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By R Wilson, R Williams, B Freeburn

McLanahan RSS14x50 scrubber screens have individually processed over 50 Mt of Pilbara iron ore. The first stage of separation in these plants with abrasive, high specific gravity, large lumps is an extremely arduous duty with high wear rates. With the Scrubber Screen layout this occurs in the attached trommel section. The initial supply of the replaceable trommel panels were of steel-backed rubber with a service life of approx. six weeks. Site Personnel established a goal of 26 week wear life in conjunction with 100 per cent reliability and while field trials were undertaken using a variety of hardened and cast steels that demonstrated wear life to the nominated requirement some unpredicted failures still occurred. With a long evaluation time and challenges to create repeatable conditions with field testing, a purpose built test unit was designed and constructed to allow controlled evaluation of a number of materials and designs. During 2016 tests were conducted with eight different materials, of varying thickness to simulate impact conditions and a number of aperture profiles to evaluate both impact and abrasion effects. From these results two designs were selected for full scale implementation to confirm the nominated goals. This paper will present details of both testing procedures and results of all materials, as well as conclusions of successful field implementation.CITATION:Wilson, R, Freeburn, B and Williams, R, 2017. Trommel panel development for iron ore applications, in Proceedings Iron Ore 2017, pp 251–256 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 24, 2017

By H. M. Thorne

Oil shale, a potential source of products presently obtained from petroleum, is found in many countries. The most extensive known deposits from the standpoint of potential shale oil in place are those in Brazil and the United States of America. Mining methods used for oil shale range from open-pit operations for shallow deposits to room-and-pillar and longwall techniques for deposits with thick overburdens. Oil shales from different sources vary greatly in the amounts and types of organic and inorganic constituents. By retorting, the organic material is converted to oil, gas, and coke. The largest percentages of oil are obtained from materials having the highest hydrogen content. Over 2,000 retorting systems have been patented, but only a few have been used industrially, and no single process seems best for all types of shales or economic conditions. Shale oils have different characteristics, depending on the source rock and method of retorting. They contain large quantities of olefinic hydrocarbons and more oxygen, nitrogen, and sulfur derivatives of hydrocarbons than most petroleums. Consequently, petroleum refining methods usually must be modified for shale oil. This is particularly true in catalytic processing. Hydrogenation, even under mild conditions, improves shale-oil refinability. Several byproducts may be obtained from both the retorting and refining steps,

Jan 1, 1964

By D Preedy, J K. Claflin, S R. J La Brooy

This paper summarises the lessons learned during a recent carbon reactivation kiln upgrade project at the Sukari Gold Mine in Egypt. The kiln is being replaced to ensure that the plant achieves full value from the current throughput expansion from 5 to 10 Mt/a.The suitability of the original engineering design criteria for kiln selection and the adequacy of the original kiln are reviewed in the light of the carbon chemistry, operating experience and a site inspection of the kiln. Particular aspects of the reactivation facility are discussed including: predrying, preheating, feeding, gas seals, kiln heat transfer, steam injection, counter-current sweep gas flow, carbon cooling, fines minimisation and removal.Design criteria for a carbon predryer, reactivation kiln and cooler combination for carbon heavily fouled by high molecular weight frothers and collectors are discussed and the abridged Ausenco datasheet for the combination is presented.Responses to a request for a budget price sent to most of the worldÆs suppliers of carbon regeneration kilns are summarised.CITATION:Claflin, J K, La Brooy, S R J and Preedy, D, 2013. Ausenco carbon reactivation design criteria, in Proceedings World Gold 2013 , pp 401-410 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 26, 2013

By H. M. Lawrence

"The land-pebble district, the larger of the two producing areas of Florida, is situated in Polk County and in the eastern part of Hillsborough County. About 80 per cent at the phosphate rock produced in the United States in recent years has been mined from this area. The phosphate ores, locally termed matrix. are beds of sands and clays containing the phosphate pebbles, considered to be Pliocene in age, derived by marine action from underlying Miocene phosphatic marls, and are covered by practically barren sands and clays that have been deposited more recently. Open-pit mining is practiced; hydraulic mining, which has been intensively developed in this district, is used exclusively for mining the matrix and, by some companies for removing the overburden, although drag-line excavators have become established and are proving economical for stripping operations. From the pits the matrix is pumped to adjacent washing plants for beneficiation. The product of the washers. after drying, enters the world markets as Florida pebble phosphate.In this district recovery of the phosphate pebbles by the washing plants has not been particularly effective in the past. The screening, designed to effect a seperation at about 20 mesh (0.033 inches), has not been well controlled. Washer rejects discarded to the waste dumps have contained appreciable amounts of material analyzing above the minimum commercial grade - 66 per cent B.P.L. (bone phosphate of lime). Such losses of commercial fractions should be considered avoidable, and have been discussed at length in a previous paper.3"

Jul 1, 1930

By Howard E. Rollman

South Central United States, an area including Arkansas, Kansas, Louisiana, Mississippi, Missouri, Oklahoma, and Texas, is a net exporter of refractories. Nearly $45 million of these materials was shipped in 1954 from plants in the area, compared with area consumption of $18.5 million. About 88 percent of all refractories production is concentrated in Missouri. The prevalent consumption pattern, however, is one of localized shortages. For example, although Texas uses more than half of the refractories consumed in the South Central United States, production of refractories in Texas is relatively small. Also, the apparent self-sufficiency of the area is in terms of value produced rather than in terms of products consumed. Nearly all of the $6,425,000 nonclay refractories consumed in the area were shipped from other States. Local resources possibly could be developed for making refractories to serve markets that currently are being supplied from outside the area. Since other industries are growing rapidly in the area, the market for refractories is expected to continue to grow--more rapidly than the national market. The Missouri refractories industry is economically important nationally. Nearly one-fourth of the clay refractories produced in the United States are made in Missouri. Moreover, Missouri produces most of the higher grade clay refractories, about 62 percent of the high-alumina refractories, and 85 percent of the superduty refractories. The competitive position of the Missouri refractories industry is strong. The national market for clay refractories and the market in the South Central United States are expected to continue to grow. The ratio of net income to the value of refractories shipped in Missouri is larger than the national average.

Jan 1, 1960

By V Chamberlain, M Appeah Owusu, M Aniawu-Asumakah, A Anyimadu, R Peattie

This is an integrated geology and plant improvement study arising from the heterogeneity seen in mineralogy and gold association at the Obuasi goldmine in Ghana. This heterogeneity comes from the two ore types mined, the one being a sulphide ore, mainly composed of gold-bearing arsenopyrites. This gold is refractory and exhibits a strong relationship between gold and As. The other is quartz veins, that are high grade and free milling. The installed circuit consists of comminution – Gravity -Flotation – BIOX – Leaching and Adsorption processes. The opportunity tested involved improved mass pull - related flotation recovery of Au in the Sulphide stream; while balancing the need for a minimum Sulphide grade for the Bio-oxidation process, occasioned by the removal of 25 to 30 % of the (quartz) stream through preconcentration by Ore sorting. The current circuit is then utilized for the sulphide route, while a smaller grind-gravity circuit is utilised for the quartz stream in a relatively inexpensive way, followed by a common leaching and adsorption circuit. Added advantages of the strategy includes faster recovery of gold from the quartz stream, with less consumption of reagents from saving on flotation and BIOX reagents for this stream. Screening and Ore sorting was successfully tested with laser technology, achieving over 98% separation of quarts (containing up to 40% of the gold). The plant schedule of Ore, the suggested circuit design for the Ore sorting, the results obtained from the different flotation regimes, as well as consequent financial modelling have been presented and discussed in this paper. This illustrates the opportunity that arises out of a detailed analysis of material versus installed circuits, even if the gains in pre-concentration do not necessarily involve rejection of gangue material. An added opportunity for future investigation, briefly discussed but not tested in this paper, would be to maintain current mass pulls but with increase in throughput (by the space created by the sorted material). This will of course require the mining ability. It could also add LOM value by altering the cut-off grade.

Nov 10, 2020

By Glen Mc Gavigan

The roof of the Sishen cave is being mined in order to exploit 6.8Mt of high grade ore. The cavity is filled with quartzite backfill in order to support the roof in the event of collapse. The cave dips at approximately 37o, is 260m along dip and 70m along strike and has a total volume of 261,391m3. GPS and optical monitoring techniques were attempted to detect subsidence but proved to be impractical. The GroundProbe Slope Stability Radar (SSR) uses differential interferometry to measure sub millimetre movement in a rock face. The SSR was applied in a non production situation and detected subsidences of 38mm/day before visual signs of instability were detected. The rate of deformation detected was slowing as a result of the roof coming to rest on underlying backfill. Monitoring during production drilling detected a sudden subsidence of 18.6mm/hour which resulted in the evacuation of personnel from the area. Further inspection of data showed that the rate of deformation was slowing and production was allowed to continue without further incident. The SSR has helped dispel the fears of workers and has proven that subsidence can be accurately measured and delineated with the SSR.

Jan 1, 2006

By Mike Lovitt

New Gold Inc. had commissioned Orica to assist with the design of the drawbell blasting at New Afton Underground copper/gold block cave at Kamloops, British Columbia, Canada. Orica have had much success in developing the single-shot drawbell method at Freeport Indonesia in 2001 in the Deep Ore Zone and they will be using it exclusively in their new Grasberg Underground Operation. RioTinto Northparkes have also used the single shot drawbell blasting in their Second Lift E26 Project and even in the E48 orebody which is a post undercut block cave, realising the safety and operational benefits of this blasting method.

Jan 1, 2013

By B. Lueger, D. Shen, M. Sedighy, R. Rand, R. Saleh, J. Cheung, M. Rifai, I. Khan, W. Sauri, D. Setianto

The world’s first active power demand stabilization system for a 3-electrode electric arc smelting furnace was commissioned at PT Vale Indonesia in December 2012 on Furnace No. 2 using an SPLC (Smart Predictive Line Controller). The SPLC technology in combination with the Furnace No. 2 rebuild and other upgrades has enabled PT Vale to increase the electrical input to the furnace by up to 20% on a stable and sustainable basis by eliminating peak powers that overload and trip out the electrical equipment, and by reducing power unbalances. The SPLC technology maintains smooth arc power using a continuously variable thyristor controlled series reactor. The SPLC compensates variations in the furnace arc with predictive changes in the circuit reactance at a speed of up to 60 times a second. The system started up quickly and has been shown to be easy to operate and maintain by PT Vale. PT Vale’s Operations Team has been testing the new system at set points of up to 90 MW on the newly re-built Furnace No. 2. Over the last 12 months, the throughput of Line 2 has increased by approximately 10% on an annual average; however, debottlenecking in other design areas of the operation is required in order to achieve 90MW operation on a sustainable basis. This outstanding success results from a combination of the furnace and other upgrades, the SPLC active power stabilization, and the skill of PT Vale in quickly adopting new technologies and maximizing the combined benefits of each technology in their operation.

Jan 1, 2014

By Zhao-cheng Liu

Iron oxide red pigment powders of high quality were synthesized from pyrite cinders. Iron ox-ide red pigment powders were synthesized by hydrothermal method from the precursor of Fe(OH)3 and Fe(OH)2 colloid, which were obtained after ammonia solution reacted with acidic leaching solution produced by the reaction of pyrite cinders with sulfuric acid. Effects of reaction concentration, reaction temperature, reaction time, pH value and n(Fe2+)/n(Fe3+) on main properties of oxide iron red were studied by experiments. The prepared particles were characterized by means of X-ray diffraction (XRD) and scanning electron microscope(SEM). The results revealed that the synthesized iron oxide red particles were _-Fe2O3 and pseudocubic with particle size of 0.50~0.75µm. Furthermore, the quality of iron oxide red pigment powders reached the first grade of national standard (GB1863-89 ).

Jan 1, 2009

By P. Lefebvre, J. Sargent, K. Major, B. Darnton

"Stillwater Mining commenced mining operations at Nye, Montana in 1987 for the recovery of platinum and palladium. Exploration identified that the J-M Reef extended for 43 km. In 1998 Stillwater Mining made the decision to develop the East Boulder mine complex, located approximately 13 miles from the Stillwater mine complex at Nye, to increase production. This paper describes the design, construction, and start-up of the East Boulder process plant.INTRODUCTIONStillwater Mining Company have been producing Platinum and Palladium from their Nye, Montana operations since 1987. The mine production from Nye had been increased in stages with mine production being delivered through several portals and one vertical shaft.The deposit is narrow veined which prevents the application of bulk mining methods and thus limits the production capabilities.In order to increase the production of platinum (Pt) and palladium (Pd) Stillwater made the decision to access the ore from the J-M Reef from the East Boulder site. The East Boulder mine site is located about 21 km (13 miles) from Nye, however as shown in Figure 1, the travel distance is closer to 188 km (114 miles). Distance, on strike, and space availability at Nye precluded the expansion of the Nye concentrator to handle the increased mining rate and supported the decision to install a new concentrator at East Boulder."

Jan 1, 2003

Many mining operations are uncertain of what costs they should be achieving. The majority of cost estimates are based on historical costs that have added contingency factors. Historical costs are a valuable source of information but a more precise costing method is necessary. There are several alternative methods for predicting costs. A methodology which provides the best indication of the achievable costs is one using a standard inventory list and a bill of quantities. The model is termed a Basic Principles model and addresses basic design principles and engineering constraints.

Jan 1, 1990

By M. A. Oskouei

Draglines are the main energy consumers in strip mines. Given the growing cost of energy and environmental concerns, it is important to properly understand dragline energy efficiency. The goal of current research at Missouri University of Science & Technology is to account for operator practice and operating conditions in modeling dragline energy efficiency. This paper presents preliminary correlation analysis and a framework for stochastic modeling of dragline energy efficiency. Thirteen operating parameters (including cycle times, payload, swing angle, and height of dump pile), operator working schedules, operating conditions, and drag, hoist, and swing energies were monitored for an 85 yd3 dragline. Operator effects were examined by two-sample t-tests. The relation between the parameters and energy consumption were assessed by correlation analysis and a stochastic modeling framework has been proposed for dragline energy efficiency. The results show that operator effects are significant (p< 0.05) and energy efficiency is correlated with operating parameters. The completed model will help the coal mines better predict energy consumption, with uncertainty, for different operating conditions.

Feb 27, 2013

By M. du Plessis, D. F. Malan

"The aim of any mine design is to ensure that the excavations remain stable for the period they will be in use. Various pillar systems are used to ensure that underground stopes remain stable and that mining activities do not affect the surface infrastructure through either surface subsidence or seismicity. Intermediate-depth platinum mines make use of in-stope pillars designed to fail while the pillars are being cut at the mining face. The pillar stress exceeds the loading capacity and the pillars crush as a result. The aim of the paper is to provide an overview of in-stope crush pillars. This will include the application, behaviour, function, mechanism, impact, and design of a crush pillar system."

Jan 1, 2015

On the 26th of June 2000 a hydraulic fill retaining barricade failed at the Bronzewing mine in Western Australia. The barricade failure resulted in the release of 19,000 m3 of saturated hydraulic fill into the mine and caused the deaths of three miners. Following this tragic accident, the practices and procedures of mines using hydraulic fills came under intense scrutiny by regulatory bodies and mining companies. At this time, the use of hydraulic fill at Normandy?s zinc/copper Scuddles mine was suspended and waste rock became the sole backfill material in use underground. By 2003, development of the adjacent Gossan Hill mine had progressed to a point where a self supporting fill material was required to enable full recovery of high grade ore. Cemented hydraulic fill (CHF) was identified as the optimal fill type and work began on designing appropriate management procedures and controls to ensure the safe implementation. This work included definition of the fill properties, plant design and construction, reticulation system design, design of stope barricades and drainage systems and fill placement control and monitoring practices. CHF placement began on 16th July 2004 and has continued to date. Significant operational experience has since been gained in areas including plant performance, fill product quality assurance, barricade construction, stope drainage and in-situ performance.

May 1, 2007

By Walter S. White

The Michigan native-copper district has produced about 5,400,000 tons of copper since mining began in 1845. The copper occurs primarily as open-space fillings and replacements in amygdaloidal flow tops and conglomerate beds of the Portage Lake Lava Series, of middle Keweenawan age. Secondary minerals with which the copper is associated include microcline, chlorite, epidote, pumpellyite, prehnite, quartz, and calcite; zeolites, other than laumontite, are not abundant. A zonal pattern of the secondary minerals transects bedding and suggests regional metamorphism mainly to the grade of the prehnite-pumpellyite graywacke facies of Coombs. Most of the major copper deposits are near the upper limit of abundant quartz in this zonal pattern. The distribution of copper in both amygdaloid and conglomerate deposits is controlled partly by primary permeability of the rocks and partly by later tectonic fracturing that was concentrated in the mechanically weak flow tops and sedimentary beds. Ore shoots and deposits are therefore controlled partly by primary structural features, such as areas of thick and thin fragmental amygdaloid or the boundaries of conglomerate lenses, and partly by regional structure: a number of ore deposits are in synclinal downwarps. The copper-bearing solutions that formed the deposits were ascending. They may have come from a large concealed intrusive, or may have been driven out of the porous tops of lava flows when the rocks were compacted and metamorphosed at great depth in the central part of the Lake Superior syncline. The second hypothesis seems more consistent with the widespread distribution of the copper, its relation to mineral zoning that represents truly regional metamorphism, its native state, and the likelihood that copper deposition was later than most or all of Keweenawan volcanism.

Jan 1, 1968

By M. A. Meyer

Underground mining accidents in the USA in recent times have prompted the Mine Safety and Health Administration (MSHA) to review emergency and tracking systems for underground mines. Several communication and tracking systems are available on the market and various systems have been installed in mines around the world. In addition, MSHA?s standard on Diesel Particulate Matter (DPM) requires mines to comply with the final PEL of 160µg/m3 by May 20, 2008. Barrick Goldstrike Mines Inc., Underground Division, has been in operation since 1995 and an extensive control and monitoring network, and a leaky feeder voice network is in place. Enhancements to the communication and control system are currently being implemented to include a PED emergency notification system, wireless LAN with tracking of personnel and equipment in the mine, and a ventilation control system that will use the tracking information and ventilation data to automate much of the mine ventilation system. Expected benefits from such a system would be enhanced communication with miners, emergency notification, location of miners and equipment, energy savings, improved ventilation control, and improved atmospheric conditions in the mine including reduction of diesel particulate matter (DPM).

Jan 1, 2009

By Joe Shoemaker

Automated Spot Generation ? No Operators below the Highwall ? No Operator Wear and Tear ? Reduced Swing Time ? Single and Double Sided Loading ? Minimized Bench Width

Aug 1, 2013

By M J. Begbie, K B. Sporle

The Golden Cross low sulfidation epithermal deposit produced approximately 750,000 ounces of Au from two ore zones: the underground Empire Vein System and the open pit stockwork. The Empire Vein System has at least eight stages of vein formation: (1) sulfide veins, (2) black veins, (3) massive veins, (4) banded veins, (5) thin white veins, (6) crumbly veins, (7) massive/platy calcite veins, and (8) flattened rhomb calcite veins. Gold mineralisation occurred relatively early in the lifetime of the system, dominantly during 2 through 4. The late calcite veins (7 and 8) and early sulfide veins (1) are barren. The vein system formed in a dominantly extensional environment, though some compressional faulting may have also existed during vein formation. There is no evidence for significant strike-slip faulting during vein formation, highlighting the fact that explorationists should pursue on-site structural patterns rather than fashionable models.

Jan 1, 1998

By Collin Stewart

Bowie Resources maintains one of the most pro-active ground control programs in the U.S. mining industry today. Its guiding philosophy is that everyone in the organization, from the miners at the face all the way through the top management, are involved in ground control. Some of the unique elements of the Bowie ground control program include: ? Roof bolt operators log the stratigraphy of test holes in nearly every cut. These ?lithgraphs? are used by section foremen to determine the need for additional roof support, and they are entered into the geologic data base for use in geologic modeling and mapping. ? Underground core drilling is conducted to obtain data for CMRR and stability maps. ? Weekly ?Quality? meetings, involving mine management and technical staff, are held to ensure that ground control information is integrated into production operations. The paper will describe the program in detail, discussing the involvement of roof bolters, section foremen, surveyors, technical staff, and production managers. It will also show how the program has contributed to the mine planning process. Case histories of successful ground control interventions will be discussed.

Jan 1, 2006