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By G. C. Smith

Process control applications in the minerals processing industry have grown extensively over the years due to the many benefits derived, both financially and operation-wise. Although control theory is widely known, conventional control does not address many of the problems posed by minerals processing circuits. Some of these problems include interactions between process units, large dead times, few and sometimes unreliable measurements of process variables, non-linear systems, disturbances entering the process, processes with varying dynamics, and many more. For the past 26 years Mintek has been active in the field of providing specific, customized solutions for the minerals processing industry. This paper focuses specifically on applications in milling and flotation control. The underlying control principles have been applied to a wide range of other processes including submerged arc furnaces. Advanced control application is implemented on a common advanced control platform, called the PlantStar. Much innovation has been brought to the fore in terms of adapting theoretical techniques and developing new methods to resolve specific milling and flotation circuit issues by using process control. The general approach adopted by Mintek when implementing advanced control is to enforce stabilization of the process as a solid foundation for optimization strategies to be built upon. In doing this, a robust control solution is presented, and the end result is flow and level stability, better product quality regulation, increase in throughput and a stable feed to downstream processes. The MillStar advanced milling control system ensures that the milling circuit is at all times easy to operate while achieving optimum product quality and throughput. Stabilization should include product size regulation and sump level control. Another important aspect of stabilization control is the handling of milling circuit constraints without introducing cyclical behaviour and with minimal disturbance to the final product quality. Process constraints may include factors such as process water limitations, cyclone feed density, and cyclone underflow angle. An optimization strategy should be developed to increase the mill throughput without affecting product quality or introducing mill overloads. The relationship between solids feed and power draw is examined and manipulated for optimization. The interactive nature of flotation circuits and the presence of recirculating streams tend to make satisfactory control almost impossible with conventional techniques such as PI (Proportional plus Integral) or PID (Proportional, Integral and Derivative) control. The FloatStar Level Stabilizer simultaneously considers all the flotation levels in a circuit by use of a multivariable algorithm, and takes compensating action in anticipation of disturbances. The FloatStar Flow Optimizer is an optimization strategy that controls the concentrate flow rate between various sections of a flotation circuit (e.g. Rougher ?Cleaner; Cleaner ?Recleaner). By controlling the concentrate flow between the sections, the mass pull, circulating loads and residence times of the circuit can be stabilized, thereby enhancing the performance of the flotation process. Optimizing grade and recovery are coupled with the dynamic optimization of circulating flows. The FloatStar Grade-Recovery Optimizer will maximize the grade in a section, whilst ensuring that recovery or any other process specific limits remain within predefined limits. With successful applications on several milling and flotation plants worldwide processing amongst others PGMs, gold, copper and nickel, Mintek has shown that it is a leader in milling and flotation control innovation

Jan 1, 2004

By Ingo Ossenbühl, Wolfgang Dolsak, Vojtech Gall, Axel G. Nitschke

"Yielding support systems for application in underground construction have a long history, primarily in mining. Typical examples are tunnels subject to loading conditions that lead to overstressing of the newly installed support or existing tunnel structures in active fault zones. Recent applications for tunnel rehabilitation projects unveiled the capabilities and flexibility of combined yielding support systems presented in this paper. Frequently, the main requirements for tunnel rehabilitation applications are a fast, safe, and simple installation along with the need for flexibility with regards to existing tunnel geometries. A combined support system consisting of steel sets with yielding connections and special groutable hoses has proven to be an efficient support measure providing a multitude of advantages compared to conventional rehabilitation approaches. The presented yielding support system provides an immediate and active support, while it allows for controlled yielding upon experiencing loads beyond its support capacity. INTRODUCTION The excavation of underground spaces leads to redistribution in the existing stress regime. This load redistribution goes along with deformations in the surrounding rock mass. Magnitude and duration of these deformations depend on the tunnel’s depth and geological conditions, but also on the installed support system. Modern civil tunneling infrastructure has generally an envisioned service life of about 120 years. Conventional tunneling provides typically a dual support system, split into the initial (or primary) and final (or secondary) lining. A typical design principle in civil tunneling is to let the vast majority of deformations acting on the initial lining cease, before the final lining is installed. Based on this approach, the loading on the final lining is significantly reduced and signs of overstressing, such as cracking of the lining, are typically limited to the initial lining. However, special cases in swelling and squeezing ground require different approaches, including yielding support systems."

Jan 1, 2016

By A. G. Nitschke, I. Ossenbühl, W. Dolsak, J. Dase

"The authors have successfully developed an innovative rehabilitation concept, which meets actual technical standards and minimizes the impact on the operation of a key conveyor tunnel. A flexible and stepwise ground support rehabilitation program utilized a combination of yielding steel arch sections with grout filled fabric hoses, which represents a fast and safe backfilling support system. The system was developed and successfully installed at Bingham Canyon Mine, the world’s largest open pit copper mine, which also includes numerous underground structures. The mine is owned and operated by Kennecott Utah Copper (RTKC) a fully owned subsidiary of Rio Tinto. The system was implemented at a conveyance tunnel, which was originally designed as a railroad tunnel, but was re-commissioned and is currently used as a conveyor belt tunnel to transport ore from the open pit to processing facilities outside the mine. The existing structure showed signs of overstressing due to movements in the surrounding rock mass, which had to be addressed with a yielding support system in order to provide safe access into the tunnel. However, the impact on the conveyor belt operation due to support installation was to be limited to the bare minimum. Keywords: rehabilitation, yielding support, mining, stabilization, and grout filled fabric hose.PROJECT DESCRIPTION The C6 Tunnel is considered a critical asset for the operation of the Bingham Canyon mine as it comprises the standard route for transporting crushed ore from the open pit to the processing facility on a continuous conveyor belt system. The C6 tunnel was originally built as a railroad tunnel. Construction was completed in 1959. The original horse-shoe shaped cross section of the tunnel was 18 feet wide and 24-1/2 feet high [8]. The tunnel length was approximately 18,000 feet. During its service life, the railroad tunnel has undergone several transformations. The length of the tunnel towards the Bingham Canyon pit was shortened over the course of mining operations and the railroad tracks in the tunnel were removed. The invert was partially backfilled (3 feet typical) and a 72 inches belt conveyor was installed. Currently, the C6 Tunnel is nominally only approximately 21 feet high and 15,000 feet long. Ground Support and Rehabilitation Measures prior to 2014 The C6 tunnel was mined mainly with conventional mining methods, using drill & blast as the typical one. However, the weak geological sections, such as those encountered in the Fortuna fault, were excavated by shaping and chipping with machine-held moils [8]."

Jan 1, 2015

By J. W. Leonard

By using physical and chemical method to increase the bulk density of newly mined coal, the productivity of a mine can be significantly increased. Greater amounts of coal can be placed in fixed volume shuttle car by increasing bulk density. This can increase mine productivity by about 15%. Small, easy to achieve changes in mining operations are required to obtain the increased productivity. This article deals with chemical methods used to increase coal bulk density, the results and discussion are based on experiments performed in the laboratory.

Jan 1, 1992

By B. J. Schat, A. W. O. Bots, O. S. Langhorst

Amsterdam City Council is building a new metro line, the North–South Line. The line passes under Amsterdam Central Station (a listed building) about 18m below street level. The retaining wall that has to be built underneath the existing building is an innovative construction consisting of two rows of steel piles interspersed with a solid mass of overlapping jet grout columns: a composite ‘sandwich’ wall. This paper gives an overview of the approach taken to designing (computational models) and building the retaining wall. Special attention is paid to the observational method used for the construction of the jet grout columns.

Jan 1, 2007

By Tracy Brettmann, Will Bohlen

An innovative retaining wall design consisting of tangent drilled shafts with supplementary seal piles was used to limit continuing bank erosion along the Brazos River in Southeast Texas. The riverbank erosion had progressed to where it was threatening the stability of both the bridge abutment and corresponding approach embankment of the heavily travelled Highway 99 bridge at this location. A tangent pile design was selected because it was both much faster to install and more cost effective than a secant pile system. The design included both 5.5-ft and 10-ft diameter shafts with depths up to 130-ft and comprised both anchored and cantilevered sections. Supplementary seal shafts were also installed between the structural tangent drilled shafts to help plug any gaps between the tangent shafts. The plumbness and diameter of the shafts were tested using a sonic caliper to make sure the shafts were installed within the specified tolerance. The initial design had to be revised when a record flood from Hurricane Harvey impacted the site during construction. Introduction The Fort Bend Grand Parkway Toll Road Authority (Owner) needed to protect the north bridge abutment with a retaining wall system due to rapidly eroding conditions of the Brazos River banks within the 300- feet-right-of-way of the State Highway 99 Jodie Stavinoha Bridge. The extent of the local scour and erosion along the north bank of the Brazos River has caused concern for the structural integrity of the bridge. The magnitude of the erosion along the north bank at the location of the bridge has been measured at about 120 feet over three recent hydrologic flood events locally referred to as Memorial Day 2015, Memorial Day 2016, and Tax Day 2016. During construction, a new record flood level occurred due to Hurricane Harvey in August of 2017 that resulted in a portion of the retaining wall needing to be redesigned due to even more erosion occurring. The Brazos River is an actively eroding and meandering alluvial river plain that naturally meanders and migrates over time. The processes of bank erosion and meander migration were ongoing before the bridge was constructed and will continue in the future. These recurring major flood events, however, rapidly increased the rate of erosion in just a few years. Background. Due to the need to protect the bridge as soon as possible, the Owner selected a project team consisting of the designer, general contractor and specialty deep foundation contractor prior to final design to work together in developing a cost-effective design that could be implemented rapidly. The project team initially considered both a secant pile and tangent pile retaining wall system using drilled shafts. After reviewing various alternative designs, a tangent pile wall with seal piles was selected based on both cost effectiveness and speed of installation. The tangent pile with seal pile option was approximately 20 percent lower in cost and 50 percent faster to install.

Jan 1, 2018

By Renwick MT

Two innovative ground reinforcement products have been developed for use in the mining industry. One of these products is a high strength polyethylene (HOPE) bar for use as a rib bolt in underground coal mining and as a corrosion proof tendon in open pit mines. The other product is a cable bolt (Ultrastrand) which demonstrates enhanced load transfer and is available in continuous lengths. Ultrastrand's exceptional in- situ performance and versatility makes it ideal for mechanised installation in both underground and surface mining operations. Details of these products are presented and results from labortaory and field trials are discussed.

Jan 1, 1992

By Crystal Poon, Paul Matlashewski, John Morkeh, Kathryn Dorfschmidt, Jose Carvalho, Chad Williams

Rockfall hazards are ubiquitous in mining environments making their control critical for safe mining operations. The complex processes involved in rockfall events necessitate a probabilistic modeling approach with well-calibrated material properties. The controls designed to mitigate rockfall hazards need to be reliable, efficient, and safe to deploy to meet the constraints present at an active mine. This paper presents an innovative solution to rockfall at Rio Tinto’s Bingham Canyon Mine. The solution incorporates the site-specific calibration and creation of a predictive rockfall model with the design, field testing, implementation, and monitoring of the rockfall controls.

By Crystal Poon, Paul Matlashewski, John Morkeh, Kathryn Dorfschmidt, Jose Carvalho, Chad Williams

Rockfall hazards are ubiquitous in mining environments making their control critical for safe mining operations. The complex processes involved in rockfall events necessitate a probabilistic modeling approach with well-calibrated material properties. The controls designed to mitigate rockfall hazards need to be reliable, efficient, and safe to deploy to meet the constraints present at an active mine. This paper presents an innovative solution to rockfall at Rio Tinto’s Bingham Canyon Mine. The solution incorporates the site-specific calibration and creation of a predictive rockfall model with the design, field testing, implementation, and monitoring of the rockfall controls.

Improve underground mine roof bolt support systems by alleviating problems associated with certain ground support systems currently being used. Approach Convert a passive resin-grouted roof bolt system into a uniform, tensionable roof bolting system. Background Resin-grouted roof bolts are one of the most common forms of ground support in U.S. underground coal mines. These support systems can be installed with a full-column of grout and be loaded with subsequent roof movements after installation. This is called a "passive" support system. An alternative to the passive support system is the mechanically-anchored, tensioned roof bolt system. This system is installed with resin grout. This system is designed to load or tension the support during installation by using a mechanical anchor, coupling, or threaded nut after the resin has properly cured. It is called an "active" support system and is used extensively for improved strata control in a laminated geologic deposition or in difficult ground conditions. To ensure that active bolts have been properly installed, the bolt loads must be checked by using a torque wrench or other suitable equipment. Unfortunately, this practice presents potential safety hazards and has limited accuracy. Laboratory and field experiments also reveal that the torque-to-tension ratio developed on active support systems can vary by 50% from bolt-to-bolt. Variations in bolt load installations can induce stress concentrations and lead to roof degradation or failure.

Jan 1, 1991

By S. C. Tadolini

Roof support systems have evolved from standing posts and timbers to a generation termed ?big nails? where steel bars are inserted into boreholes and anchored with expansion shells and/or resin cartridges. These systems have been effective but are limited to mining height. Additionally, the properties of steel do not resists shear forces or have the flexibility being required in difficult ground conditions. The next generation of roof support systems is coupling the best parts of the ?big nail? and resin grouted cable bolt systems. This paper will present the advanced technical solutions of the next generation of cable systems that includes an indented high-capacity PC-strand used with a variety of fixtures. Case histories of support applications will be presented.

Jan 1, 2012

By Thomas M. Barczak

With the development of the shield support, the primary requirement for successful ground control in longwall mining is to provide stable gate road and bleeder entries. Wood cribbing has been the dominant form of secondary support. However, the cost and limited availability of timber, along with the poor performance of softwood crib supports, has forced western U.S. mines to explore the utilization of other support systems. The recent success of cable bolts has engendered much interest from western operators. Several innovative freestanding support systems have been developed recently including: (1) "The Can"' support by Burrell Mining Products International, Inc., (2) Hercules and Link-N-Lock wood cribs and Propsetter by Strata Products (USA) Inc., (3) Variable Yielding Crib and Power Crib supports by Mountainland Support Systems, (4) the Confined Core Crib developed by Southern Utah Fuels Corporation; and (5) the MEGA prop by MBK Hydraulik. This paper assesses design considerations and compares the performance and application of these alternative secondary support systems.

Jan 1, 1996

By Ryan Sullivan, Lisa Smiley, Jewels Stover

The Westerly Storage Tunnel (WST) Project is part of Project Clean lake, the North East Ohio Regional Sewer Dist years. When completed in 2020, WST will be nearly 2 miles of 25-ft diameter tunnel 200-250 ft below ground. The storage tunnel will manage higher flow volumes, keeping stormwater out of the combined sewer system reducing overflow occurrences. Three deep shafts provide access to the tunnel at the tunnel boring machine (TBM) launch and retrieval sites, as well as a vent shaft. Support of excavation for the access shafts was constructed utilizing unreinforced concrete diaphragm walls. This innovative, value-engineered alternate design significantly reduced risks associated with conventional secant piles combined with a rib and liner plate system. Implementation of the diaphragm wall technology resulted in a water tight, continuous shaft keyed into rock. This case study examines the design, methodology, and installation challenges unique to each shaft, as well as the benefits of the final product to the overall project.

By T. Lux, H. -J. Krassnig, I. Filzwieser, E. Hecker, R. Degel, A. Filzwieser

Non-ferrous metals find their applications in smartphones, tablets and computers. These materials with their particular properties are the basis of our modern life. SMS group is well prepared for this huge market and for growing future challenges. A large contribution here is the new joint venture PolyMet Solutions that was founded by SMS group and Mettop, an Austrian engineering company, with the objective to develop new technical solutions for the primary copper production lines as well as for non-ferrous metals starting with the primary smelting of concentrate and ending with the electrolysis. PolyMet Solutions provides the process know-how whereas SMS group supplies the plants and equipment and Mettop the key components. SMS group and Mettop also cooperate in the field of tankhouse technology. Together with Montanwerke Brixlegg AG, Mettop has developed together with a parallel flow technology (METTOP-BRX Technology), allowing a current efficiency of above 98 % at a current density of 420 A/m², which is a milestone in copper electrolysis. For the secondary copper production route, SMS group and PolyMet Solutions developed an innovative refining furnace (PolyRefine) for the smelting and refining of copper scrap. The refined copper is directly charged to the Contirod line to produce copper rods and wires. The innovative cooling solutions of SMS and PolyMet Solutions come into play where furnaces have to stand the highest loads and stresses, for instance in areas of very high temperatures or temperature fluctuations, aggressive exhaust gases and slags, or at critical spots such as taphole areas. Custom-tailored cooling systems for furnace vessels make sure varying loads are compensated in a targeted and effective manner. The solutions include air cooling, spray cooling, cooling technologies with integrated copper elements such as CFM (Composite Furnace Modular) cooling systems, plate and finger coolers. The major innovation in the field of furnace cooling is the ILTEC (Ionic Liquid Cooling) Technology which paves the way for increased plant safety. This revolutionary, patented cooling technology is jointly marketed by Mettop and SMS group. It permits water-free cooling to be implemented and thus makes operation safe wherever it is applied. INTRODUCTION Non-ferrous metals or NF metals are changing the world. There is no modern industrial sector that can do without these valuable metals. Non-ferrous metals find their applications in smartphones, tablets and computers. These materials with their particular properties are the basis of our modern life. The importance of the non-ferrous metals market is reflected by two figures. In 2018, the production of non-ferrous metals was worth more than 237 billion Euros. This contrasts with 255 billion Euros of the value of iron and ferro- alloy production in the same year (International Organizing Comittee for the World Mining Congresses, 2018). Hence, the NF metal industry is almost as important as the iron and steel industry. SMS group is well prepared for this huge market and for growing future challenges. A large contribution here is the new joint venture PolyMet Solutions that was founded by SMS group and Mettop, an Austrian engineering company, with the objective to develop new technical solutions and to enhance customer value. The prices of nearly all metals have come under pressure during the past few years. Therefore, competitive technologies are regarded a crucial factor to achieve success in this critical market situation respectively to stabilize the market position.

Jan 1, 2019

By R. P. Sloan, A. S. Whitford

In November 1999, CCI's Empire Iron Mining Partnership and MinnovEX Technologies Inc. developed an expert system for advanced control of their Empire IV Grinding Section. Empire IV is comprised of three autogenous Primary Mills and six autogenous Pebble Mills, with a single Pebble Crusher and high pressure Roll Press. The challenges of controlling and optimizing three distinct grinding lines that are inter-woven by a pebble crushing circuit were met with innovative and unique solutions. This paper will detail the approach employed at Empire and will focus on the aspects that make this application unique.

Jan 1, 2001

By Matthew C. Janes, Mark C. Spence

"A former coal gasification site next to Rock Bay in Victoria, BC, Canada required a barrier to permit dewatering and excavation of the bay and surrounding property. The adjacent property owners had stringent requirements at the boundaries of their properties. Isherwood Geostructural Engineers designed a temporary steel sheet pile (SSP) water retention structure and excavation shoring system along the perimeter of the site. The project involved challenging geotechnical conditions in soft clay soils and a multi-faceted construction staging plan involving the diversion of two large storm water outfalls that drained into the bay. Despite a well-conceived design and construction plan, unexpected site conditions and delays led to significant changes in design and construction approach. Employment of the Observational Method and on-the-fly geotechnical investigation were instrumental in maintaining project momentum and schedule. The paper presents the geotechnical and geostructural design details and construction events as they transpired, highlighting the key issues, discussions and lessons learned.INTRODUCTIONFor over 100 years, the Rock Bay Site, in Victoria, British Columbia, Canada, had a legacy of contamination left behind from previous industrial activities. The site was the former location of a coal gasification plant that was in operation from 1862 to 1952. The site was also an infilling location for a nearby tannery and sawmill. The remediation of the Rock Bay Site involved the excavation and replacement of approximately 300,000 tonnes of contaminated soils on Transport Canada’s property. The project commenced in 2004 and has occurred over several phases on multiple properties. In the third and final phase of the project, a temporary steel sheet pile (SSP) excavation shoring system and ocean barrier wall – required to seal off the bay – was employed to enable disposal and replacement of approximately 90,000 tonnes of contaminated soils from the shoreline and base of the bay."

Jan 1, 2016

By Michael J. Brnich

During the past 15 years the number of reportable mine fires has declined. A decline in the number of reportable fires is a gross indicator that allows experts to say something about the underground coal industry generally: There has been some improvement in overall mine fire preparedness. However, such an indicator is less reliable as a predictor of readiness at any particular operation. An indication of fire fighting preparedness would have to be assessed from evidence gathered at the mine site. In other words, there are two levels from which to view the problem. On a general level, there has been significant improvement in the industry's fire response capabilities over the past two decades. Specifically, however, little data has been gathered on a site-by-site basis to determine what improvements might be made on a local level. These improvements would move beyond regulatory compliance. It is expected that this manuscript, based on work conducted at an underground coal mine in the western United States, will help to focus attention on some central concerns involving this critical issue.

Jan 1, 2006

By Karel Rössler, Petr Vítek

"The Ejpovice tunnels in Czech Republic were built by EPBM in soft Clyashale, and in weathered profile with low soil overburden. The segmented liner at the cross-passage openings required support, which would not interfere with the EPBM clearance envelope during the scheduled pull back of the EPBM through both tunnel tubes. For that reason support frames or radial bolting could not be used. Steel rods inserted into the neighboring segments during the ring assembly, and later grouted were tested and realized as an innovative solution. The paper presents practical experience gained with the segmented liner support during cross-passages construction. INTRODUCTION An innovative solution using the grouted dowels was developed and realized for sixteen cross-passage openings of the twin Ejpovice Tunnels, whose construction was part of the railway track Rokycany – Plzen modernization. The following paper described practical experience gained with the innovative support of cross-passage openings, which was realized by short steel dowels grouted within the segments of the EPBM segmented liner. The paper is a continuation of the paper published in WTC 2015, which described the design aspects of the grouted dowels support, while the following paper concentrated on the production, and the performance of the dowel support observed during the breakout for the cross-passages openings. The connection by grouted dowels was patented by Metrostav, a.s. Company THE EJPOVICE TUNNELS CONSTRUCTION The Ejpovice tunnels construction started in 2013. The start of the high speed train operation through the tunnels was planned for 2018. The project was funded by the state government with the support of European Union funds of up to 70%.The tunnels were excavated with one EPBM (Earth Pressure Balanced Machine) with the external diameter of 9.89 m. The segmental liner inner diameter was 8.7 m, and thickness of 0.4 m. First, the South tunnel tube was excavated from the East portal, then the EPBM was pulled back through the South tunnel, and the excavation was started from the same portal for the North tube. After the South tube was freed from the EPBM excavation operations the cross-passage construction started. Due to the short time schedule, in the North tube the cross-passage construction started while the tunnel was still under construction. Therefore, the cross-passage construction was performed concurrently with the segments transportation, and with the EPBM pull-back through the tunnel. There were 8 cross-passages along the tunnels with a maximum distance of about 500 m, Fig.1."

Jan 1, 2016

By Jerry Rowe

There are numerous examples of historic and recent mines that have no closure system or have poorly designed closure systems. These mines may contaminate water resources, land resources and cause significant impacts to human health and the environment. As a result of these problems, many regulatory agencies around the world require that mine closure systems be implemented to manage ARD and protect water resources. In this sense, the paper discusses some of the key elements that need to be evaluated when selecting a mine closure system. These include the specific site climatic, hydrogeologic, hydrologic and geochemical conditions that must be considered for closure design. Two examples of innovative mine closure systems that have been implemented to take advantage of site specific conditions to effectively manage water are provided. The mine closure systems incorporate passive measures to control ARD (acid rock drainage) and protect water resources.

Sep 21, 2013

By A K. Bayer

When the human eye fails in the evaluation of quality parameters in the extraction of minerals the use of laser-induced fluorescence analysis (LIF) can supply more detailed information on the composition of rocks. On the basis of measurements of selected raw materials engineering concepts for the use of this method in the mining industry as an innovative system for horizon control of mining machines will be described and the most important analysis parameters, influencing factors and interference variables are presented.

Jan 1, 2003