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By J. W. Craven, M. Katom, K. M. McCaffery

At Ok Tedi, ore type and SAG feed size distribution vary widely and frequently. This makes control of the SAG mills by application of the power/pressure relationship difficult. Power logic has traditionally been conservative due to power spikes associated with rapid size-distribution changes. A new expert system was installed in early 2000. The system incorporates multiple state fuzzy logic to deal with frequent and radical ore type and size variations, along with monitoring of motor temperatures. A short-term power spike no longer warrants immediate radical action. This has resulted in increased mill throughput and improved circuit stability. Key words: SAG mills, Mill control, Fuzzy logic

Jan 1, 2003

By S. K. Kawatra

With the increasing importance being placed upon modernizing the coal industry as a result of recent developments in the international energy balance, computer control has been and is being instituted in many coal cleaning plants. Control techniques that are well established in many base metal industries have been adapted to coal washing. Essential to any control scheme is an accurate measure of the parameter which is to be controlled. A sensor is required that will provide information both quickly and precisely. In fine coal circuits, the critical parameter that must be measured and controlled is the per- cent ash contained in the clean coal product and tailings. Measuring the ash content of these slurry lines on a continuous basis enables the operating conditions in the circuit to be adjusted so as to obtain optimum separation efficiencies at all times. An on-line ash monitor has been developed and tested at Michigan Technological University which is capable of making percent ash and percent solids determinations instantaneously. Two radioisotopes are employed in this system to generate signals that can be related to the density and the ash content of the slurry. Such data provide a means to execute a short term control strategy.

Jan 1, 1982

By Jean-Claude Bianchini, Paul Bauernfeind, Erwin Gartung

Introduction The city of Nuremberg, located in Bavaria in the Federal Republic of Germany, started building a subway in 1967. The construction operations began in a southern suburb, where no complications were encountered in the design and execution of the job. As the first subway line approached the downtown area of the city, the civil engineering challenges increased rapidly. Tunnels had to be excavated next to, or below precious historical buildings, and the work of the responsible engineers was closely watched by the public, who were very anxious about any damage to the existing beautiful old houses and churches. The job has been handled successfully to date in cooperation with the owner-designer, the geotechnical consultant and the contractors, who jointly went through a process of systematic learning and gathering of experience, and who developed a modern tunneling technique specifically tailored to the natural properties of the encountered ground conditions and the requirements of the city of Nuremberg. The application of scientific methods has been an important part of this development. Research into the geotechnical properties of the predominantly encountered soft Keuper sandstone, studies of the geomechanical performance of grout reinforced sand sections and finite element analyses of various tunnel problems for the prediction of displacements, for the assessment of stability, or

Jan 1, 1979

By H. Sevim

In long-term open pit production planning, a series of nested and maximum-value pits is usually generated first. These pits are then considered as possible pushbacks over a number of planning periods. To determine the best pushback in each planning period, the pits are evaluated for their technical and economical feasibilities under certain production constraints. Parameterization is a commonly used technique to generate a series of pits. In almost all cases, however, some of the consecutive pits generated by this technique are too far apart from each other. This is called the "gap" problem. It may make the entire pit series useless for production planning purposes. A new pit gener¬ating algorithm has been developed to overcome the gap problem. Through this algorithm, a series of nested maxi¬mum-value pits can be generated with a controllable size increment. The logic of the algorithm is illustrated through a small hypothetical case. Its capability of generating maximum-value pits that are as optimal as those generated by parameterization and its advantages over parameteriza¬tion are presented through an actual gold deposit case.

Jan 1, 1996

By I. S. Parrish, D. W. Kappes, G. G. Austin

Micron-sized gold disseminated in lower Cambrian siltstone has been found at the Sterling mine near Beatty, NV. A shoestring-shaped body has been developed by central and fringe drifts and is being mined via a modified retreat room and pillar system. The siliceous ore crushed to 5.08 cm (2 in ) is stacked to 4.6 m (15 ft) over a layered sand, gravel, and impervious PVC base. Gold is leached using a 0.1% cyanide solution and deposited on activated coconut shell carbon. Stripping of the carbon by hot solutions of 1% NaOH and 20% Ethanol yields overall recovery of about 75% of the fire assay head.

Jan 1, 1983

By James C. Burrows, Frances Kramer Mesher

Tungsten-containing ores are mined on all continents of the world. China is the world's largest producer and controls the world's largest reserves. The USSR, itself a sizeable producer, is estimated to be the world's largest consumer. The major use for tungsten in the noncommunist world is in production of cemented tungsten carbides for cutting, drilling, and wear parts. Other major uses include lamp wires, steels for tools, and armaments. Real tungsten prices have been in a general decline since 1977-1979 as the tungsten market undergoes basic and lasting structural changes.

Jan 1, 1986

By Jan M. Mutmansky, David R. Kalasky

Computer simulation continues to be one of the most successful analytical applications of computers in the mining and mineral processing industries throughout the world. Through simulation, managers and engineers can explore the impact of new technologies, equipment designs, plans and operating strategies to improve their operations. It is not uncommon for a single simulation application to provide a quick payback of analysis expenses (within weeks or months) yielding long-term financial and operational dividends. The paper will present a summary of the types of software systems that are available for use on PCs and other computer systems. Support software for curve fitting, statistical analysis, and optimization of simulation models will also be presented. Methods of leveraging simulation efforts through networking and coupling of software systems will be discussed. Finally, the trends in simulation in the mineral industries will be analyzed. Areas of strength and weakness of simulation will be discussed along with the usefulness of commercial general-purpose and custom-writ- ten simulation packages. The future possibilities for simulation in the mineral industries will be outlined and predictions on trends for the future will be presented.

Jan 1, 1996

By Gregg Sherry, Bob Gordan

INTRODUCTION This paper report presents the general case history for the construction of the North Outfall Replacement Sewer (NORS) project. A 1982 City of Los Angeles Wastewater Facilities Plan recognized that a 19.3 km (12¬mile) section of the North Outfall Sewer (NOS), from Culver City to the Hyperion Treatment Plant, was deteriorating and had insufficient capacity. Built in the 1920s of unreinforced concrete and lined with vitreous clay tiles, the originally unventilated NOS suffered considerable corrosion by H2S gas. This caused roof tile and concrete to fall to the bottom of the pipe, which, over the years, reduced the 11.9 M3/S (420 cubic feet per second (cfs)) design capacity of the NOS to a current level of approximately 8.5 M3/S (300 cfs). This worsening condition, thereby contributing to the polluting of Santa Monica Bay. This situation culminated in the State of California Regional Water Quality Control Board, Los Angeles Region, issuing a Cease and Desist Order on January 27, 1986, which required the City of Los Angeles to eliminate such dry weather overflows through a number of prescribed actions. One of these was to construct the North Outfall Replacement Sewer (NORS) by April 1, 1993. PROJECT DESCRIPTION The NORS Project involved the construction of over eight miles of tunnel and related structures. It consisted of a main tunnel conduit to convey sewage to the Hyperion Treatment Plant and four diversion lines connecting the main tunnel to major existing

Jan 1, 1993

By P. Somasundaran

Flotation of oxide minerals is controlled by a number of factors, such as surface potential and solubility of the mineral, concentration and type of various inorganics, properties of the collector, pH, ionic strength and temperature. The role these factors play depends on the mechanisms of adsorption of the collector inorganics or polymer additives. The major mechanisms include electrostatic interactions, chemical adsorption, chain-chain interaction between adsorbed collector species and modifications of the surface by inorganics. In real systems, flotation is, however, markedly affected by various other processes, including aging of the minerals, surface precipitation of the collector on the mineral and associative interactions between various collector species leading to highly surface active, for example, ionomolecular complexes. These effects are reviewed here with selected examples.

Jan 1, 1999

By G. R. Rao, K. A. Natarajan, P. Devasia

The role of growth conditions and adhesion of Thiobacillus ferrooxidans on the leaching of chalcopyrite was investigated. Thiobacillus ferrooxidans grown on sulfur, thiosulfate and ferrous ion substrates was used in this comparative study. Growth on sulfur, a solid substrate, requires bacterial adhesion unlike that required in the presence of soluble thiosulfate and ferrous ion in a mineral-salts medium. Solid substrate-grown cells showed higher rates of leaching than those grown in liquid media. An initial lag period noticed during leaching by solution-grown cells was absent when solid substrate-grown cells were used. Such a behavior is attributed to the presence of an inducible proteinaceous cell-surface appendage on the sulfur-grown cells. This appendage aids in bacterial adhesion onto the mineral surfaces. Such an appendage is absent in solution-grown cells, as substantiated by electrophoretic measurements. The importance of bacterial adhesion and the direct mechanism in leaching by Thiobacillus ferrooxidans are demonstrated.

Jan 1, 1997

By Norman E. Breslow, John A. Montgomery, Sanford W. Horstman

Reconstruction of historical exposures to silica dust is required in an ongoing cohort mortality study of workers in the diatomaceous earth (DE) industry. However, historical data were collected using three different sampling methods. This study was conducted to derive empirical quantitative relationships from linear regression equations between the three methods: standard impinger, total mass, and respirable mass. Dust from one diatomaceous earth processing plant was sampled simultaneously by all three methods. Results from 61 clusters of the three sampling devices indicate that the phcle size distribution of the dust varies with the two parent products sampled. baghouse product and main product. The relationships between particle counts and respirable mass are: Respirable mass (mg/m3) = 0.064 (mppd) impinger count for baghouse product dust, and respirable mass (mg/m3) = 0.018 (mppcf) impinger count for main product dust. The relationships between particle counts and total mass are: Total mass (mg/m3) = 0.837 (mppcf) impinger count for baghouse product, and total mass (mg/m3) = 1.21 (mppcf) for main product dust. In all four euuations, the intercept did not differ significantly from zero, and the correlation coefficients ranged from 0.90 to 0.95. Results are compared with data from four previously published studies.

Jan 1, 1991

By G. A. Kosick, L. Kuehn

The design of an information management system (IMS) for a mineral processing plant requires prior consideration of many factors, which can be broadly categorized into two domains, process plant considerations and IMS considerations. The process plant considerations include: plant characteristics, management and personnel issues, existing organizational standards and policies, and the level of existing hardware and software systems. The IMS considerations include: system functionality, system sizing and desired performance, hardware components, software components, and system support issues. All of these aspects must be addressed in order to achieve a functionally successful and cost effective system. The purpose of this paper is to lay out these design issues and, in doing so, to provide process engineers with a guideline with which to tailor a system that is best suited to their specific application. The paper is completed by presenting an approach that has been used in two Canadian concentrators. Both of these plants have incorporated MillEX, a software system designed specifically as the central component of a mineral processing IMS.

Jan 1, 1993

By Kenneth F. Lane

In most industries it is normal commercial policy to try to gear production to the market. In times of scarcity output is pushed to its maximum and in times of glut output is reduced. Because of the effects of supply and demand, these times correspond to times of high and low prices respectively so the policy results in maximising long run total profits. Stockpiling is often an integral part of the policy. Stocks are accumulated during depressed market conditions and sold off when demand revives. This further increases the long run total profits. However, such policies cause violent fluctuations in short term profitability and impose severe financial strains. Indeed planning and implementing the policies are a central management concern which is often critical to the success of the industry. The mining industry is no exception and, for many raw materials, trying to balance supply with demand is an international problem. Stockpiling and restricted production agreements are common elements of policy. But very little attention has been paid to the one additional control which is unique to the mining industry, namely, the cut off grade. This neglect is apparent at all levels from individual mines to national economies.

Jan 1, 1979

By Richard Newcomb

Since the report of the 1972 Rapid Excavation Conference in the city of Chicago, speculation has continued concerning the estimates of tunneling demand. Little has been published that would persuade me to modify substantially the rather tentative estimates that originated with the National Academy of Sciences-National Academy of Engineering (NAS-NAE) study of 1968 which were recomputed by the United States in the survey of the Organization for Economic Cooperation and Development (OECD) in 1970. The OECD estimates, of course, hedged the really difficult question of forecasting civil construction tunneling demands. In the United States contribution, this was done by predicting both an upper and lower bound for important categories of demand. A discounting procedure was then applied to each of the major sectors of expenditures, permitting a forecast that reflected the current subjective assessment of how extensively and how likely cities were to adopt plans that required tunneling. This was done for water, utilities, transportation and other novel underground facilities. The purpose of this paper is a modest one. In it I wish to describe the efforts made since 1972 to generate more thoughtful and more robust estimates of urban sector demands, and to apply what has been learned to the most difficult category of predictions: those for urban mass transit systems. The estimates of the Underground Construction Research Council funded by the National Science Foundation have been described at an earlier panel of this Conference. The principal effort I am familiar with is that of

Jan 1, 1974

By R. M. Bowen

To help solve problems associated with the optimization of complex coal preparation systems, a mathematical model has been assembled which can simplify calculations pertaining to the core of the plant, i.e. the coal cleaning section. It uses algebraic expressions, derived by fitting hyperbolic equations to Mayer curves, to calculate optimum settings for a specified array of coal cleaning units and feeds. This is done without search procedures, and with usually only minor iteration of a simple calculation to specify optima within 0.02% of specified product ash contents. The key to the calculation is a relationship derived via the analytical geometry of conic sections facilitating easy application of the incremental ash theory of separations. The model has been assembled in a generalised form to cater for N processes in parallel, each giving M separations to produce P final products. Examples are given involving assessment of some complex circuit options.

Jan 1, 1986

By Richard Komarek

When limestone (Ca03) is calcined in rotary kilns to produce quicklime (CaO), it is not unusual for 10% to 20% of the stone to abrade and emerge from the kiln as quicklime fines (-6.3 mm or -0.25 in.). While there are various industrial processes that can use fines, handling and shipping is tricky and dangerous. Due to the highly caustic nature of quicklime, airborne dust easily bums eyes and skin. On the other hand, money has already been invested in mining (or buying) the raw material and in the equipment and energy needed for calcining. Discarding the fines will not only waste that investment, but add even more cost in transportation and possibly dumping charges. So the question becomes, how can fines best be turned into a revenue-generating asset? Some plants convert leftover quick-lime fines into calcium hydroxide - Ca(OH)2, also known as hydrated or water-slaked lime - for sale into agricultural applications. For farm uses, hydrated lime fines are preferred over quicklime because they are easier to handle. And they are favored over raw limestone fines for their higher concentration of calcium and greater solubil¬ity. From the producer's viewpoint, quicklime fines are ideal for this use because they go through hydration faster than the larger chunks of quicklime. Those larger chunks, or "pebble lime," are more readily salable and more easily handled, for such uses as steel, copper, aluminum and magnesium production, water waste treatment, chemical, paper, glassmaking and flue gas desulfurization in coal- fired boilers.

Jan 1, 1993

By Randal J. Barnes

Computer based techniques for solving the Ultimate Pit Limit Problem have appeared in mining literature since the early 1960's. The majority of papers pertaining to this subject can be partitioned into one of two categories: discussion of the pros and cons of a particular algorithm, or a case study presenting specific applications of an algorithm. Subsequently, there has a1 so been considerable debate concerning the best techniques between, essentially, two camps: those favoring the moving cones techniques, and those favoring the techniques which yield true optimal pit designs. The purpose of this paper is not to add to this debate, but rather to present a few new ideas (partially a new look at an old idea), which can be easily implemented to noticeably improve any ultimate pit limit approach independent of the particular algorithm used. These ideas fall under the heading of "bounding the optimum" (Barnes and Johnson, 1980).

Jan 1, 1982

By Fathi Habashi

LEACHING IS the process of extracting a soluble constituent from a solid by means of a solvent. In extractive metallurgy it is the process of dissolving a certain mineral (or minerals) from an ore or a concentrate, or dissolving certain constituents from metallurgical products such as calcines, mattes, scrap alloys, anodic slimes, etc. In this respect, either one of two purposes can be achieved: 1) Opening of ores, concentrates, or metallurgical products to recover the metal values. 2) Leaching easily soluble constituents (usually gangue minerals) in an ore or a concentrate in order to have it in a more concentrated form, e.g., the

Jan 1, 1970

By Adolf J. Jonaitis

Outokumpu developed TankCell flotation cell technology beginning in 1990, following 35 years of successful flotation cell experience and application. In 1994, Outokumpu proved favorable operating success of 100-m3 (3,500-ft3) TankCells for porphyry copper and zinc flotation. In 1995, evaluation of a 150-m3 TankCell led to the successful application of these large cells in several operations. More than 350 TankCells of 100 m3 and larger in volume have been installed and are in operation. Key features of the Outokumpu TankCell design will be described. In addition, discussion of operating data from various metallic mineral flotation operations worldwide will be presented. Large flotation cell development continues today, with operating cell volumes of up to 160 m3 (5,500 ft3) in operation.

Jan 1, 1999

By John D. Shaw

1. Introduction 2. The Hydraulic Mine _ (i ) Development (i i ) Extraction ( i i i ) Transport 3. The Water Circuit 4. Manpower and Results 5. Modifications 6. Conclusions 1. Introduction The Kaiser Resources Ltd. hydraulic coal mine is located in south eastern British Columbia, Canada, at the western end of the Crowsnest Pass, next to the Town of Sparwood. The seam presently being mined is the number 10, known locally as the Balmer seam, which is a high quality coking coal, 50 feet in thickness and of an average inclination of 35 degrees. The mine was designed in the late sixties as a small scale trial unit, and was to use a single monitor unit, working 3 shifts per day on a 5 day per week basis. Experience has proved the method to be so successful as to warrant the expansion of the ancilliary facilities to cater for the increased production. The annual raw coal production from this single monitor unit has risen from 108,988 short tons in 1970 to 942,334 short tons in 1975, with a total mine labour force of about 160 men including the surface de-watering plant, mine supervision and mine administration.

Jan 1, 1977