit some slags to be sold, but often in low volumes at low prices. Dry granulation offers advantages over these common slag handling practices, including the production of by-products, the recovery of thermal energy, and the eliminated consumption and safety hazards of water. For these reasons, there have been various studies in dry granulation and heat recovery, but most have never been brought to commercial scale due to scalability and cost challenges. Ecomaister- Hatch has developed and brought to commercial scale a reliable and simple dry granulation and heat recovery technology. Here we review common slag handling practices, the developments in dry slag granulation over the last three decades, introduce the Ecomaister-Hatch dry slag granulation process, and elaborate on future applications of the technology in the processing of argon oxygen decarburization and blast furnace slags.

Aug 17, 2017

By Gerhard Finstermann, Ichiro Maeno, Takehiko Saito, Hironori Shimogama, Konrad Krimpelstätter

Automobile manufacturers are developing Electrified Vehicles with light steel body structure designs that reduce mass and therefore greenhouse gas emissions over the vehicle’s entire life cycle. This raises the demand for the production and development of Advanced and Ultra High-Strength Steels (AHSS / UHSS) and Electrical Steels with increased permeability and reduced core loss to improve energy conversion efficiency. To meet this requirements the steel market is tending towards new generations of AHSS with improved formability (3rd generation AHSS) and high-silicon steels with higher strength and thinner products. With this growing demand for advanced high-strength steels and electrical steels, producers are faced with a unique and interesting challenge in producing materials that strain or exceed the capabilities of existing mill equipment and automation designed to produce low- to medium-carbon sheet. While specialty steel producers have known for decades how to process special high-strength steels and thinner gauges, this equipment typically does not offer the yield and productivity desired by the market, necessitating innovation in re-engineering existing equipment to meet the market demands more economically than new construction. In the case of cold rolling, this can be supported through variable roll geometries, more effective roll-gap lubrication technologies, application of strip heaters (Warm Rolling) to reduce risk for edge crack propagation and strip breaks as well as continuous rolling managed by state-of-the-art automation technologies.

Oct 1, 2019

By Yi Luo

Longwall coal mines are frequently located in steep mountainous areas with narrow valleys. In order to protect surrounding watersheds and residential structures, support areas are left under the valleys. However, the indirect subsidence effects to the residential structures due to the potential topography effects can be a serious problem. The present study examines a longwall mine in southern West Virginia located in an area with an average slope of about 30°, or 58%, and with an overburden depth that varies from 49 to 376 m (160 to 1,235 ft). A comprehensive investigation was carried out to assess the subsidence and topography effects, as well as other ground control issues at this site. Surface and subsurface movements and deformation were predicted and their direct effects on nearby streams and structures were assessed. The potential and indirect subsidence influences of surface topography effects were assessed. The techniques and results of this investigation are presented in this paper. It shows that the direct and indirect subsidence effects on the streams and residential structures should be insignificant. The post-mining observations agreed well with this study.

Jan 1, 2010

By W. B. Collingwood, D. Misra, T. Ghosh, S. Bandopadhyay

Understanding the variability of sulfur and calorific value in coal seams is critical to planning mining operations and marketing the mined coal. In this study, statistical and geostatistical techniques were used to explore the underlying spatial trends present in a large coal deposit. Eight prediction models for the sulfur content of the coal seam were developed. Six of the models were created using geostatistical techniques, while the remaining two models were created using other techniques. The performance of each model was examined by conducting cross validation exercises. The results of the study showed that very pronounced trends and anisotropies were present in the sample data, which had to be accounted for in the modeling. The study found that a cokriging model using sulfur and ash is the best prediction model for predicting sulfur content in this coal reserve.

Jan 1, 2014

By KOKOWSKI J., RUDZIŃSKI Ł.

The LUMINEOS network was established in 2013 to monitor mining-induced seismicity in Legnica-Głogów Copper District (LGCD), located in south-western Poland. Since the starting time, the network was improved and today consists of 17 seismometers and 10 accelerometers. Up to now, the strongest recorded earthquake in the region had Mw4.0. Both raw seismic data and earthquakes catalog for events recorded by the LUMINEOS network are fully open and available on the EPISODES platform (https://tcs.ah-epos.eu/#episode:LGCD). During the last 7 years, the network improvements gave us a possibility to increase location accuracy for shallow mining events. This accuracy is influenced by factors such as the configuration of seismic stations, noise level at seismic stations, and the influence of the velocity model. Here we encountered two main issues which are worth to discuss. The first one is the low detection threshold of two seismic stations and their significant impact on the location errors. The second one is the large uncertainty in the S-wave picking. Even though S-waves are not so clearly visible on seismograms, they are very helpful in the estimation of source location and strength of seismic events in the region. In our work, we present the history of LUMINEOS network and corresponding improvement on location accuracy as well as the influence of noisy stations on the error distribution and how it is connected with location results. We also investigate the effect of the S-wave phases and how they are related to the accuracy of the earthquakes locations in the network.

Apr 26, 2022

By Paul W. Shelley, Daniel J. Hodges

The mining industry is undergoing a period of rapid transformative change.  This is the result of the social and financial accountabilities that the industry is faced with because of the world’s desire to cap average temperature increase to 1.50C above pre-industrial levels (UNFCC, 2016).  To limit global warming to 1.50C, greenhouse gas emissions must peak before 2025 at the latest and decline 43% by 2030.  In hard rock mining, comminution is identified as the major energy consumer, being responsible for 40-60% of the electricity use.  It follows that comminution is the major greenhouse gas emission process of the mine.  All effort is being made to radically reduce the carbon emissions of comminution. Grinding media plays a large role in the energy consumption and carbon emission story.  In recent years industry practitioners have attempted to quantify the grinding media carbon footprint.  This paper makes a definitive contribution to that discussion.  The grinding media carbon footprint is quantified in Scope 1, 2 and 3 emission terms in the context of a grinding media supplier.  Major emission contributors, steel, natural gas and electricity are discussed in detail.  The steel industry transition is a key factor. The paper will explore the steel industry transition and its effect on grinding media manufacturing.  The carbon footprint of heritage steel process routes are analysed and compared with the process routes of the future.  Emerging steel making technologies are presented and discussed.  The future of the steel manufacturing and procurement route for grinding media is proposed. This narrative allows for a comparison between the heritage carbon footprint and the future carbon footprint of manufactured grinding media.  Of equal importance is the opportunity of reducing the grinding media carbon footprint in the field.  The paper explores possibilities of reducing the grinding media carbon footprint at the customer site.  Media in use options are presented that take account of the mineral characteristics, the mill dynamics, and the product metallurgy to optimise both carbon footprint and media performance. It is intended that this is a landmark paper in the discussion of the carbon footprint of grinding media.

May 4, 2025

By VIVEK KUMAR HIMANSHU, Murari Prasad Roy, Kaushik Dey, Rakesh Kumar Singh, Ashish Kumar Vishwakarma

Sublevel stoping is the most popular and practiced mining method in underground hard rock mines. Proper planning and its execution is the key requirement for stope extraction using this method. The stope extraction has been a challenging task since decades. The major reason is the unavailability of free faces as compared to opencast bench blasting. The geological and geotechnical parameters change gradually even within the stope itself. So, the blast design parameters should be planned according to the scenario of the upcoming ring. The blast design parameters like burden, toe spacing, inclination of blastholes, diameter of blastholes, charge density of explosive, etc., play an immense role in the rock damage. For the proper breakage of rock, the movement of burden is the prime objective. To study this, an explicit dynamic based modeler of M/s Ansys was used. The burden values were varied from 20 to 65 times of blasthole diameter to assess the optimum burden value during the study. The models were simulated for the rock having uniaxial compressive strength as 35 MPa and 102 mm blasthole diameter. Three holes were simulated having depth around 14–14.5 m. Different blast design parameters and respective blast-induced ground vibration have also been measured at the experimental site. The core samples of the rock present at the experimental site have been used for the evaluation of geotechnical parameters. These geotechnical parameters were used in the simulation models. The volume of rock excavated along the free face has been calculated in each model by varying the burden. It has been found that the burden value can varies from 35 to 40 times blasthole diameter (3.6–4.1 m) to achieve a greater volume of rock along the free face for 102 mm blasthole diameter and rock of 35 MPa uniaxial compressive strength.

Dec 22, 2023

By R. Tamir

This paper will describe the benefits of utilizing the decision support system, DSS to support the methodology of structured decision-making in the mining environment. It will outline the layers of the mining related decision making – 1. Creation of “one truth” situational awareness utilizing 2. existing planning, ERP, operational and monitoring agents, a. Expressing plan verse performance across mining phases and functions compared with the actual and trends to evaluate performance. b. Creating alternate courses of action and the implications up and downstream. 3. It will review the current condition were although a multitude of technologies resolve multi variable issues they do not interact in a way that assists decision makers throughout the organization in making high-quality decisions that will push the overall performance envelope. 4. The paper will show the benefits of integrating military methodologies to resolve multi variable complexed issues (operational, financial and other), operating in changing environments in order to meet time sensitive objectives with restricted resources. This is achieved by creating a shared situational awareness thru incorporating information from a multitude of data generating agents, creating COA, selecting the appropriate and turning it into a plan. The paper will discuss the implementation and suggest a path.

Feb 1, 2023

By Pelin Altinkaya, Maria Leikola, Jussi Liipo, Mika Haapalainen, Mari Lundström, Eero Kolehmainen

With decreasing ore grades, the tailings of mining operations are becoming of increasing interest as metal-containing secondary raw materials. The objective of the current work was to investigate chloride leaching of gold, copper, cobalt, nickel, and zinc present in the flotation tailings. In the current study, the effect of cupric ion as an oxidant (0–50 g/L) and NaCl (150–250 g/L) on metals extraction was investigated. The other parameters, such as pH (1.8), temperature (95 °C), solid/liquid ratio (25%), oxygen feed rate (1200 mL/min), leaching time (24 h), and stirring rate (950 rpm), were kept constant. Gold dissolution rate was shown to increase with increase in cupric ion concentrations up to 50 g/L. Also, increase in NaCl concentration up to 250 g/L increased gold extraction. Majority of the copper present in the flotation tailings could be dissolved with all the all solutions investigated. The other base metals, cobalt, nickel, and zinc extractions were also shown to increase with increase in the cupric ion and sodium chloride concentration. However, even in the absence of cupric ion addition (t = 72 h, 250 g/L NaCl), the final extraction of Cu, Ni, Zn, Co, and Fe increased up to 98, 93, 83, 76, and 80%, respectively. This shows the power of inherently originating oxidants present in the tailings. Furthermore, the solid analysis of the leach residue indicated that leaching the flotation tailings in pure NaCl may result in partial gold dissolution. The results demonstrate that significant amount of metals present in the tailings could be extracted even with only NaCl as added chemical in the presence of oxygen feed, oxidizing agents originating directly from the raw material. This can provide an advantageous cyanide-free method for extraction of metals from very low-grade tailings with low chemical consumption.

It is widely accepted that particles stabilise flotation froths and that stable froths result in improved flotation performance. Predicting the effect of particle addition on froth stability is, however, challenging. Dynamic surface tension measurement using maximum bubble pressure presents an attractive technique to investigate the effect of surfactant and particles at the air-water interface. The range of bubble lifetimes that can be studied (typically 0.1 to 60 s) is analogous to variations in air rate in flotation cells, and the corresponding changes in surface tension give an indication to the diffusion and adsorption rates of particles at the interface. In this paper, we use dynamic surface tension measurements to investigate the effect of particles on bubble surfaces at the microscale and link this to bulk froth stability measurements carried out using a froth column. Using the maximum bubble pressure method, the results show that the addition of particles results in lower surface tension, both at the dynamic (i.e. short) bubble lifetimes and towards equilibrium (i.e. 60 s bubble lifetime). This corresponds with the bulk froth stability measurements, where the three-phase system yielded more stable froths than the surfactant only system. Furthermore, increased particle loading at the air-water interface, whether through higher surfactant concentrations or lower air rates (longer bubble lifetimes), gave lower surface tension and higher froth stability. This demonstrates the link between bubble loading and froth stability. It is proposed that the maximum bubble pressure technique can be used to predict froth stability for two- and three-phase systems, enabling the effect of particle loading to be accounted for and quantified. Moreover, the technique has the potential to allow rapid determination of particle and surfactant diffusion at the air-water interface and prediction of the corresponding effect on bulk froth behaviour.

By Maurício Covcevich Bagatini, Maycon Athayde

Nowadays, the HPGR (high-pressure grinding rolls) is an intermediate step between filtering and balling in the most modern iron ore pelletizing operation. The operation debottlenecks filtering process and reduces pressure over the typical milling process to control particle size to the balling. The present study evaluated aspects of microwave application to the iron ore concentrate fed to HPGR in a bench scale unit. Iron ore concentrate was irradiated varying the microwave exposure time and grinding efficiency was evaluated. The moisture influence in the HPGR efficiency was also assessed. The pellet feed blaine surface area (BSA) improved by 300 cm2/g and % < 325# fraction by 3%. Scanning electron microscope (SEM) images show the formation of micro-cracks onto the particle surface induced by microwave; the effect observed helped improve the milling process performance, in addition to the moisture reduction observed due to the temperature increase.

By Ronald G. Schmidt

AND SOME RIN UP HILL AND DOWN DALE, KNAPPING THE CHUCKY STANES TO PIECES WI&apos; HAMMERS, LIKE SAE MANY ROAD MAKERS RUN DAFT. THEY SAY IT IS TO SEE HOW THE WARLD WAS MADE. Sir Walter Scott St. Ronan&apos;s Well - 1824 In the minds of many, geologic exploration has advanced little since the early nineteenth century. In truth, despite the development and refinement of new and potentially valuable technological tools, the approach or philosophy of the explorationist has received meager attention in professional literature. In many areas, the explorationist relies upon experience, subjective judgement and general intangible inspiration, often traveling together under the misleading pseudonym of "art," in achieving both an exploration plan and in making the myriad day to day decisions necessary to the execution of that plan. Without a solid, objective basis for decisions, exploration under this concept is little more than guesswork largely by intuition, and it is small wonder that many exploration programs flounder in a sea of over-expenditure inefficiency or fail to fulfill their expected goals within the funding which has been provided. From a rational management point of view, such a state of affairs is frustrating and inconsistent with the application of the same scientific principles which are presumed to be the basis for the exploration methods which are used. This somewhat presumptuous point of view cannot be extended as a general condemnation of the many exploration programs which are both technically and economically successful. On the other hand, the

Jan 1, 1968

By A. E. Kehew

Earth resistivity surveys using the Wenner electrode configuration were made in unmined areas and reclaimed spoils at three surface lignite mines in western North Dakota. The study sites were the Center, Indian Head, and Falkirk Mines. Automatic interpretation of the curves was accomplished with the method of Zohdy and Bisdorf (1975). Overburden materials become more homogeneous with respect to resistivity during the mining and reclamation process. The spoils curves show localized hetero-geneities probably related to discontinuous moisture content variations in the spoils. Consistent resistivity differences in spoils occur between mines with over-burdens of different mineralogic compositions. Groundwater chemical composition in terms of total-dissolved-solids (TDS) is inversely correlated (r=-0.61) with apparent resistivity at the 80-foot spacing from a survey centered at a piezometer screened near the base of the spoils. Better inverse correlation is probably pre-vented by high variability in TDS within the spoils groundwater. A useful predictive relationship may be the plot of mean apparent resistivity at the 80-foot spacing for ar. entire mine against mean TDS for all wells in spoils at that mine. Data from more mines are needed to test the hypothesis.

Jan 1, 1982

By Jimmie C. Rosenbruch

The Federal Bureau of Mines evaluated the prospects for using geothermal energy to generate electricity for mines in remote areas. Given the development of a geothermal resource for this purpose, the subsidiary uses of space heating and agriculture were then examined to see if other industries might be viable given a cheap source of heat energy. Sites investigated were located in three areas of Alaska: Kobuk in the northwest, Unalaska in the southwest, and Stikine River in the southeast. Each site was relatively close to mineral deposits whose prospects for development would be enhanced with cheap power.

Jan 1, 1975

By C. E. Stack

For the purposes of this presentation, "refractory clay" is intended to include any clay suitable for refractory products and thus represents a description based on industrial application. Other common examples based on use would be white-ware clay, bleaching clay, paper clay, or cement clay. Most users and producers of refractories have specific quality requirements which determine the quality or type of clay that can be utilized. Many clays can however be interchanged or substituted in use by changing manufacturing processes or upgrading less desirable clays. U.S. Bureau of Mines publications (Ampian, 1985) categorize days into six groups. These are kaolin, fire clay, ball clay, bentonite, fuller&apos;s earth, and common clay. These are practical groupings based on clay production and usage in the United States. Among these groups bentonite, fuller&apos;s earth, and common clay are primarily composed of the minerals, smectite, illite, or chlorite, and are non-refractory. Kaolin, ball clay, and fire clay are commonly used in refractories and thus qualify as refractory clays.

Jan 1, 1986