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By R. Ramírez, N. Aslin, G. Ríos, T. Bravo, A. R. Almansa

Lacy copper has been an on-going concern at Atlantic Copper for at least 10 years and was first reported to Glencore Technology in mid-2010. Over the past 12 years, many of the plates were replaced due to age and general deterioration however; plate passivation and lacy copper issues have persisted. After analyzing all the possible causes of this phenomena, it was found that the problem is caused by a degradation of stainless steel as a consequence of the deposition of Sb oxides. These deposits act as passivating agents of stainless steel, which reduces the density of copper nuclei, causing defective copper deposit, with low thickness and ductility. After doing several tests for reducing/removing the phenomena, the over-riding factor was found to be the anode-cathode overlap. An adequate overlap eliminates the problem of "lacy copper". This was verified during an eight month trial with anodes extended 2.5cm in length. Longer anode not only avoids the appearance of lacy copper, but also recovers cathodes that already have lacy copper. On the other hand polishing of plates only gives rise to a temporary solution that requires on-going polishing, to avoid the re-appearance of lacy copper. INTRODUCTION The electrolytic copper refinery of Atlantic Copper in Huelva (Spain) was commissioned in 1970 with an initial capacity of 40,000 t of cathodes per year. In 1975 the copper refinery was expanded to 108,000 t/year. From 1994 to 1996, a new expansion together with the implementation of ISA permanent cathode technology led to a capacity of 215,000 t/y. Since 1995, a progressive increase in the current density up to 350 A/m2 has been accomplished, which together with an increase in the number of cells from 1,120 to 1,204, has led to the present cathode production capacity of 290,000 t/y A lack of copper deposition in the lower part of the steel permanent cathodes was first reported in 2010. This phenomenon is known as “Lacy copper” because of the appearance of the copper deposit as it can be seen in Figure 1. The occurrence of this phenomena was relatively low and was assumed to be originated by an excessive anode scrapping. Nevertheless, in December 2015 Lacy Copper was observed in a significant amount of copper cathodes giving rise to the following issues: Increased tramp copper – housekeeping and maintenance problems Poor appearance of cathode deposit and untidy looking bundles

Jan 1, 2019

By J. P. Jylhä, A. Jokilaakso

The Outotec Flash Smelting process is widely used in primary copper production. A layer of slag on top of matte (copper–iron sulphide melt) creates a barrier through which matte droplets descend. Droplets of different sizes settle through the layer at different rates, which increases possibility of copper losses as smaller matte droplets may be removed with the slag. In this work CFD-DEM (computational fluid dynamics – discrete element method) coupling was used to simulate matte droplets settling through the slag during slag tapping. Discrete droplets and slag flow were simulated with DEM and CFD, respectively. This new approach enables tracking and solving movement and interactions of individual droplets. User-defined models were created to take coalescence and reaction kinetics into account. Coalescence created larger droplets, while the reactions decreased droplet size and increased its density. Drag caused funnelling effect, which pulled droplets towards the centre line of the descending cluster. This research is the only study known by the present authors in modelling liquid-liquid systems with the CFD-DEM coupling. Simulating coalescence and chemical reactions for discrete droplets enables more realistic simulations. However, CFD- DEM simulations are computationally resource intensive already without additional models, so a full scale industrial settler modelling still waits for further increase in computer performance. INTRODUCTION Flash smelting is a method used in copper and nickel production. In the flash smelting process, oxidation of sulphides in a concentrate is used to release energy needed to smelt the feed. In the process, copper matte is formed. Matte has copper content in the range of 55 – 70% (Sridhar, Toguri, & Simeonov, 1997), the rest is mainly sulphur and iron but has still many other impurities (Taskinen, Seppälä, Laulumaa, & Poijärvi, 2001). Oxidized iron forms iron-silicate slag while SO2 is collected for acid production (Davenport & Partelpoeg, 2015). The Outotec flash smelting furnace (FSF) can be divided in four major component: concentrate burner, reaction shaft, settler and uptake. Concentrate, flux and oxygen enriched air are injected into the reactor through the concentrate burner. The mixture then reacts in the reaction shaft forming matte and slag, which are collected in the settler, while off-gases flow out of the reactor through uptake for heat and dust recovery, and SO2 collection for H2SO4 production. The matte and slag form separate layers due to immiscibility and density difference. Raw material feed is continuous, but the matte and the slag are tapped periodically. A flash smelting furnace is depicted in Figure 1.

Jan 1, 2019

By Ravi Ray, Kostas Kaklis, Zach Agioutantis

"Modern underground mining is becoming more complex and geotechnically challenging. The engineer uses numerical, analytical, and data-driven methods (empirical and/or experimental) or their combination to overcome these challenges. Each method has its advantages and disadvantages. Nevertheless, given the amount of innovation and experience involved in developing each of these techniques, it will be prudent to use all their benefits rather than favoring one technique over the other. Pillars are the most important support element in an underground mine. A holistic geo-mechanical solution needs to be determined to design mine pillars using a proper sequence and exact mix of the three methods. A combination of these methods, in sync, can encompass the several advantages of the three methods while eliminating their disadvantages. This paper presents a conceptual three-tier solution to the pillar design problem, to improve its design pedigree, using a proper combination of numerical, analytical, and data-driven methods. At the focus of this proposed method lies the Ground Reaction Curve (GRC) concept.INTRODUCTIONAlthough the stability analysis of underground excavations is a challenging problem, its understanding has improved tremendously over recent years through the use of improved tools and techniques. The trial and error method was replaced with more scientific methods like the empirical and analytical methods that are still in use today. Empirical methods were developed based on large data sets obtained from experiments and observations (e.g., coal pillar strength equations). Analytical methods were developed based on mechanical understanding of stability (e.g., safety factor for vertical pillar loading, Convergence Confinement Method). Improvement in computing power and numerical techniques led to the development of several numerical methods (e.g., finite difference, finite element) suitable for geo-mechanical analysis.Each of these methods have certain advantages and limitations. Nevertheless, the user is often puzzled over the proper method selection and over the proper sequence of using them. This exercise becomes more challenging when different methods are combined, where, for example, one has to estimate the pillar strength based on empirical equations (e.g., Mark-Bieniawski coal pillar strength equation), determine the factor of safety based on an analytical approach (e.g., tributary area load divided by pillar strength), and analyze pillar-strata interactions using numerical analysis (see Esterhuizen, Mark, and Murphy, 2010b).Challenges increase when current pillar design methods are designed as passive structures to balance the fixed dead weight of the overburden. This classic suspension design approach does not recognize the self-stabilizing capacity of the overburden (Frith and Reed, 2018). A practical solution to address these issues is the use of numerical analysis. However, one should always keep in mind that the numerical modelling approach may have certain practical limitations."

Jan 1, 2019

By Sina Mostaghel, M. Guo, E. Klaffenbach

The current paper is focused on evaluating the behavior of copper in a copper production slag and the assessment of metal recovery possibilities. For this reason, thermodynamic calculations were carried out to determine the influence of parameters such as slag composition, temperature and oxygen partial pressure on recovery of non-ferrous elements. It was found that the formation of a solid face centered cubic (fcc) phase, mainly consisting of iron, limits the extent of reduction that can be achieved for an industrial process. However, it could be discovered that solubility of iron in the Cu-rich liquid alloy strongly depends on presence of other elements, particularly arsenic. As part of the results of this study, the solubility of Cu in the slag at onset of fcc phase formation is presented as function of temperature, oxygen partial pressure and concentration of MgO and CaO. It was concluded that lower temperature (1200°C) and higher CaO addition (16 mass-% in this study), would result in the highest achievable copper recovery from slag. INTRODUCTION Copper slag is produced as a by-product of the copper production process. The slag is still containing a high amount of copper and other valuable metals. This demands further treatment of the slag as a secondary source of metals. In addition, the physical/mechanical properties of slag allow its use in several applications such as hydraulic engineering, civil engineering, as an abrasive and many more. These applications help reducing the use of natural resources like rock and sand. By decreasing the content of heavy metals such as Cu, Pb, Zn and As in the slag, its application in abovementioned fields becomes more attractive as the probability of releasing these elements to the environment is further reduced. To develop a pyrometallurgical slag reduction process, it is necessary to understand what describes the end point of the reduction. This point is expected at maximum copper recovery without facing operational challenges. Existing literature provide some information on the effect of different parameters such as temperature or concentration of different slag formers, on solubility of copper and heavy metals in different phases. However, due to complexity of industrial slags, equilibrium experiments and accurate thermodynamic modelling are essential to be able to reliably predict the behavior of different elements in the system and determine the end-point of reduction.

Jan 1, 2019

By Kevin J. Melong

"Redpath Canada Limited and joint venture partner Thyssen Mining and Construction Canada have recently completed the sinking of the Scissors Creek service in Saskatchewan through its joint owned company, Associated Mining Construction (AMC). The Scissors Creek service shaft was sunk at Nutrien’s Rocanville mine. The following paper outlines the shaft sinking plant and the methodology related to sinking and shaft lining. KEYWORDS Hydraulic shaft jumbo, Hydraulic shaft mucker, Potash shaft sinking, Shaft lining, Sinking galloway INTRODUCTION The sinking and lining of shafts at mines to access mineral deposits has always been one of the great mining challenges for owners, engineers and contractors. Over the course of history in Canadian mining, the sinking of potash shafts through the notorious Blairmore formation of Saskatchewan has proved to be some of the most challenging shaft sinking projects on record. There is no doubt that today’s shaft sinking business demands the utmost in safety performance while delivering projects within schedule and budget. Given these requisites, Redpath and TMCC (executed under the joint venture company, Associated Mining Construction or AMC), were taxed with developing the shaft sinking system to deliver this program in the safest and cost effective manner, with due regard to schedule and quality. Traditionally the potash shafts sunk in Saskatchewan involved a significant level of manual labour, owing to the methodology of excavation by means of chipping the frozen shaft sections with hand held pneumatic machines, and manually placing tubbing segments or steel liners of the shaft lining system. Most certainly, the AMC team wanted to make a step change from those earlier sinking programs and develop systems for sinking this potash shaft that removed the high level of manual work, thus making this project inherently safer, while endeavoring to sink more efficiently. With that in mind, the team embarked on a design program to improve its overall shaft sinking systems without the requirement for excessive capital and methodology flexibility to adapt to potential changing conditions expected to be encountered during shaft sinking. This was especially important should the new approach be met with less than expected success, and retrofitting of the system was required. The concepts were developed to provide for a much improved work environment, while easing the manual labour burden on the workers with innovative equipment and approach to the work."

Jan 1, 2019

By Burden of Occupational Cancer in Canada Project Team, Demers P. A., Kim J., Arrandale V. H., Jardine K.

"In 2012 diesel engine exhaust (DEE) was classified as a human carcinogen by the International Agency for Research on Cancer (IARC) and is one of the most common workplace carcinogens internationally. We estimate that approximately 2.4% of lung cancers (n=560) and a suspected 2.7% of bladder cancers (n=200) are attributable to occupational exposure to DEE annually in Canada. High levels of exposure to DEE in mining results in a disproportionate number of cancers in this sector (approximately 220 lung and 20 suspected bladder cancers annually). These could be prevented by reducing the number of workers exposed and level of exposure. KEYWORDS Bladder cancer, Diesel engine exhaust, Economic burden, Lung cancer, Mining, Occupational cancer, Prevention, Regulation INTRODUCTION Diesel engine exhaust is a complex mixture of gases and particulates containing known and suspected carcinogens such as benzene, polycyclic aromatic hydrocarbons (PAHs), and metals. Approximately 900,000 Canadians are exposed to diesel engine exhaust at work, making it the most prevalent occupational lung carcinogen in Canada (CAREX Canada). Diesel engine exhaust is recognized as one of the most common workplace carcinogens in the world, but its classification as a human carcinogen by the International Agency for Research on Cancer (IARC) was relatively recent. In 2012, after decades of mounting evidence, diesel engine exhaust was upgraded from a probable (IARC Group 2A) to a definite human carcinogen (IARC Group 1) (IARC, 2014). The IARC evaluation was based on strong evidence in humans for an increased risk of lung cancer, as well as strong evidence in animal studies. The key human evidence considered by IARC was from epidemiologic studies of workers in truck transportation, rail transportation, and mining industries, where the use of diesel engines is widespread. These studies provided strong sufficient evidence for an increased risk of lung cancer, as well as limited evidence for bladder cancer. The human studies used particulate matter, generally measured as elemental carbon (EC) or total carbon, as a surrogate for diesel engine exhaust to assess the risk associated with level of exposure. The animal studies reviewed by IARC showed sufficient evidence for cancer with exposure to whole diesel exhaust and the particulate matter fraction of diesel exhaust, but not for the gas phase components."

Jan 1, 2019

By S. C. Richardson

The electrowinning (EW) circuit involves using DC current in the electro-deposition of metal ions dissolved in an electrolyte solution. This paper reviews a method to generate an electrical model of an EW circuit and the resulting DC current flow and voltage distribution within the circuit. Topics include: calculations of electrolyte conductivity and the equivalent electrical resistance of the electrolyte within the electrolyte pipelines connected to the EW circuit; the breakdown and classification of the EW cell voltage into thermodynamic and ohmic potentials; methods to calculate current flow and voltage distribution throughout the EW circuit; and the development of an interactive visual computer model to simulate an actual EW circuit. Stray current can pose an electrical shock hazard to employees in electrolytic tankhouses. Increased awareness and understanding of the voltage distribution and potential stray current in an EW circuit can help mitigate the risk of tankhouse workers becoming exposed to electrical shock hazards. INTRODUCTION Copper electrowinning tankhouses include rectifiers that deliver large amount of DC current to a series of electrolytic cells consisting of electrolyte solution and electrode pairs. The design also includes metallic conductors in the circuit which include the rectifier’s positive and negative busbar, inter-cell busbar, and the anode and cathode frames. The electrolyte acts as an electrical conductor that transfers current via ions between the anodic and cathodic electrodes within the cell. Electrolyte, as a conductor, is also capable of conducting DC current outside the main EW circuit through the connected electrolyte feed and return pipe systems. DC current that follows a path other than the intended path through the series of electrolytic cells is referred to as “stray current”. Developing an electrical model enhances understanding of voltage distribution and current flow in an EW circuit. This paper discusses the derivation of the various representative components of the model as well as the output from the model. An interactive visual computer simulation incorporates the model output in order to aid in the understanding of voltage distribution and current flow throughout the EW circuit.

Jan 1, 2019

By F. A. Auld

"During the period 1958-1980 seven deep shafts were sunk from the surface in the UK. From 1977 until 1989 sixteen deep shafts were sunk in the UK, all concrete lined. Subsequently from 1989 up to the present day no deep shafts have been sunk in the UK, a period of 30 years. Developments in the design and construction of deep shaft linings in the UK therefore were predominantly carried out throughout the period 1977–1989. This knowledge is recorded in several published papers by the author over that period which will be referred to in the paper. INTRODUCTION The paper includes a review of past precedent for the design of deep shaft concrete linings in the UK and sets out the principles for future designs, including the design load to be adopted and Factors of Safety (SFs) to be used in the design. Hydrostatic pressure increases with depth from the surface and therefore the concrete lining must increase in thickness and strength throughout its depth to resist the pressure. High strength concrete mixes were developed to enable economic linings to reach greater depths and these will be detailed. The ground conditions to sink through in the UK consist of predominantly competent (self-standing when excavated) rock, which can be water bearing, and hence a hydrostatic pressure resisting lining is required. The paper describes the construction measures needed to produce a dry shaft by way of pour length, joint detail, backwall grouting and joint sealing details. PAST PRECEDENT FOR UK DEEP SHAFT SINKING AND LINING Seven deep shafts were sunk from the surface in the UK from 1957–1977 over a 20-year period (Auld, 1987). These are listed in Table 1. Three shafts were for British Coal, two were for Cleveland Potash Ltd and two were for the Central Electricity Generating Board. The British Coal shafts were 5.486 m and 7.315 m internal diameter to depths of 550 m and 780 m, respectively. At 5.5 m internal diameter and a depth of 1150 m, the two Boulby Mine shafts for Cleveland Potash Ltd are currently the deepest shafts in the UK. The two Central Electricity Generating Board shafts of 5 m and 10 m internal diameter, to depths of 255 m and 440 m, respectively, were ventilation shafts for a pumped storage scheme. Six of the shafts were sunk by Thyssen (GB) Ltd and one by Cementation Mining Ltd."

Jan 1, 2019

By M. Z. Emad, M. U. Khan, A. ur Rehman

Stemming plugs are used as an accessory in drilling and blasting industry. They supplement conventional stemming material (i.e. drill cutting) with retention of gases in the drill hole that result in better fragmentation of rock and improved explosive utilization. Better fragmentation and explosive utilization along with economic benefits enhance efficacy of the project. Incorporation of stemming plugs in drilling and blasting industry is in exercise for about thirty years. The efficiency of stemming plugs is a key factor in their rising induction in mining industry. Different studies have been conducted on the economic viability of these plugs. The focus of this paper is the selection of stemming plugs for a bench blasting operation and the examination of blasting operation efficiency based on ergonomics and human factors. Three types of stemming plugs were evaluated during multiple blasts at a limestone quarry. Their performance was evaluated using split desktop software. Based on the human factors plastic molded stemming plug (stemming plug-1) was found to be the best among all selected plugs. INTRODUCTION Surface mines and quarrying operations heavily depend on bench blasting to achieve high volumetric targets and production demands. Use of explosives is the most economic method adopted for rock breakage and movement. Extensive research had been performed to enhance explosives energy utilization. This include changing the drilling pattern, application of air decks, stemming plugs, and use of other supportive devices. Optimization of explosive energy has been a major concern in those mines that rely on drilling and blasting operation to carry out main production. Due to continually increasing cost, efficient mining demands, and associated hazards of using explosives, it is necessary to utilize explosives at their best. Efficiency of a blasting operation is generally evaluated by the fragmentation size. From post blast conditions at blasting site to efficiency of processing plant, anything can be affected due to improper blast resulting in bad fragmentation. Better fragmentation is necessity for better operation of the system along with consideration of the safety of operation, environmental issues and related costs. For developing a blast design, an engineer should always attempt to minimize the cost of operation without compromising with acceptable technical and safety necessities [1]. Blast performance is dependent on many different factors associated with the process. These factors have been gauged as blast geometry, explosive specification, and rock mass properties [2]. Similarly, in 2013 Mohammad et al. concluded that fragmentation dynamics depends on blast hole diameter, primer, spacing, stemming, burden, and delay timing for blasting operation [1]. At the work site where this study was performed, blast holes were filled by drill cuttings and muds to help in confining gases. In a blast hole, gas confinement helps in better rock fragmentation along with reduced flyrocks. This practice is most common in many countries including Pakistan. Due to lack of homogenized particle size, the effectiveness of confinement is variable and majorly based on the size of stemming. Extremely small sized drill cuttings often result in hole blow out along with flyrocks from the collar. This improper blast energy will result in poor blast, bad impacts on environment, and reduced operational efficiency. In addition to the stemming material, the length of stemming is also a prime consideration. The decrease in stemming length will increase the quantity of explosive in the blast hole and an increase in stemming material generally improves stemming performance.

Jan 1, 2019

By M. Mahdi, L. So, A. MacMillan, D. Metcalfe, J. Woloshyn, D. Sauter, N. Uys, JP. Janse van Rensburg

For city smelters, with limited real estate, efficient slag cleaning furnaces followed by water granulation to produce an iron silicate product is the preferred process approach. Water granulation, however, consumes large volumes of water and requires high maintenance due to abrasive slag/water slurries. Air granulation offers an alternative to water granulation, which eliminates water use and has low maintenance requirements. Although full-scale operation has not been implemented for copper slags, full-scale operation for platinum group metal (PGM) converter slag has been implemented. A review of full-scale air granulation performance for PGM converter slag is provided. Based on PGM converter slag granulation performance, parallels to copper slag granulation are drawn and full-scale operation for copper slag is modelled using computational fluid dynamics (CFD). INTRODUCTION Typical slag management practices in the copper industry include dumping, slow air cooling, and water granulation, as shown in Figure 1. Dumping is the most commonly used slag handling method for most metal production plants, but presents challenges including the requirement for a large slag pit, requirement for expensive/high-maintenance “hot” mobile equipment, risks associated with transportation of molten slag, and no value recovery from slag as a sellable by-product or from slag as a source of heat.

Jan 1, 2019

By Bruce Hebblewhite

"Historically there have been a number of different hypotheses and empirical models developed in an attempt to describe the nature of fracturing above longwall panels in underground coal mining. The motivation for such models varies, ranging from understanding the impact of mining on surface subsidence to back-analysis of caving behaviour in the immediate roof behind the longwall face. One of the most critical motivating factors that is taking on increased importance in many coalfields is the need for better understanding, and hence prediction of the impact of mining on overlying strata, particularly strata units acting as aquifers for different groundwater horizons.This paper reviews some of the major prediction models in the context of observed behaviour of strata displacement and fracturing above longwall panels in the Southern Coalfields of New South Wales, south of Sydney. The paper discusses the parameter often referred to as “height of fracturing” in terms of the critical parameters that influence it, and the relevance and appropriateness of this terminology in the context of overlying sub-surface subsidence and groundwater impact. The paper proposes an alternative terminology for this parameter that better reflects what it is and how it is used. The paper also addresses the potential role of major bedding shear planes mobilised by mining and their potential influence on overlying subsidence and groundwater interference.INTRODUCTIONKnowledge of the detailed nature of rock deformation and failure above any form of large-scale underground mining is always going to be limited to interpretation from a very incomplete set of data. It is extremely difficult, if not impossible, to directly measure the detailed nature of the rock failure, fracture networks, and deformational behaviour above an extracted mining area. Limited techniques such as borehole extensometry can provide some evidence of relative or incremental deformation in the direction of the borehole (usually vertical). However, such data cannot assist below the horizon where full caving has caused major rotation and dislocation of rock blocks and effectively destroyed the instrumentation borehole. Above such a horizon, the data is only valid along the axis and in the direction of the borehole, and to the level of detail defined by the extensometer anchor spacing intervals. It is often also restricted by major shear planes intersecting the extensometer borehole and cutting off the instrumentation below the level of the shear horizons."

Jan 1, 2019

By N. Snyders, I. Mwandawande, S. M. Bradshaw, M. Karimi

"Computational fluid dynamics (CFD) was applied to predict the average gas holdup and the axial gas holdup variation in a 13.5 m high cylindrical column 0.91 m diameter. The column was operating in batch mode. A Eulerian-Eulerian multiphase approach with appropriate interphase momentum exchange terms was applied to simulate the gas-liquid flow inside the column. Turbulence in the continuous phase was modelled using the k-_ realizable turbulence model. The predicted average gas holdup values were in good agreement with experimental data. The axial gas holdup prediction was generally good for the middle and top parts of the column, but was over-predicted for the bottom part of the column. Bubble velocity profiles were observed in which the axial velocity of the air bubbles decreased with height in the column. This may be related to the upward increase in gas holdup in the column. Simulations were also conducted to compare the gas holdup predicted with the universal, the Schiller-Naumann, and the Morsi-Alexander drag models. The gas holdup predictions for the three drag models were not significantly different. IntroductionColumn flotation is an important concentration technology that is used in the mineral processing and coal beneficiation industries. The growing interest in the use of column flotation in mineral processing has been attributed to the simpler flotation circuits and improved metallurgical performance compared to conventional flotation cells (Finch and Dobby, 1990). Flotation columns have also found other applications outside mineral processing, such as de-inking of recycled paper (Finch and Hardie, 1999).In column flotation, a rising swarm of air bubbles generated by means of air spargers is employed to collect the valuable mineral particles and separate them from the gangue minerals in a countercurrent process. Wash water, which is continuously fed at the top of the column, is used to eliminate entrained particles and stabilize the froth. The column volume can be divided into two sections – the collection zone in which the bubbles collect the floatable mineral particles, and the cleaning zone (or froth zone) where product upgrading is enhanced through the removal of unwanted particles entrained in the water mixed with bubbles from the collection zone."

Jan 1, 2019

By G. Bonin, R. P. Preston

"This paper presents a series of case studies where spherical camera photographs were used to generate 3D shaft models using photogrammetric methods. The shaft models were, checked for accuracy by comparing them to overlapping laser scan data, provided survey data or idealized shaft models. Short lengths of model were found to more accurately reproduce the shaft surface, with a best observed accuracy of 8 mm. Longer models encountered errors with accumulated errors as exhibited by slight deviations from vertical or slightly conical model shape. At present, the models are considered acceptable for general documentation and gross change detection. INTRODUCTION Shaft inspections are required by mining regulations in many jurisdictions and are commonly completed by trained mine personnel via visual inspections. This can be time consuming and prone to errors due to lapses in attention and the rapid travel rate required to inspect an entire shaft in a reasonable amount of time. Similarly, because of the time requirements, there can be impacts on other aspects of mining as a result of occupying the shaft for inspections. Spherical cameras with supplemental light systems offer a modern addition or alternative to conventional inspections. These cameras can be lowered relatively quickly to collect high definition, fully illuminated videos of the shaft that can be reviewed in detail later while the shaft returns to service (Gillis et.al., 2019). The use of cameras offers a further opportunity for valuable survey data generation from the same original data stream. The video data can be processed into three-dimensional (3D) models using Structure-from-Motion (Westoby et al., 2012) based photogrammetric methods. Depending on the quality of the source video and availability of survey control (required for all photogrammetry models) these models can be very accurate. Shaft surveying can be conducted with traditional theodolite methods but such surveys are time consuming and limited in their data density. Similarly, scans can be completed using conventional terrestrial laser scanners, but this requires a significant number of distinct setups to provide sufficient overlap between scans. Work is being conducted both on the laser scanning (SLAM, Durrant-Whyte & Bailey, 2006) and photogrammetry fronts towards kinetic scanning (Benecke, 2017) systems. The major advancement which is permitting these kinetic systems is Inertial Measurement Units (IMUs) which can provide localization in GPS denied environments and reduce errors associated with the open traverse format associated with shaft scanning."

Jan 1, 2019

By Yongteng Dong, John P. Quinn, Bradford Wesstrom, Guikuan Yue

With increasingly low-grade copper ores being mined, it is difficult to handle growing concentrations of As, Sb, Bi and/or Fe in the whole flowsheet, especially during copper electrorefining. To better elucidate the effects of those impurities on the quality of cathode deposit and/or current efficiency, a detailed speciation study of the electrolyte under industrial conditions is required to quantitatively describe their distribution in the solution, thereby facilitating their effective control and removal. In the present study, a thermodynamic model of complicated iron-arsenic-copper-sulfuric acid electrolyte under industrial conditions was developed. The main species of those elements involved in the electrolyte were first identified, and their thermodynamic data were collected and critically assessed. Those data were then used to estimate the activity coefficients of species, and to calculate the equilibrium constants from 25°C to 70°C. The developed model provides a mathematical tool that is capable of quantifying the concentrations of free ions and complexes in terms of temperature and solution composition. Finally, oxidation-reduction potential measurements were employed to validate the model. INTRODUCTION In copper electrorefining, impurities like arsenic, antimony, bismuth and/or iron can partially dissolve in the electrolyte and accumulate gradually, and eventually cause problems such as bad cathode deposit (co-deposition with copper or mechanical inclusion from the floating slime), lower current efficiency, etc., which eventually increases the operating costs. The presence of impurities may substantially reduce properties of copper products such as conductivity, corrosion resistance, mechanical properties, and leads to more energy consumption (Schlesinger et al., 2011; Jafari et al., 2017). To remove these impurities, various methods have already been proposed and applied in industrial copper production, such as solvent extraction, ion exchange, chemical precipitation, absorption by activated carbon, etc. (Cunningham et al., 1997; Navarro et al., 1999; Toyabe et al., 1987). In addition, adding reducing agents such as sulfur dioxide and trivalent arsenic could also precipitate arsenic, antimony and bismuth from copper electrolyte, by changing the distribution of impurities with various valence (Braun et al., 1976; Xiao et al., 2007). The disadvantages of those methods include high energy consumption, serious contamination, lower selectivity and efficiency, and so on.

Jan 1, 2019

By T. Moyo

Ammoniacal solutions are attractive and effective lixiviants for the dissolution of chalcopyrite, allowing for the formation of stable ammine complexes with copper while rejecting iron. Chalcopyrite dissolution in ammoniacal solutions is reviewed from literature, and results from a recently completed study evaluating it through electrochemical and controlled leach studies are discussed. Ammoniacal leaching of copper ores dates back to 1916 in the leaching of low grade copper ores in the Kennecott leaching plant and in the Calumet and Hecla mines, followed by the commercialisation of the Sherrit Gordon process for the ammoniacal leaching of sulphide copper ores in 1948. Since then ammoniacal leaching has received intermittent focus from researchers with the development of the Anaconda’s Arbiter process and the unsuccessful Escondida process. In these leaching processes, the formation of surface deposits has historically been reported to result in the passivation of the chalcopyrite surfaces, whereas oxygen mass transfer in solutions has been the focus of process design improvements. Results of studies on high grade chalcopyrite material is presented in this paper which show that although a surface deposit was formed, it did not result in the passivation of chalcopyrite in ammoniacal solutions, and that while oxygen transfer is critical, it is not the direct oxidant in the reaction. INTRODUCTION Ammonia and its salts have been used in the hydrometallurgical treatment of non-ferrous metals such as copper, cobalt and nickel from oxide ores. Its chemistry allows for the selective dissolution of desired metals, leaving behind gangue including iron. Chalcopyrite is a copper sulphide ore known to be very stable and hence recalcitrant to many hydrometallurgical processing methods. Thus, the dissolution of chalcopyrite continues to be an attractive area of research. The dissolution of chalcopyrite in ammoniacal solutions is possible due to the stabilisation of copper(I) and copper (II) ions by ammonia in alkaline media. Ammonia has become more attractive as a lixiviant during the present socio-economic climate due to its low toxicity, relatively low cost and ease of regeneration by evaporation (Meng & Han, 1996). Ammonia processes are ideal when the gangue minerals are acid consuming e.g. with calcareous or dolomitic gangue (Paynter, 1973).

Jan 1, 2019

By E. Talebi, P. Roghanchi

"This study aims to discuss personal and behavioral parameters contributing to heat-related accidents. To study the prevention approaches, it is essential to look at the various factors at the individual, management, and industrial levels. Qualitative risk analysis methods are used based on the public data in the USA to find the impact of the environmental and behavioral parameters on the heat stress and heat strain of mine workers. The effects of individual factors such as worker experience, age, fitness, lifestyle, acclimation, and more are illustrated. The significance of factors such as the roles of the mine management and regulatory agencies are addressed.INTRODUCTIONOccupational hazards in mining industry endanger the health and safety of the workers and productivity loss for mining companies. Among those hazards is the exposure to excessive heat that has adverse effects on the health of mine workers. The intensity of heat load is a significant factor in fatal and non-fatal heat-related accidents. Severe environmental conditions combined with a high level of activity in the mining industry increases the vulnerability of individuals to health and safety hazards (Ngwenya, Oosthuizen, Cross, Frimpong, & Chaibva, 2018). Lack of regulations and legislation addressing the heat issue in the mining industry (i.e., underground and open pit mines, processing plants) also raises widespread concerns.Along the climate change, various sources contribute to the overall heat load at a mine site (Hanna, Kjellstrom, Bennett, & Dear, 2011; Kjellstrom, Lemke, Hyatt, & Otto, 2014). In underground mines, the majority of heat comes from different sources such as geothermal gradient, equipment, auto compression, groundwater, and blasting (Maurya, Karena, Vardhan, Aruna, & Raj, 2015). On the surface, however, the majority of heat load can be sourced to solar energy. The exposure to excessive heat might result in heat-related illnesses, fatigue and fainting, loss of concentration, performance reduction, and production loss (Kocsis & Sunkpal, 2017; Roghanchi, 2017). The severity of the effects depends on duration and level of exposure and the response of an individual to heat stress. The response of an individual is influenced by different factors including age, gender, fitness, lifestyle, experiences, and past medical history."

Jan 1, 2019

By S. Frimpong, E. Gbadam, W. Nyaaba, G. Somua-Gyimah

Recent studies towards dragline excavation efficiency have focused on incrementally achieving automation of the entire excavation cycle. Initial efforts resulted in the development of an automated dragline swing system, which optimizes the swing phase time. However, the system still requires human operation for collision avoidance. For full dragline autonomy, a machine vision system is needed for collision prevention and big rock handling during the ‘swinging’ and ‘digging’ phases of the excavation operation. Previous attempts in this area focused on collision avoidance vision models which estimated the location of the bucket in space in real-time. However, these previous models use image segmentation methods that are neither scalable nor multi-purpose. In this study, a scalable and multi-purpose vision model has been developed for draglines using Convolutional Neural Networks. This vision system averages 82.6% classification accuracy and 91% detection in collision avoidance. It also achieves an 87.32% detection rate in bucket pose estimation tasks. In addition, it averages 80.9% precision and 91.3% recall performance across terrain recognition and oversized rock detection tasks. With minimal modification, the proposed vision system can be adjusted for other automated excavators. Keywords: Surface mining, dragline bucket, deep learning, machine learning, oversized rock, convolutional neural network, machine vision, object detection, earthmoving equipment. INTRODUCTION Complete excavator automation is widely regarded as the next phase in efforts toward improving earthmoving efficiency. Earthmoving often involves complex, forceful interactions between an excavator and the ground. The nature of these interactions depends largely on the type, properties and physical characteristics of the earth material. This process is further complicated by the random occurrence of tree roots, boulders and other such obstructions. Therefore, the ability of a controller to detect changes in the operating conditions, adjust the digging strategy and respond in real-time is of utmost importance. Early studies into autonomous excavation identified some key performance criteria which included the following [1]: • The autonomous excavator must be able to work in any type of earth material. • Its excavation accuracy must be within 50mm. • It should be able to handle different surface and underground obstacles autonomously. • It should be able to operate at the speed of the average operator in any condition. • Its operation should be capable of safe integration with other site systems.

Jan 1, 2019

By B. Krysa, A. Mitsui, T. L. Koehler

The presence of arsenic, even at trace levels, in copper processing leads to the risk of arsine gas where reducing conditions exist that can reduce any soluble arsenic present to its minus 3 valance state and generate hydrogen gas from the solutions. This risk is understood to be significant within the industry, particularly in the case of liberator cells where copper concentrations in solution are drawn down to remove the copper and impurities from the bleed stream. However, there are numerous other potential areas where the arsine gas risk exists including contact between active metal such as iron, zinc or aluminum and arsenic bearing solutions in pyrometallurgical dust treatment, refining and acid plant operations. In turn this breaks down to different mitigating strategies dependent on the risk scenarios considered; for example, how this risk interacts with Change Management, Confined Space Entry or Contractor Training. The ISO 45001 is an emerging standard meant to improve employee safety, reduce workplace risks and create safer working conditions all over the world. The paper shows a case study of how a framework consistent with the tenets of ISO 45001 has been used to provide a consistent assessment of this risk for a wide variety of copper operations and the expectations of how this may be used to effectively improve the effectiveness of barriers against future incidents. INTRODUCTION Arsine gas (AsH3), first identified in 1775, is a highly poisonous, colorless, non-irritating gas with a mild garlic odor that is heavier than air. Arsine gas is generated when reducing conditions are generated in the presence of hydrogen ions and arsenic compounds. Present permissible occupational exposure limit as defined by Occupational Safety and Health Administration (OSHA) as an 8-hour time-weighted average is ppm (0.2 mg/m3). Further increasing the risk, conventional respiratory protection utilizing half or full masks with gas filtering cartridges provide minimal protection against arsine. In copper processing plants, the risk of arsine generation is well understood in liberator cells, which are part of the electrolysis process. In this process, solutions containing copper are reduced in copper concentration removing not only the copper, but also arsenic, antimony and bismuth. The residual solution can be bled to control impurity build-up in the refinery. In this process, if the copper concentration is reduced to the point where As3- can form, arsine gas is generated via reaction with hydrogen ions generated during the plating process. The copper concentration at which arsine gas is generated depends on copper concentration at the cathode surface, the temperature and the acidity. As a result, there is always a risk of arsine gas generation in the liberator cell. Process measures to minimize or mitigate arsine evolution are tight control on final copper concentration, warm temperatures, fresh feed distribution and internal acid recirculation rates. Operator exposure protection measures are hooding, ventilation, arsine detection systems, restricted personnel access, automated shutdown controls and pre-defined evacuation plans.

Jan 1, 2019

By O. Mejia

"As study was undertaken to investigate the relationship between mill liner wear and grinding energy efficiency and to assess the opportunity to control mill speed to improve energy performance as mill liner wears. The study involved analysis of plant operating data and liner wear profiles over time. The operating work index was found to be an effective tool to identify the decrease of grinding efficiency along the liner service. The plant data show that the mill grinding efficiency as determined by monitoring the operating work index, and throughput decreases as liner wears. However, efficiency and throughput can be maintained by either changing the liner more frequently or by increasing the mill speed. Two scenarios for increasing mill throughput were analyzed. The first one involves changing the liner before the efficiency drops and the second one requires increasing the mill speed from 75% to 79%. Both scenarios show financial benefits that can be used in mill operations.INTRODUCTION The analysis of the mill power draw is used in this study as a key parameter for comparing mill liner profile and its effect on mill performance. Current technology and simulation software used in the mining industry do not factor in the impact of liner wear profiles in grinding efficiency and mill throughput (Toor, 2013). To address this gap, this study provides an analysis of key factors affecting mill throughput and grinding efficiency: mill speed, ball loading, and liner profiles. Several years of plant mill operating data, published research papers, and MillTraj® simulation results are used to demonstrate that face angles impact grinding efficiency and throughput and that mill speed can be used to overcome this problem. Moreover, the liner profile wear analyses clarify a mismatch between actual and estimated power draw calculations."

Jan 1, 2019

By L. Yuan, J. H. Rowland, R. A. Thomas, D. Bahrami, G. P. Cole

"The past several decades have seen a steady increase in the use of atmospheric monitoring systems (AMS) in underground mines as sensor technology has advanced and costs for this technology have decreased. The AMS is a reliable tool for early mine fire warning by detecting gaseous products of combustion in underground mines. During a mine fire emergency, mine decision makers rely heavily on the prompt and accurate knowledge of the ventilation and fire situation in the mine, such as fire location, fire size, and the spread of smoke to make effective and efficient decisions on firefighting strategies and miner evacuation. Meanwhile, a prediction of the potential for fire development at a later time, such as whether the currently designated mine escapeways will be contaminated by smoke and toxic gases with the progress of the fire, is critical for effective decision-making to save lives that are in danger. The AMS monitoring data, including carbon monoxide (CO) concentration, airflow rate, smoke, etc., can provide information as to whether the smoke has reached the locations where AMS sensors are installed and if a mine-wide smoke spread has occurred. The National Institute for Occupational Safety and Health (NIOSH) has undertaken a task to integrate real-time AMS monitoring data with the mine fire simulation program, MFIRE, to simulate and predict the spread of smoke and toxic gas in a ventilation network based on the real-time AMS data. This paper reports the developed real-time method for characterizing the size and location of an underground mine fire and for predicting the spread of contaminants throughout the mine ventilation network using sensor data from the AMS.INTRODUCTIONNIOSH conducts research to develop workplace solutions to improve detection of and reduce the risk of hazardous conditions in underground mines. The advancement of senor technology and the increasing demand for real-time mine parameters monitoring have led to extended applications of atmospheric monitoring systems (AMS) in underground mines worldwide. In the United States, AMS is primarily used for early mine fire warning by detecting carbon monoxide (CO) in fire hazard areas, such as belt entries. Mine fires can grow rapidly, and time is the critical element. Prompt detection, timely and accurate warnings to those miners potentially affected, and a proficient response by underground miners can have a tremendous impact on the social and economic consequence of a small underground mine fire (Conti et al., 2005). The early detection of a mine fire could gain time for the first responders to put out the fire before it develops into a disaster. An AMS system with CO sensors has especially played an important role in the early detection of mine fires. The continuous monitoring of an underground mine atmosphere with an AMS could generate a large amount of data in a mine fire event. However, the current application of AMS is mainly limited to sending out an alarm when monitored CO concentration exceeds a certain level. An opportunity arises as to whether these data can be further used in fire emergency response. In order to make effective decisions on firefighting strategies, mine workers’ seeking refuges, evacuation and escape, and the timing on when to send rescuers, decision makers need accurate and timely knowledge of the ventilation and fire situation in the mine. Information about the fire intensity, where in the mine the smoke and toxic gases have spread, and whether designated mine escapeways have been compromised by smoke and toxic gases from the fire would greatly increase the effectiveness of these decisions. However, the monitored AMS data only provides atmospheric conditions in the vicinity of sensor locations. What is concluded from the monitored AMS data highly depends on the decision makers’ capability and experience. Predictive insight into fire growth and smoke transport would greatly help decision makers during a fire emergency."

Jan 1, 2019