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By S. H. Amini, A. Noble

"While many classic mineral processing circuit design approaches rely on deterministic methods, numerous studies have shown that the uncertainty inherent to the various input parameters can significantly influence design decisions. In a separation circuit, many of the technical uncertainties can be mathematically represented as statistical distributions for the unit recovery and feed grade. These uncertainties are then propagated by the circuit design and reflected in the circuit performance indicators, such as product grade and global recovery. An effective design strategy entails identifying which units are most influential in this uncertainty propagation and thus merit further consideration. Unfortunately, few analytical tools provide this information, particularly those that rely solely on deterministic methods. However, one promising approach is through the application of Taguchi’s method, in a fashion similar to statistical tolerancing of manufactured products. Since the technical challenges are fundamentally similar, Taguchi’s method shows promise in evaluating the level of compounded uncertainty by various circuit designs while determining the role of each separation stage on the overall selectivity and variability of separation circuits. This paper demonstrates Taguchi’s method in several two and three unit circuit designs. INTRODUCTION AND METHOD DESCRIPTION Uncertainty in Mineral Processing Circuit Design Analysis and estimation of uncertainty propagation in mineral processing separation circuits is an essential and significant aspect of an optimal circuit design procedure. Most of the current circuit design methodologies have been constructed, implemented, and validated using a deterministic modeling approach. However, numerous studies have shown that the inherent uncertainty induced by uncertain design parameters can be a significant factor in many mineral processing applications (e.g. Kraslawski 1989; Xiao and Vien 2003; Ghaffari et al. 2012). Thus, an effective circuit design methodology must be able to quantify uncertainty in separation circuits with limited input data. This paper describes Taguchi’s method, as an experimental design technique, to approximate uncertainty in mineral processing applications, and then the similarity of results between Taguchi’s method and Monte Carlo Simulation is investigated. Monte Carlo Simulation The term “Monte Carlo Simulation” has been used to refer to a variety of stochastic simulation methods spanning a broad array of business, technical, and scientific domains. Most generally, Monte Carlo Simulation refers to numerical analysis which is based on (pseudo) random sampling from a domain of input parameters with a known statistical distribution. This methodology allows one to determine the distribution of expected results from a standard deterministic process model. Execution of a Monte Carlo simulation begins by identifying the domain of input parameters, statistical distributions for each parameter, and a deterministic process model which describes the anticipated result as a function of the inputs. Next, one discrete random sample is taken for each input parameter, considering the input distributions. The process model is then solved for this mix of input parameters, producing a single simulation result. This procedure is then repeated a “large” number of times, utilizing new randomly sampled input parameters for each simulation iteration. Once the desired number of iterations is reached, the results of each independent simulation are aggregated to produce descriptive statistics such as minimum, maximum, mean, standard deviation, kurtosis, and other distribution parameters. Given enough iterations, the Monte Carlo method fully explores potential synergies between the input parameters. The methodology does not require the process model to be differentiable, continuous, or even analytically defined. While the number of required iterations varies in relation to th"

Jan 1, 2017

By T. Carageorgos

The removal of arsenic from process streams as ferric arsenate compounds is being practised by mining industries. Therefore, the solubility and stability of these solids is of considerable importance to the mining plants that have to keep the environment free from pollutants. There is some information on the solubility of the ferric arsenate compounds, mainly on scorodite, obtained from synthetic solution. However, there is not so much work on ferric arsenate compounds formed at high temperatures (175 - 230°C) during the leaching process. In the present work, the solubility of the ferric arsenate compounds formed during acidic pressure oxidation of arsenopyrite is presented. The results of the solubility tests showed that the ferric arsenate compounds formed at high temperatures (200 - 230°C) and high pressures (1034 - 1551 kPa 0,) released arsenic into solution in amounts less than 1.2 ppm and iron in amounts no higher than 1.0 ppm. So, they seem to be potential compounds for arsenic and iron disposal.

Jan 1, 1998

By M. R. Grundy

The Robinson project is based on the porphyry copper and gold deposits in the Robinson Mining District, near Ely in Eastern Nevada. The district was mined from the late nineteenth century to 1978 by Kennecott Copper Corporation and its predecessors. Operations ceased when falling copper prices in the late 1970's made their outdated mill and smelter complex at McGill uneconomical. In October 1991, Magma Copper Company (Magma) acquired the many claims that cover the known porphyry copper deposits in the district These occupy a disturbed area about nine miles long and three miles wide between the towns of Ely and Ruth. Magma proposes to build a copper / gold mine and concentrator and expand the existing gold leaching facilities. Several pits, previously mined by Kennecott Copper Corporation, will be enlarged; the use of larger, more modem equipment will result in higher productivity and lower operating costs in general. ICF Kaiser Engineers, of Oakland, California, were awarded the con-tract for detailed design of the process facilities, which was essentially complete by the end of 1993. The project at present is awaiting completion of the environmental permitting process; state air and water permits are in hand, and the Bureau of Land Management's (BLM) current schedule indicates that the final obstacles to construction will be cleared by early fall of this year.

Jan 1, 1994

By Patrick J. Doig

The NS9 Drop Shaft contract formed part of the Waste Pollution Abatement Program (WPAP) conducted by the Milwaukee Metropolitan Sewerage District (MMSD). The contract involved the construction of two shafts, a deaeration chamber and connecting tunnel, and ancillary facilities. Portions of the construction were located in saturated overburden where dewatering was prohibited. Ground freezing was utilized for temporary support of the excavation. This paper concentrates on the freezing system and the excavation of frozen ground, with particular emphasis on the use of mechanical cutting equipment, including a raiseborer and a roadheader.

Jan 1, 1991

By T. McWaters

Miami Copper Company began a block-caving operation in 1911 using a gravity mill to separate copper minerals from the Pinal Schist host rock. The tailing was deposited by the upstream method using perimeter launders and spigot valves in six canyons adjacent to the mill until 1932. In 1928 the larger and more distant Solitude tailing pile was developed which by 1932 was receiving all tailing except for upsets. In 1925 Miami Copper converted its gravity mill to flotation which began to produce higher sulfide copper recoveries.

Jan 1, 1990

By L. C. de Kooker, K. Esmaeili, I. Musonda, M. Ferentinou

A numerical investigation of the effect of pore pressure regime on the safety factor and the critical failure mechanism is presented for fly ash storage facility. Pore pressures’ measurements from standpipe piezometers and pore pressure estimated from seepage analysis are used to compare the factor of safety for a fly ash slope. This was applied for considering static and seismic scenarios. A probabilistic approach was applied to account for the uncertainties resulting from the limited data available and support a qualitative risk assessment evaluation. Slope stability analysis is conducted in two and three dimensions, adopting the limit equilibrium analysis approach, and also a finite element seepage analysis, to assess the stability of the slope. The two-dimensional cross-sections were extruded to three-dimensional models to estimate the factor of safety and associated shear failure. The results from the performed analysis suggest an increase in safety factor values of 5%.

Mar 27, 2024

By John Murray, Daniel Ebin, Robert Gould, Yiming Sun, Lizan Gilbert

The Atlanta Plane Train Tunnel West Extension is being constructed at Hartsfield-Jackson Atlanta International Airport using the Sequential Excavation Method (SEM). The tunnel has shallow ground cover and mixed-face conditions and passes underneath the SkyTrain and MARTA stations and airport terminal buildings. It includes a twin tube Bifurcation with a span of over 45 feet and ground cover of 12 feet. A flat roof is being constructed at the Bifurcation to maximize rock cover and minimize surface settlements. This paper focuses on design and construction challenges for the Bifurcation and tunneling beneath the world’s busiest airport, while minimizing impacts to operations.

Dec 1, 2022

By Paul K. Edwards

The forces of nature have concentrated sand at various geographical locations that are being mined and processed for a large variety of industrial uses. While most operations serve a number of industries, this paper deals only with the foundry requirements. The forces that have decomposed a source rock, transported this material and redeposited it, have created two general types of sand. These types are classified as the (1) Lake and Bank Sands and (2) Silica Sands. The Lake and Bank sands will contain 92 to 94% Sio2 while silica sands are in excess of 98.5% Si02 and most of the producers wash these sands to up grade their products to 99.5% or better. Included in the Lake and Bank sand would be the river sands that are used primarily for construction purposes. The Foundry Industry is broken down into three types of castings : 1. Grey Iron Foundries The grey iron castings largest market is the automotive industry in Ohio, Northern Kentucky, Indiana, Illinois and Michigan. These castings are poured at temperatures ranging from 2400° to 2700°F. The Silica Sands or the Lake and Bank Sands will satisfy the requirements of the grey iron castings. There are 2 ½ to three million tons per year shipped from the state of Michigan far grey iron castings by the Lake and Bank Sand Producers.

Jan 1, 1974

By R. Bishop, J. Baggett, J. Monsalve, J. Hole, N. Ripepi, A. Abassi

This work focuses on the operational and safety issues associated with karst voids in large opening underground mines. Issues include water inrush, structural instability, and engineering uncertainty in these environments. Coupled with the fracturing prevalent in folded sedimentary rocks, karsts are complex and challenging ground control risks. Traditional methods of predicting karst locations, such as probe drilling, are impeded by the inconsistent spatial distribution and variable sizes of the features. Ground penetrating radar (GPR) is a geophysical technique that transmits radio waves into a medium and subsequently detects reflected waves via a receiver. The travel time and energy of received signals are then processed and interpreted. The difference in material properties between limestone and open karsts causes strong reflections. GPR is frequently used as a geophysical surveying technique in several industries, however there is a lack of published research on underground mining GPR applications. The purpose of this work is to prove the viability of GPR in underground stone mines for karst detection, and to discuss the importance of karst detection ahead of mining. INTRODUCTION The Mine Safety and Health Administration (MSHA) currently lists 116 active underground stone mines in the United States, the vast majority of which extract limestone for crushed stone products. These limestone mines have the potential to encounter karst voids at some point in their operation, as most karstic regions of the United States develop in limestone rock masses (Kuniansky, Weary, & Kaufmann, 2016). Karsts, the cavities formed by the dissolution of carbonate rock, have long plagued the mining and tunneling industries, as well as been a hindrance on the Earth’s surface, producing sinkholes and ruining otherwise valuable land for construction and public use. The impact of karsts on the Gavarres tunnel in Spain is well documented by Alija et al; constant instability conditions, material spills into the tunnel, and unexpected cavities seriously delayed the project deadlines and “were not foreseen in the design” (Alija, Torrijo, & Qunita-Ferreira, 2013). At the water supply project in Sohngua River, China, Bin et al detail the presence of both water and sediment filled karsts which are sources of disastrous conditions at this tunnel (Bin, et al., 2017). A hydrological tunnel in Lebanon encountered numerous massive karsts in the tunneling path which required remediation via friction anchors, rockbolts, welded wire fabric, channel steel arch segments, invert steel beams, and shotcrete (Leech, Jaoude, & Ghanem, 2008). From a design standpoint, rock mass classification schemes, such as the RMR from Bieniawski and the Q-system from Barton, are not able to represent the true nature of a karstified carbonate rock mass, and therefore complex case-by-case analyses of underground conditions are necessary (Andriani & Parise, 2017).

Jan 1, 2019

By Pafos Busch, Martin Fischer, Johannes Jaeger

The Spitzenberg Tunnel is a 600 m (1,970 ft) long twin tube motorway tunnel on Germany’s Autobahn A44 between Kassel and Eisenach. Since flexibility was considered to be very important in the continuously changing geological conditions, NATM was chosen as the construction method. When passing an old quarry with only 1,80 m (6 ft) of overburden, the excavation works became extraordinarily challenging. This paper not only describes the special methods, like double sidewall drifts and pipe umbrellas applied in this zone but also highlights the cooperation between the parties involved, which in combination made the project a joint success.

Jun 13, 2021

By R. F. Harig

Designing an underground nuclear waste repository is a complex process. Although many decisions are involved before the design is complete, the first three--what the target horizon is, what the underground boundary is, and where the entry point will be located--are important because they establish the basis for the entire repository design. Even more important than these decisions, however, is the data on which the decisions are based. Because the current data are limited, an aggressive data gathering program is needed during the next design phase to augment information about the intricate interplay among all facets of the repository design and the geologic medium in which the proposed repository is to be developed. Although unique to modern engineering enterprises, the challenges involved in designing a repository in the unsaturated zone are within current technology and engineering practices.

Jan 1, 1991

By Yi Luo

Bolting the mine roof is one of the noisiest underground mining operations. The main contribution to the noise is the drilling of the roof bolt holes, especially drilling in hard rock. Previous research shows that the specific energy consumed in drilling bolt holes is inversely proportional to the bite depth (i.e., penetration per drill revolution). Less specific energy at a reasonably high bite depth means less energy is wasted in the drilling process for producing heat, bit wear and noise. Therefore, proper control of the drilling operation to achieve a reasonably higher bite depth can reduce drilling noise from its sources as a proactive noise control approach. In order to explore the feasibility and develop the proactive technology for reducing drilling noise, drilling tests have been conducted in laboratory settings. The preliminary results show that significant reduction in noise dose can be achieved by drilling in medium hard rock with uniaxial compressive strength of about 276 bars (4,000 psi) and at a reasonably high bite depth of about 4.6 mm/rev (0.18 in./rev). This paper presents the findings from laboratory experimental studies.

By W. Edwin Dill

For the mining industry, the Internal Revenue Code and regulations offer a range of choices in arriving at the allowable depletion. Each case is essentially unique. Two prerequisites can optimize these opportunities: communications between the mining company's tax specialists and its technical staff; and an understanding of IRS definitions. For the latter, a logical starting point is consideration of exploration and development, since they precede production and depletion is unallowable prior to production. Criteria for selecting engineering and accounting options for exploration and development indicate the necessity of interaction between these company functions to achieve the most favorable tax position.

Jan 1, 1982

By Firat Atalay

Estimating the spatial distribution of ore grade is one of the most critical steps to proceed with an investment decision on a deposit. Kriging is the most widely used method to estimate the ore grade, but alternative techniques are being developed. Machine learning algorithms can be used as alternative methods to classical kriging. In this paper, the iron (Fe) grade of a deposit is estimated with the XGBoost algorithm, and the results are compared with kriging estimation results. For the estimations, samples collected from drillholes were used. Due to the different natures of the estimation methods, different steps were taken to perform the estimations. The results show that XGBoost produced higher-range estimates, which is a desired result in ore grade estimation, and the minimum and maximum of the estimates were lower and higher than the kriging estimates, respectively. However, like kriging, the estimation results were smoother than composites, and the variance of the XGBoost estimates was lower than the variance of composites. This means that even though estimation with XGBoost mitigates the smoothing effect, the estimation results suffer from smoothing like kriging.

Dec 1, 2024

By Jr. Pickering

Commercial quality kaolin deposits occur in fluvial sediments in both central-eastern Georgia and in the eastern Amazon River area of Brazil. Distinctive coarse and fine particle size kaolin deposits are present in both areas; they have many remarkable similarities for mineral deposits occurring at such wide geographic separation. Industrial, mineralogical, crystalline, and chemical resemblance of the coarse and fine kaolin deposits from the two areas will be described in detail. Knowledge of similarities of the Brazilian clays to those which have dominated world production in Georgia will help to develop superior quality kaolin products for world use in paper, paint, plastic, ceramic, and other applications.

Jan 1, 1997

By F. W. Brackebusch

Paste is a high density mixture of water and fine solid particles with a relatively low water content (10-25%) such that the mixture has a consistency as measured by the ASTM slump cone test from slightly greater than zero up to nearly 12 inches (305mm). Particles of different size classes will not segregate or settle when the paste is not being agitated or when it is stationary in a pipeline. Cement may be a component of paste. Larger particles of aggregate can generally be added to a paste without greatly changing the pipeline transport characteristics. A paste may bleed water slightly when it is allowed to be motionless for periods of up to several hours, but the solids do not become so dense that the paste cannot be easily re-fluidized. The dividing line between the definition of a high density slurry and a paste is not sharp. It is a practical matter that must be considered when designing a pipeline transportation system. If the pipeline is very short, there is very little risk of plugging the pipeline with a high density slurry when flow is stopped for short time periods. With longer pipelines the mixture must remain stable without motion for periods as long as several hours to avoid pipeline plugging. The fine particles in a paste mixture can be composed of mine tailings or naturally-occurring clays, silts and fine sands. The mineralogy of the particles thus can have a wide variety from quartz and feldspar to clays, micas and even salts.

Jan 1, 1993

By Stuart Hammer

The mining industry has seen a flurry of merger and acquisition activity of late. Rising metal prices, increased spending on infrastructure in developing nations and the growing demand for companies to diversify have helped fuel M&A activity in this industry. Many analysts believe that the robust M&A activity will continue, particularly if the demand for mineral resources in India and China remains strong. Because prospective purchasers need to evaluate the various risks confronting target companies, acquiring mining companies requires a considerable amount of due diligence. Of these risks, environmental risk is critical and warrants significant analysis. The failure to properly assess environmental risks associated with remediation, reclamation, compliance or litigation can undermine the transaction. Such assessment is a difficult endeavor, however, due to several challenges that companies face when assessing environmental risks. To make matters more complicated, despite these challenges, many sellers ask buyers to assume all environmental risks with limited post-closing indemnification rights. This article addresses the most significant issues that commonly arise when conducting environmental due diligence and allocating environmental risk in connection with M&A transactions in the mining industry.

Jan 1, 2008

By William M. PhD. Schafer

The net acid generation (NAG) pH method is an important analytical tool that supplements static and kinetic tests for assessment of the acid generation risk of rock samples. This method is useful because it is simple, rapid and cost-effective; it combines features of the static and kinetic tests; and it can be conducted at mine assay labs. The NAG pH test is particularly effective for operational testing programs used to classify, selectively handle, and route potentially acid-generating waste rock. The NAG pH procedure is based on a 24 hour oxidation of a pulverized rock sample with hydrogen peroxide and subsequent measurement of the sample's pH. If the NAG pH is below a critical value, determined empirically, then the sample has the potential to generate acid in the field. The critical NAG pH value is typically within the range of 3 to 4.5, but the exact relationship between NAG pH and potential acid generation should be determined individually for each mine site, based on comparison with results of acid base accounting, humidity cell tests, and mineralogical analyses. Calibration and use of the NAG test for predicting ARD risk at several mines are described in this paper.

Jan 1, 2000

By Thomas E. Shufflebarger

Glass sand is a virtually pure, fine- to medium-grained, quartz sand. It is produced in 25 states from a variety of chemically different source rocks. Deriving their raw material largely from either friable sandstones or loosely consolidated sands, 59 operations produced 14.9 million tons of melting sand in 1976. About one-third of this tonnage was obtained from the Oriskany and St. Peter Sandstones. Glass-sand prospects are discussed in this paper with regard to chemistry, environment, transportation, and costs. Demand for a quality product will range from 36 million to 46 million short tons in 1995.

Jan 1, 1978

By C. J. Roos

Ground-engaging tools are used to prevent damage to the main components of earth-moving equipment. These tools consist of everything from shovel teeth to replaceable drill bits to dozer wear plates. The costs of these "consumable" items are increasing with the costs of raw materials. This project developed a tool to be used by Newmont Mining Corp. to predict the consumption of excavator teeth at a particular mine site. This paper presents the results of the Montana Tech research project in which an equation was developed to predict excavator teeth consumption based on production rates and rock properties.

Jan 1, 2010