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By Sushanta Majumder

The physico-chemical characteristics of raw materials used for the production of iron ore pellets have a strong influence on the productivity of pelletization operations and on the quality of pellets. Since iron ores from different sources are used for making iron ore pellets and since the quality of the ores varies with time, there is a need to optimize and control pellet plant operations on a regular basis to achieve optimum productivity while maintaining pellet quality within the desirable specifications. In order to achieve this objective, a model-based on-line optimization system was implemented on two industrial scale induration furnaces. The optimization system consists of a rigorous mathematical model of the induration process, a model for the permeability of the bed of pellets, a statistical model for the quality of iron ore pellets and an optimization module based on sequential quadratic programming. The rigorous model is tested on-line using the wind-box temperature available real-time. The process was optimized to enhance induration furnace productivity for the given constraints on pellet quality parameters such as the cold compressive strength (CCS) and Tumble Index (TI), and other equipment design parameters. Process variables such as induration machine speed, cold air flow rate and hood temperature profile were used as the optimization variables. The on-line optimization system was successfully implemented in two industrial induration furnaces and lead to enhanced productivity. Details of the on-line optimization system and results of process optimization will be presented.

Sep 1, 2012

By Brian Stimpson

A recent study by the National Academy of Engineering concluded that if the U.S. Coal Industry is to double production by 1985 it must open 30 new 2,000,000 tons per year surface mines in the eastern states and 100 new 5,000,000 tons per year surface mines in the western states, in addition to major growth in underground mining. Major expansions in coal mining are also planned in other countries. Engineering geology can play an important part in coal mine development, operation and abandonment (Table I), and with the increasing scale of surface coal mining and the requirements of environmental legislation, it seems certain that engineering geology and geotechnics will play a growing role in surface coal mining.

Jan 1, 1976

By M Astorga, J Jackson, J Gaunt

The Ban Houayxai mine (BHX) is a relatively low-grade, low-cost, open pit gold-silver deposit in Laos operated by Phu Bia Mining, a subsidiary of PanAust. The ore production rate at BHX is 4.5 Mt/a, with direct tipping to a semi-autogenous grinding/ball mill circuit with a carbon-in-leach process plant. Approximately 100 000 oz of gold is produced per annum.The operation is located in mountainous terrain with minimal run-of-mine stockpiling. This results in limited capacity for blending from stockpile, with the mill instead reliant upon direct feed ex-pit. Since commissioning in 2012, the plant has seen significant variation in milling rates due to variability in the feed properties of the oxide, transition and primary ores. As part of an ongoing continuous improvement program, an integrated approach was initiated, focusing on maintaining and enhancing production in the future as the proportion of harder primary ore increases. This will specifically focus on direct blending from the loading face using the ore properties and blast fragmentation to maintain mill throughput.This approach was based on the concept of physical assets management, commencing with improving information and knowledge of the condition of the orebody through modelling the characteristics, variability and performance of the feed for processes relevant to throughput. These models are used to support both mine and process plant production planning.The key ore feed characteristics and parameters modelled for the life-of-mine are blastability index, powder factor, crushability or impact resistance and grindability. These predictive spatial models were based on the data from diamond drill holes used in resource definition and geotechnical drilling programs by integrating geotechnical, geological, geochemical and metallurgical data.At the early stages of implementation, the models are being utilised for ore blending decisions to provide guidance and support for budgeting, long-term mine planning, blast design for mill feed and providing the mill with an expectation of performance.CITATION:Jackson, J, Gaunt, J and Astorga, M, 2014. Predicting mill ore feed variability using integrated geotechnical/geometallurgical models, in Proceedings Orebody Modelling and Strategic Mine Planning Symposium 2014, pp 165–176 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 24, 2014

By Ludwig Schmidt

Large quantities of gasoline are lost each year by evaporation from bulk-storage station tanks. The rate of evaporation from bulk-station tanks is influenced by two principal factors: First, the vapor pressure of the gasoline in the tank; and second, the amount of "breathing" of the tank. The vapor pressures of the gasoline govern the amount of the gasoline vapor in the air-vapor mixture above the gasoline in a tank at a given temperature. This is one of the principal factors in determining the total pressure of the air-vapor mixture within the tank. The "breathing" of the tank is caused by the inflow of air from the atmosphere during certain periods of the day and the expulsion of the air-vapor mixtures at other times, caused by atmospheric variations. The pressure built up within a tank and the amount of gasoline in the air-vapor mixture are both a direct function of the temperature existing within the tank. Therefore, two of the most common methods for reducing evaporation losses from bulk-station tanks are: (1) The use of vapor-tight tanks equipped with relief valves and operated at 1 or 2 ounces of pressure and about .5-ounce vacuum; (2) reducing the temperature of tanks and their contents by painting them a light color, by insulation, and in some instances by using water sprays. Water sprays, although effective, usually are too expensive to operate economically. In order to determine and compare the effects of various colors, insulation, and pressure in reducing the evaporation losses of gasoline held in storage in bulk-storage tanks, the Bureau of Mines made observations from May 29 to October 15, 1930, on five horizontal tanks of 12,000-gallon capacity each, which were erected at the plant of Black, Sivalls and Bryson Manufacturing Co., Kansas City, Mo. This report gives in detail the results of these evaporation tests.

Jan 1, 1931

By R. J. Durrheim, Y. Yabe, M. S. D. Manzi, DSeis team, N. Z. Nkosi, S. B. Mngadi, Jr. H. Ogasawara

On 5 August 2014, the Orkney M5.5 earthquake, the largest in South African gold mining districts, occurred with an unusual strike-slip mechanism at great depth of 4.78 km below the surface. In a rare case, the ML 5.5 earthquake occurred within the area covered by the legacy 2D and 3D reflection seismic data acquired in the 1990s and 2000s for gold exploration and mine development. In addition, the earthquake ML 5.5 rupture plane was recorded and accurately delineated by the underground in-mine seismic network near the source region. The integration of the legacy 2D reflection seismic data and mine seismicity data allowed us to identify a near-vertical structure, striking northnorthwest-south southeast (NNW-SSE). The ICDP-DSeis team drilled three holes (Hole A, Hole B, and Hole C), and two holes (Hole B and Hole C), intersected the upper edges of the ML 5.5 rupture. These holes recovered metasediments, metabasalts, intrusive rocks including dolerite sills and lamprophyre dykes adjacent to the fault zone, and the fault gouge. Late Prof. Tullis Onstott and geomicrobiologists installed a packer in Hole A and successfully recovered saline water and detected gas (~10 MPa). Slip weakening and rupture propagation are significantly influenced by the existence of fault gouges and the production of wear material between two sliding rock surfaces. Using the fault gouge material recovered from Hole C, we conducted friction experiments under dry and room temperature conditions at high slip velocity of ~100 mm/s and normal stress of 2 MPa. The resulting steady-state frictional strength was ~0.66 over a slip weakening distance of ~9.1 m. The steady-state frictional strength was high, which may be caused by large gouge thickness, and the rate of wear generation. As a result, it is proposed that the Moab Khotsong ML 5.5 seismogenic zone is complex and could be controlled by three main processes: a) the complex structural architecture of the seismogenic zone (e.g., intersection of fault, lamprophyre dykes, and dolerite sills); b) the mechanical process induced by tectonic and/or mining related stresses; and c) the mechanical and chemical processes caused by the water and rock interaction.

Jan 12, 2025

By P. K. Sollars, M. A. Alspaugh

In May of 1996, Twentymile Coal Co. began Longwall mining in the Foidel Creek Mine's East Mine District. These Longwall panels are some of the longest in the world (5.48 km/18,000 ft) with very difficult and challenging geometry. The conveyance system is 1,800 mm (72 in) wide, has a 4,500 mtph (5,000 stph) capacity and employs multiple tripper drives. The trippers include traditional powering designs as well as unique regeneration and braking designs. Several components were developed specifically for this application including a mobile tail brake. Control algorithms were carefully developed and tested via computer modeling. A world production record was achieved in the third month of operation and over 1 million tons were mined in June 1997.

Jan 1, 1998

The base metal ore from the hanging wall of White's orebody at Rum Jungle, N.T., is composed of copper and oth.er sulphides in a rock described as a phyllite,.which consists essentially of micaceous minerals with a little graphite.Fast selective flotation was obtained in acid circuit below pH 3·5. In neutral or alkaline circuit flotation was generally slow and selectivity very poor due to the ready flotation of part of the sericite. However, it was found that fast selective flotation could be obtained in neutral or alkaline circuit by either of two treatment methods following pre-conditioning in acid circuit; firstly by decanting or filtering a substantial part of the circuit liquor, and secondly by neutralizing with soda ash or lime, providing the collector was added before neutralizing. Otherwise pre-conditioning with acid brought about no improvement whatever.To explain this behaviour, three possible reasons for the flotation of part of the sericite are examined. There is evidence that some sericite floats because of thin films of either sulphides or graphite, but it seems likely such particles will float under all the conditions investigated.On the other hand, if it is assumed that part of the sericite floats because it is activated by metallic ions derived from the circuit water, a reasonable explanation can be given for the variations in flotation behaviour.INTRODUCTIONWhite's uranium orebody at Rum Jungle, N.T., sixty miles south of Darwin, is mined and treated by Territory Enterprises Pty. Ltd. (a subsidiary of Consolidated Zinc Pty. Ltd.), who are managers of the Rum Jungle project on behalf of the Australian Commonwealth Government.This ore contains a significant quantity of copper sulphides, and a flotation plant recovers a copper concentrate from the tailing remaining after the uranium has been extracted.In contact with the hanging wall of the uranium-copper orebody, a further mass of non-uraniferous sulphide ore occurs, and the present paper relates to the behaviour in flotation of this base metal ore.

Jan 1, 1959

By L. D. Patts, S. J. Janisko, E. G. Cauda, A. D. Bugarski, G. H. Schnakenberg, J. A. Hummer

Filtration systems with disposable filter elements (DFEs) are used in the underground coal mining industry to control particulate matter emissions from diesel-powered permissible and nonpermissible coal mining equipment. This study was conducted in underground mine conditions to evaluate three types of high-temperature DFEs used in those filtration systems. The DFEs were evaluated for their effects on the concentrations and size distributions of diesel aerosols and concentrations of nitric oxide (NO) and nitrogen dioxide (NO2). Those effects were compared with the effects of a standard muffler. The experimental work was conducted directly in an underground environment using a unique diesel laboratory developed in an underground experimental mine. After an initial DFE degreening period, the filtration system with all three DFEs was found to be very effective at reducing total mass concentrations of aerosols in the mine air. The effectiveness of DFEs in filtering aerosol mass was found to be a function of the engine operating conditions. The efficiency of the new DFEs significantly increased with operating time and buildup of diesel particulate matter in the porous structure of the filter elements. A single laundering process did not exhibit substantial effects on the performance of the DFE elements. The effectiveness of DFEs in removing aerosols by number was strongly influenced by engine operating mode. The concentrations of nucleation mode aerosols in the mine air were found to be substantially higher for DFEs when the engine was operated at high-load modes rather than at low-load modes. Initial heating of certain DFEs resulted in visible white smoke and substantially elevated aerosol number concentrations. The effects of the DFEs on the total concentration of nitrogen oxides (NOX) were found to be minor. The NO2 fraction was found to be generally lower for the DFEs than for the muffler. The engine-out NO2 fraction of the total NOX was found to be substantially higher for low-load modes than for high-load modes..

Jan 1, 2011

By A. Jahedsaravani, M. Massinaei, M. Zarie

Deep learning is a subset of machine learning that uses artificial neural networks for extracting high-level features from image data. In the present study, a soft sensor is proposed for the prediction of the flotation performance through froth features generated by the use of pre-trained convolutional neural networks. Several state-of-the-art convolutional neural networks (AlexNet, GoogLeNet, VGGNet, ResNet, and SqueezeNet) pre-trained on the ImageNet database are used to predict the metallurgical performance of two flotation systems. The first case study is a batch copper flotation system video-captured over a wide range of process conditions. The second case study is an industrial coal flotation column equipped with a continuous video recording system. The pre-trained networks are used to extract features from the froth images, and these features are subsequently used to predict the flotation conditions and performance. The prediction results by the pre-trained algorithms were compared with the traditional image processing algorithms. This demonstrates the ability of the pre-trained structures to generalize to images outside the ImageNet database. GoogLeNet outperforms other network architectures and provides more accurate predictions of the flotation process behavior and performance.

May 5, 2023

The development of an onboard contaminant diagnostic monitor to continuously measure contaminant level in a mining machine was advanced to a prototype stage in this contract. Several concepts were investigated and it was found that a static spool type sensor was the most reliable and accurate. Laboratory and field tests showed that an instrument based on this concept is capable of measuring contaminant levels and/or size distribution, depending on the configuration of the sensor. Moreover, this instrument can function on emulsions or homogeneous fluids. Current laboratory equipment can operate on homogeneous fluids only.

Jan 1, 1983

By E. W. Sawyer

Attapulgite is a magnesium aluminosilicate clay mineral which exhibits unique, processing-enhanceable physical and chemical properties that are related to its current commercial uses. Properties of commercial interest are gelling, absorption, adsorption, binding, acid neutralization and many others. Major industrial applications are: (1) absorption by heat treated grades utilized in industrial oil and grease absorbents and in agricultural pesticide carriers; (2) gelling of aqueous liquid products by colloidal grades for stabilization and viscosity control in salt water drilling fluids, suspension fertilizers, liquid animal feed supplements, paints and tape joint compounds; (3) adsorption by heat treated varieties for the removal of catalysts, color bodies and other polar compounds from hydrocarbon streams; (4) gelling of organic liquids by colloidal attapulgite/surfactant blends in oil-type paints, fibrated and nonfibrated asphaltic coatings and mastic compositions, and (5) the binding of feeds and molecular sieve sorpents with colloidal type attapulgite products. These applications and other less common uses and potential uses will be discussed along with, the necessary selective mining and plant processing features related to each property and application.

Jan 1, 1986

By Stainier X.

The connexion between the Kent and the Continental coalfields on the one hand and the western British coalfields on the other has been for many years a controversial subject between geologists. These coalfields were once considered as detached portions of a former extensive sheet of Carboniferous deposits, but some geologists seem now to incline to the view that they were never connected. The writer hopes to show that the problem is one of the most difficult of geological investigations; that we are still far from a perfect solution; and that both of the extreme theories must be set aside. The physiography of NW Europe during the Carboniferous, with its various generations of earlier folds, is outlined and the features of the Lower and Upper Carboniferous anticlines and synclines discussed, followed by consideration of the denudation of the coalfields and local descriptions of the Malvernian range and Usk anticline, the Pennine chain, the Shropshire coalfield and the Kent coalfield. An attempt is made to trace the transverse Midland anticlines southwards and to deal with the intervening syncline: for example, if the dissymmetrical profile of the Pennine Chain holds good at its southern end then the syncline west of the chain must be deeper than the syncline east of it (the Kent syncline), and in this syncline the deepest part must be at its south-eastern corner, and therefore south of the diagonal ridge. T here is some actual evidence of the existence of Coal-Measures in this syncline, as the results of the Batsford and Burford borings prove. The hypothetical character of most of the conclusions will prove, beyond any doubt, how fa r geologists still are from a perfect settlement of this problem, and how much this settlement is dependent on the more or less advanced state of knowledge regarding all the geological features of these coalfields and of the surrounding country

Dec 1, 1916

By Willaim A. Berg

Vegetative stabilization can help meet the esthetic objections and pollution problems posed by mine wastes. However, mine wastes are often unfavorable growth media and special treatments and techniques are needed for plant establishment and continued growth. The establishment of vegetation on mine wastes was the subject of many papers presented at the International Symposium on Ecology and Revegetation of Drastically Disturbed Areas held at Pennsylvania State University on August 3-16, 1969. This paper is a summary of those papers presented at the symposium that dealt with the nutritional and physical aspects of plant establishment on a variety of mine wastes. The synopsis presented is a combination of excerpts from the abstracts, notes on the oral presentations, and rough drafts of some of the papers. The papers will eventually be published in the symposium proceedings.

Jan 1, 1970

By D. Doungdeethaveeratana

The extraction kinetics in a novel solvent extraction process have been investigated. In this process, the liquid-liquid emulsion is generated by bottom gas injection into countercurrently flowing aqueous and organic phases. This process has a number of advantages over the mixer-settler unit or the spray column in terms of simple equipment configuration, without any mechanical moving parts, and the ease of cleaning and process control, while providing a sufficiently large interfacial area for rapid mass transfer. The overall rate increased with increasing gas injection rate and height of the aqueous phase but decreased with increasing injector diameter at the same gas injection rate. The variation of the overall rate constant was correlated against a set of dimensionless numbers, representing the operating conditions. Extraction rates and efficiencies comparable to those in a mechanically generated emulsion were attained in this new process.

Jan 1, 1998

By C. L. Lin

Linear grade distribution measurements determined from polished sections of randomly oriented particles can be used to estimate the extent of liberation for multiphase particles of specified size. Two techniques, optical image analysis and microprobe analysis, have been used to establish linear grade distributions. Both techniques were evaluated and compared using variable grade samples of products from a copper porphyry flotation circuit. The statistical significance of the linear grade distribution data obtained by optical image analysis was assessed. The average chalcopyrite content of these samples, as determined by chemical assay was used to estimate the variance of the experimental procedure. For a given accuracy, the number of particles required to obtain an unbiased representation of the sample was determined.

Jan 1, 1985

By V. Voller

A relatively simple model of grinding which incorporates both the Bond grindability equations and the population balance equations has been extended to form a comprehensive simulation package that can describe most kinds of conventional grinding circuits. The package has two programs, with the first consisting of an input program which helps the user to specify the prescribed circuit, while the second program performs the actual simulation. The package serves two main purposes - i) as a check on mill design, with the output providing not only predictions for the product passing size but also of the full product size distribution, and ii) as a means to assess the likely effects on the product size distribution of operating under different sets of conditions.

Jan 1, 1981

By K. Barbetti, J. Avraamides

"The processing of gold ores with high silver contents can provide operational challenges, such as high cyanide consumption, retardation of gold leaching and competition during adsorption stages of carbon-in-pulp/leach/column (CIP/CIL/CIC) circuits. In particular, the silver, which is about 1.5% of the value of gold, competes with gold during carbon adsorption due to its higher concentration in many Ag-Au ores, potentially leading to gold solution losses. Fresh and partially fouled (barren and regenerated) activated carbons were evaluated at various Ag:Au ratios and total metal concentrations with regard to the adsorption kinetics and equilibrium loadings. Conventional Freundlich isotherms were found to be highly inaccurate for predicting equilibrium loadings in the competitive adsorption environment. An integrated model, which incorporates competitive adsorption kinetics with a modified competitive adsorption isotherm model has been developed and validated using plant and laboratory data. The model performance and some of its salient features will be discussed.INTRODUCTIONThe processing of gold ores with high silver contents can present a range of operational challenges, such as high cyanide consumption, retardation of gold leaching and competition in carbon adsorption circuits. Silver is often present at significantly higher concentrations than gold in many gold-silver ores and competes with gold in carbon adsorption circuits, limiting the gold loading rate and capacity, resulting in gold solution losses and reduced gold recovery.Curtin University’s Gold Technology Group has evaluated fresh and partially fouled (barren and regenerated) activated carbons at various Ag:Au ratios and total metal concentrations to determine the adsorption kinetics and equilibrium loadings for gold and silver. Conventional Freundlich isotherms were found to be highly inaccurate for predicting equilibrium loadings in the presence of both gold and silver.An integrated model, which incorporates competitive adsorption kinetics with a modified competitive adsorption isotherm model has been developed and validated using plant and laboratory data. This paper describes the model performance and some of its salient features."

Jan 1, 2016

By B C. McLellan

The decline of ore grades on land, increasing demand and high prices for various minerals have led to an increased interest in mining the deep ocean sea floor. The potential deep ocean reserves are vast and in some circumstances the grades are high enough to consider mining. However, the consequences of such mining are as yet uncertain. This paper will present the results of a comparative assessment of life cycle impacts of deep ocean minerals. Two alternative extraction technologies from different deep ocean resource types were examined and key commodities are considered. Initial results indicate that the energy requirements will be higher than the average land-based resources, but may fall within the range of the deepest terrestrial mines.CITATION:McLellan, B C, 2015. Comparative life cycle impacts of deep ocean minerals and land-based counterparts, in Proceedings Third International Future Mining Conference, pp 253–260 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 4, 2015

By Massoud Hassanabadi

Filtration using Ceramic Foam Filters (CFFs) is a method widely used to separate inclusions from molten aluminium. In the present work, the specific permeability and form drag coefficients of nominal 50 mm thick commercial Al2O3- based CFFs, of grades 30, 50, 65 and 80, have been calculated from pressure drop experiments using high (60–500 mm s−1) and low (0.2–10 mm s−1) water velocities. Moreover, 2D axial symmetric Computational Fluid Dynamic (CFD) models have been developed, using COMSOL Multiphysics® to validate the experimental results. The empirically obtained values were defined as global parameters used to model the pressure, as well as the velocity fields in the water pipes and in the CFFs. The modelled pressure drop over the filter thickness for the high water velocity experiments showed < ± 1% deviation from the corresponding experimental results for all CFF grades. Moreover, the developed model also showed good agreement with the experimental results obtained from the low water velocity experiments, where the deviation of the pressure drop for the CFF samples of grade 30, 50 and 65 were ≤ ± 4.6% and for CFF samples of grade 80 ≤ ± 13.4%.

Hydrofluoric acid (HF) is traditionally used in plant operation to separate feldspars from quartz. It acts during the conditioning step as a pH regulator and an activating agent providing an excellent selectivity. However, a corrosive chemical environment and the ecological impacts from the potential fluoride ion contamination are limiting factors to use this chemical agent at an industrial scale. Investigations of the amine-feldspar interactions in the absence and presence of non-linear long-chain alcohols were carried out on two ore samples. The presence of alcohol molecules led to form a closed packed layer only on the surface of feldspars. The highest order and packing at the feldspar surface were observed with a particular alkyl chain structure as Guerbert alcohols. A new flotation process was developed and tested at both lab and pilot scales on different feldspar ores. The Guerbert alcohols allow to perform a feldspar concentrate with very low content in quartz (2.3-3.5 %) and feldspars recovery from 78 to 81 % while the aliphatic isoalcohols show a more higher recovery level (88-89 %). New HF-free process is strongly dependent on the pH range (1.7-2.5) and sulphuric acid consumption during conditioning steps. Optimal amine/alcohol weight ratio is ranged between 0.8 and 1.0. The values below 0.8 decrease strongly the flotation selectivity and the quartz recovery within the feldspar concentrates is higher than that occurs with HF.

Sep 1, 2012