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By Lloyd Buckingham

Barrick Gold Corporation (Barrick) has undertaken innovative methods of evaluating and improving the performance of grinding mills in several of its operations around the world. The results have been positive with some of the mines showing more than 20% net energy improvement leading to more than 43,000 tonnes per year reduction in CO2 emissions in four of the operations reviewed.

Jan 1, 2012

By M. Saghaeian, R. Hejazi, M. Mohammadinejad, M. Zare

"Water quality and quantity at the Tailing Thickening Section of processing plants is considered to be a crucial factor and impacts the performance of several sections. Therefore, gaining stable and effective performance at the Tailing Thickener Section is one of the principal goals of minerals processing plants. Different factors such as: qualitative and quantitative sustainability of plant feed, the balance between the mass of input and output water flow, the dissolving method and distribution of flocculant and the amount of dirt, solid percent of thickener inlet pulp, affect the performance of Tailing Thickener. The present study investigates the successful improvement of Tailing Thickener performance at Jalal Abad Hematite Iron Ore Concentrate plant through optimizing the above operational parameters. For this purpose, the following optimizations have been done: homogeneity and sustainability of plant input feed rates, fine pulp removal collected by the bag filters at the input of the thickener, adding an quietness box before moving the tail pulp into the thickener to reduce the pulp turbulence, replacing flocculant pump and injection pipes, improving water mass balance which leads to optimizing and stabilizing the concentration of input tail pulp into the thickener, adding a mixer to increase the flocculant preparation time, increasing the locations for adding flocculant to thickener from 1 point to 6 points. Applying the above modifications and monitoring the Tailing Thickener performance over the course of months, has led to the improvement of recovered water quality from 500 ppm to 200 ppm, increasing the solid underflow of the thickener from 40% to 48.5%, and similarly, reducing water loss by 60%. Of other important effects, due to improvement of water quality, grade of final concentrate 0.5% increased and because of 73% increase in monthly working hour, concentrate tonnage 55% increased. Finally, sludge thickener optimization has had a significant effect in selecting and designing the dewatering system from the underflow of the sludge thickener."

Jan 1, 2018

By B. Orberger, J. M. Milazzo, S. B. Blancher, J. Lützenkirchen, J. L. Dubos

"Industrial dusts are commonly agglomerated using empirical recipes with binders such as bentonite, while Sludges are agglomerated into mixes. Those materials contaminate the products, are expensive and generate significant amounts of slag. Achieving cold dust agglomeration with little or no binder requires understanding the controlling parameters in order to predict and optimize the process behavior. This in turn necessitates comprehensive dust characterization to base predictions on measurable characteristics. In the present work we collected 13 Mn-rich dusts over all the process chain: feed fines, smelting, and refining dusts, as well as ferromanganese alloy dust. This is the first systematic study of dusts along the Mn-processing chain for chemical, physical and mineralogical parameters. X-Ray Diffraction, Qemscan® and laser granulometry analyses show that the mineralogy, Particle Size Distribution (PSD) and morphology evolves from complex heterogenous to simple, homogenous along the process chain: The mineralogy of the primary ore dusts shows various hydroxides, oxides, carbonates, tectosilicates and phyllosilicates. The furnace dusts contain oxides, tectosilicates and carbonates with volatiles, while the refining dusts present only oxides and metal. Finally, the Metal dust is nearly pure metal. Particle morphologies and PSD vary from jagged, irregular particles with broad PSD (>1 mm to <0.3 µm) to smooth and spherical with narrow PSD (100 µm to <0.3 µm). The Metal dust is an exception with angular particles. The Cationic Exchange Capacities (CECs) of all samples range from 0 to 22 meq/100g. Specific surface areas (SSAs) range from <0.1 to 27m²/g, and seem to decrease with from ore feed to Metal dust. This may be due to the disappearance of hydrated and/or sheet-bearing minerals, since a smaller grain size usually implies an increased SSA. The zeta potential varies strongly over the range of the samples tested. However, beside the Gabon ore which has an Isoelectric Point (IEP) ~ 4.1, the other IEP ranges between 2 and 2.5."

Jan 1, 2018

By T Schrimpf, I Bryan

The life cycle of a mining project begins with initial regional exploration and ends with mine closure and rehabilitation. Between resource definition and the commencement of mine construction is the study phase. In this phase technical concepts and processes are defined, evaluated and assessed with the aim of establishing whether the deposit is economically feasible. The study phase usually involves various steps from a concept/scoping study to prefeasibility and ultimately definitive feasibility study. The complete study phase can take several years. Although the costs for studies are low in comparison to actual construction and operating costs of a mining project, they are significant especially for junior exploration and mining companies advancing projects to the point of being funded.The studies aim to determine selected parameters for the project, eg mining and processing methods, operating strategy, etc and provide a roadmap for project development ahead. Although mining studies are of the utmost importance for the mining project and the project owner, they are usually carried out using a conventional engineering approach: the consultant or design engineer works to a defined scope of work. The resulting design might be based on good engineering, but might often also fail to provide the solution for the project owner that delivers the best shareholder value. An alternative to this more traditional approach to project evaluation is what we have termed a value engineering approach. Value engineering is a creative, organised effort, which in the case of a mining study analyses the requirements of the study for the purpose of achieving the essential outcomes with the highest shareholder value. The outcome of a study is a concept that delivers the highest achievable value of the resource project and shows the way ahead to realise this value. Through a group investigation by experienced, multi-disciplinary teams the value of the resource is improved through the study of alternative options, methods and processes. The scope of the study is not limited to a narrowly defined engineering scope, but to the creation of value.The study commences with the identification of key value drivers and risks, based on the available information (drill data, geotechnical data, metallurgical test work, etc). This enables the quantification of key uncertainties, risks and value adding opportunities. Study efforts concentrate on key value drivers and are not unnecessarily spent on side issues. This approach can significantly reduce the time frame and costs for the study phase.This paper describes in more detail RMDSTEMÆs value engineering approach to mining studies and illustrates it with examples and case studies.CITATION:Schrimpf, T and Bryan, I, 2012. The application of value engineering principles to mining studies, in Proceedings Project Evaluation 2012 , pp 163-170 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 24, 2012

By H. Memarian

In the last few decades, many developing countries have tried to expand and improve upon higher education, which is acknowledged to be the leading factor for development. In this respect, develiping countries have significantly increased the number of tertiary institutions and their students. These rapid expansions, along with all the benefits, have drawbacks as well. An example is the status of mining engineering education in Iran. Presently, the number of active mining engineering departments in Iran (27) is more than the sum of similar departments in Canada, Australia, the United Kingdom, and South Africa (23 altogether). Also, the number of annual mining graduates in Iran (645) is more than the cumulative graduates of the United States, Canada, the United Kingdom, and Australia (613). The expansion of mining engineering education in Iran has coincided with the closing or merging of similar mining departments, as well as a decline in the number of interested students in the industrialized world. The present study shows that the need for development and the excessive number of high school graduates, resulting from high population growth in the early 1980s, are the two primary factors influencing the significant expansion of mining engineering education in Iran.

Jan 1, 2007

By Z. Zhiqun, V. A. Marple, B. Y. H. Liu

"IntroductionIt is commonly understood that aerosol particles may be injurious to human health if they are of a size that enables them to enter the respiratory tract. Coal Workers' Pneumoconiosis (CWP) is one disease known to be caused by coal mining related particles.The location in the respiratory tract where the particles are deposited is primarily a function of the equivalent aerodynamic diameter (EAD) of the particle. The equivalent aerodynamic diameter is the diameter of a spherical particle with a density of 1.0 gm/cm3 with the same falling speed as the particle in question. For a spherical particle the calculation is rather simple in that the equivalent aerodynamic diameter is simply the diameter of the particle in question multiplied by the square root of the density of the particle. For irregularly shaped particles, such as coal particles, there is no simple way to make the EAD calculation. For example, Figure 1 is only one of an infinite variety of particle shapes that can be found in practice and the aerodynamic size of this particle and, therefore, its deposition location in the respiratory tract would be nearly impos-sible to estimate accurately.The normal method for determining the aerodynamic diameter of particles has been to experimentally measure the size of the particles in a settling chamber or with an inertial classifier such as an impactor, cyclone or a centrifuge, since inertial classifiers have the property of classifying the particles according to their aerodynamic diameters."") However, these devices can only give limited information on the EAD of a single particle with a specific shape. Impactors and cyclones, for example, collect particles in size ranges and not at a specific size, so the determination of the EAD of a specific particle is not possible. A centrifuge, on the other hand, can measure the EAD of a specific particle but the equipment is costly and procedure laborious, and it may not be possible to disperse a particle of a specific shape into the centrifuge. The centrifuge can be used to determine the EAD of clusters of spheres in various arrays, but introducing particles of a specific irregular shape may not be feasible. Furthermore, the EAD is a function of the orientation of an irregularly shaped particle and the orientation of a particle in an inertial classifier is unknown. The orientation may also vary as the particle passes through the classifier.Because of the difficulty in determining the EAD of an irregularly shaped particle, we have undertaken a program to apply theoretical numerical methods to calculate the EAD of any shape particle. In our laboratory we have, for some time, been using numerical methods to determine the flow field of air within instruments such as impactors, (2) inlets, (3) and virtual impactors (4) Recently, this technique has been expanded into the three-dimensional regime, and the flow fields and particle motion characteristics within cyclones (5) and glove boxes have been studied. We have now begun to use these numerical three-dimensional flow programs to study the flow field around irregularly shaped particles to determine their drag coefficients, falling speed, and thus, their EAD."

Mar 1, 1989

By I. Yelkin, Erico Tabosa, Alex Jankovic, R. Hayashida, R. Faveere

"The mining industry faces growing challenges from more complex and lower grade deposits, rising costs, limited energy and water availability, and increasing societal pressure to operate more sustainably. Mining operations need to be more efficient, not just to reduce environmental impact, but also to remain economically viable.To maximize profitability and sustainability, existing operations and new projects must consider integration and optimization of all stages of production. A mining operation is essentially a series of inter-connected processes, with the performance and outputs of each stage affecting the subsequent ones. Optimizing stages in isolation can result in sub-optimal overall performance.The industry has long recognized the benefits of holistic optimization using the Mine-to-Mill concept, and there are many well documented successes. However, it is increasingly common to observe operations simply increasing explosive consumption in the mine and expecting optimization of the entire value chain (mining and processing). For true holistic optimization, blast intensity is not necessarily increased, but rather adjusted to best suit the requirements of the different types of ores treated, the circuit configuration and equipment, installed comminution power and the downstream beneficiation processes. It is a fully integrated effort with optimization of many aspects in the mine, comminution and separation processes.To be successful, optimization of the production chain from mine to process requires a site-specific, structured methodology supported by extensive ore characterization, auditing, surveys, data analysis, mathematical modelling simulations and a cost / benefit analysis. Following this methodology, optimization strategies are rapidly identified and implemented considering mine and plant constraints. Management needs to set up appropriate KPIs and site personnel need to be trained for the new operating strategies to be successfully incorporated into site practices and procedures in the production environment. This will ensure the benefits are achieved and maintained. This paper describes the methodology employed by Hatch to improve overall efficiency and profitability from mine to process. Two case study examples at Russian gold operations and benefits achieved are presented."

Jan 1, 2018

By Harry E. Krumlauf

The year 1957 was one of declining metal price and production. Many lead-zinc-copper mines were forced to close, and the remaining mines limited production to stay more in line with demand. High cost of labor, supplies, and equipment and high taxes aggravated the situation. Some operators postponed or abandoned expansion programs because of uncertain economic conditions. Output was curtailed by elimination of over- time employment and reduction of the working force. The number of employes laid off was small- reduction in the labor force was accomplished by not replacing those who left a company&apos;s employ.

Jan 2, 1958

By L. Harris

Los finos de coque son materiales que se producen en toda planta de gas y coque y que no pueden ser usados directamente en los hornos metalúrgicos debido que sus propiedades físicas y quimicas ison ndeseables. En este sentido, los finos de coque se producen en altos hornos de fierro y plomo, donde una capa de carbón sin aglomerar y parcialmente coquificado, permanece en la parte superior de la carga y es durante esta descarga que se separa del coque grueso. Sin embargo, el coque descargado es muy grande para el horno y debe reducirse a un tamaño pequeño. Por tanto, el texto señala que para que el coque llegue a los hornos debe contener más de 20% de finos y en el caso de los hornos de plomo, es necesario que se separe de los finos debido a que puede generar un sofocamiento en el rendimiento de los hornos. Así también, describe la operación de la planta de coque en La Oroya, como las características deseadas del coque.

Nov 20, 1967

By D. J. Hains

IN this paper we shall examine the Why, Where and How concerning the agglomeration of iron ores and concentrates. Fig. l answers the questions @f why there is so much interest at the present time in the art of agglomeration. The use of sinter or pellets in the blast furnace has materially increased their rated •capacity. ':'President Hains Company Ltd. Engineering J. S. McMahon ( 1) reports an increase from 653 tons of .pig iron per day to 1140 tons of pig iron per day with the use of a 100 per cent sinter burden on one of his blast furnaces. In the United States the use of 100 per cent pellets has increased pig iron production from approximately 1800 tons per day to over 3000 tons pig iron per day (2). In our economic system the general objective is to produce more and better commodities cheaper. Fig. 2 shows the decrease in coke consumption with increased tonnages from the furnaces when using -

Jan 1, 1961

By Clement K. Chase

Since the dam of cyanidation leaching techniques for precious metals, certain manganese-bearing silver ores have been a problem due to low silver extractions. Since simultaneous occurrence of silver and manganese is common in nature, this situation has made many otherwise attractive silver deposits uneconomic in the past. Several older techniques have been useful but at $1.29 per ounce of silver, the economics were unfavorable. With the new look in silver prices and some improvements in processing technology, neglected silver districts offer new promise.

Jan 1, 1981

By Kenneth W. Luke

In the development of the ultimate pit limits for a narrow ore body, pa¬rameters necessary in the design of a functional, or working, pit become highly sensitive factors in the determination of ore reserve levels and their associated waste to ore stripping ratios. Through the use of geologic cross sections, ore reserves can be roughly calculated by utilizing a straight line approximation for pit wall slopes. The optimum position of the pit floor can be substantially altered from such a preliminary design though with the introduction of functional mining parameters, such as a ramping network, and working bench heights, berm widths, and bench to bench wall angles. Originally a computer program was developed to quickly evaluate changes in cross-section pit design with minimal alteration of input data. After developing a satisfactory technique of cross-section evaluation which incorporates working mine parameters, an optimization algorithm, or procedure, was developed and included in the program to eliminate much of the tedious manual decision-making required in determining the optimum location of the pit floor on each cross section. Optimization in this case implies the maximum profit pit. When pit and processing costs are defined or hypothesized, this computer program can be used to design the maximum profit pit, constrained by the recognized functional mining parameters. A second way of stating the optimization is that the program can be used to develop a pit design which minimizes waste stripping at any desired ore reserve level. The basic method of cross-section evaluation parallels present manual methods. Program input is a combination of data obtained directly from cross sections developed for, geological interpretation and pit design parameters selected by the mine planner. As a result it is easy for the mine planner to comprehend what the program is accomplishing, and thus participate in the development of the computer assisted design.

Jan 1, 1971

By E. M. Murphy

(Presented by invitation at a meeting of the Spokane Local Section of the Institute, Feb. 17, 1912.) EIGHT years ago the Hecla mine, a lead-silver producer, situated at Burke, Idaho, was producing ore from but two levels, the 300- and the 600-ft. All hoisting was done with a 12- by 16-in. slide-valve, double-reel, hoist. The hoist was being worked to its capacity and was unsuitable for hoisting from greater depths. As the work of opening a new level was about to be started, it became necessary to remodel the then-existing equipment or install a new hoist. The recent advent of electricity from Spokane had made available a cheaper power than steam. By a series of tests conducted throughout the Coeur d&apos;Alène district, it was found that it cost $109 per year to generate a horse-power with steam. Electric power was to be had for $50 a horse-power per year. It was decided to substitute for the engines a motor-drive, of sufficient capacity to operate from the 900-ft. level, and ultimately install an entirely new hoist. After disconnecting the engines, installing a new shaft, and making a few minor changes, a 300-h-p., 2,300-volt, 514-rev. per min., variable-speed motor of the induction type was geared to the reel-shaft. The reels were supplied with 3/8 by 4-in. flat rope, and the duty of the hoist was about as follows: Cage, 1,700; ore, 2,600; car, 1,400; rope, 2,250; total, 7,950 pounds. The Bristol ammeter chart, Fig. 1, shows the combined current-consumption of the hoist- and mine-motors. The large intermittent load is clearly shown ; this produced harmful fluctuations in the voltage of the long, lightly-loaded, 60,000-volt transmission-line from Spokane to the Coeur d&apos;Alènes. The power company received no compensation for the increased cost of producing power for this intermittent or fluctuating load. In order to protect its system from similar excessive

Sep 1, 1912

By Donald H. McLaughlin

ZEST in the search for new supplies of metallic ores and petroleum is difficult to maintain with stocks of raw materials accumulating and with over- production rightly or wrongly blamed for most of our industrial troubles. Enthusiasm over new methods of prospecting has consequently diminished and exploration programs in many fields have been drastically cur- tailed. Very naturally the effects have been felt with particular keeness in highly specialized phases of the work, such as geophysical prospecting, for the feverish scramble for new areas in which to drill beneath magnetic or electrical anomalies has abated, and there is even a lull in the firing in the battle over salt domes on the Gulf Coast. It is unquestionably an unhappy time for many of the organizations dependent on this work, but in certain respects the situation may be beneficial in correcting unsound practices that .have grown up through the necessity for haste and for quick decisions. With the restriction of the field to the more competent workers by the harsh rule of survival of the fittest, a general improvement, not only in technique but in business methods, can be expected which may go far in restoring public confidence. Geophysical prospecting in the short period that it has been utilized in North America, has suffered severely both from over-popularity and from excessive abuse. The former evil now

Jan 1, 1931

By M. B. C. Brandt

Richter magnitudes for seismic events were calibrated for use as a Local magnitude scale in the West Rand (WR), Far West Rand (FWR), and Klerksdorp–Orkney–Stilfontein–Hartebeesfontein (KOSH) gold mining areas. Richter magnitudes are currently calculated from seismograms recorded by local surface cluster networks using tabulated calibration values for Southern California, published in 1958. The Richter (1958) model is incorrect for distances of less than 30 km and should be applied only to crustal earthquakes in regions with similar attenuation properties to those of Southern California. When compared to the South African National Seismograph Network (SANSN), the cluster networks, on average, overestimate seismic event magnitudes by approximately 0.1 of a magnitude unit. A calibrated Local magnitude scale was derived by means of a multiple regression analysis between the Local magnitudes reported by the SANSN and the largest zero-to-peak trace amplitudes measured on the cluster network horizontal seismograms, after modelling the attenuation of the seismic waves as these progress from the epicentre to the station position. Magnitudes reported by individual stations for the same event show a significant scatter around the average magnitude owing to the near-surface amplifications of the seismic waves at the recordings sites. Average magnitude should be estimated using as many magnitudes of individual stations as possible to ensure an accurate estimate. Larger event magnitudes should be compared with those recorded by the SANSN.

Nov 1, 2021

By S Whitton, W Wimmler, L Wimmler

“Given the increasing scrutiny of the mining industry and its relatively poor record with regards to mine tailings management, increased requirements to minimise water usage (often accompanied by very high costs of water) and the need to demonstrate achievable long-term closure strategies, it is likely that the option of a filtered tailings system will need to be considered in many operations in future.” (Australian Centre for Geomechanics, 2018). Given such a statement as a conference introduction, it is only appropriate that a range of potential technologies are investigated and compared, to create awareness for even underrated but appropriate technologies. The advantages and disadvantages of all technologies need to be considered and analysed. Suppliers are swift to promote their technologies advantages; however aspects of sustainability are not always fully understood. Perhaps a combination of two filtration technologies is appropriate. This paper delves into the technical details, good or bad, of four mechanical dewatering technologies in tailings dewatering and provides insight on an undervalued and, in the author’s opinion, young technology – the screw press.

Jul 1, 2021

By C. Bester, G. M. Rohde

A major challenge in the mining sector is the responsible management and efficient storage of mine residue. Over recent years numerous tailings dams have experienced unintended spills and failures, with severe consequences for the mining industry, the environment, local communities, and the regional economy. The fourth industrial revolution (4IR) is impacting society due to increased interconnectivity, processing speed, and automated technologies. This paper explores whether 4IR technologies have the potential to mitigate risks associated with tailings dams. Experts in the field of tailings dam operational management were surveyed to determine their view on the risks associated with tailings dams and the potential of 4IR technologies to mitigate these risks. The survey found that a majority of experts believe that certain 4IR technologies have the potential to reduce the risks associated with tailings dam failures.

May 27, 2025

By Megan Badonie, Devlon Shaver, Evan J. Owen, Virginia T. McLemore, Jakob Newcomer

Critical minerals are becoming more important in our technological society because they are used in many of our electronic devices, batteries, and magnets. In New Mexico, low to moderate concentrations of critical minerals are found in Late Cretaceous coal and related strata in the San Juan and Raton Basins. These rocks are being characterized as part of the DOE’s CORE-CM (Carbon Ore, REE, and Critical Minerals) program. The New Mexico coal, humate, and clinker deposits are relatively low in REE (<325 ppm TREE), Li (<90 ppm), V (<168 ppm), Co (<51 ppm), Ni (<108 ppm), Zr (<557 ppm), and many other critical minerals compared to normal economic deposits. Some of these rocks are enriched in Al2O3 (<40%) and Sr (<3740 ppm), both critical minerals. Common minerals hosting the critical minerals in these rocks include clay minerals, zircon, and rutile/anatase. As the demand for some of these elements increases because of increased need and short supplies, the dollar value per ton of ore rises, enhancing deposit economics. Ultimately, economic potential will most likely depend upon production of more than one commodity, maybe even from coal, humate, and clinker deposits.

Feb 1, 2024

By Ernesto Furtado de Mello Neto, Eliezer Thuler, Claudio Vano Nunes, Carlos Alberto Cristofari

The Brazilian steel industry is dealing an adverse scenario with direct competition from global emerging markets. In this scenario, the need to improve asset operational performance, makes complex studies involving technical knowledge and asset life behavior, become important tools to support companies strategic accomplish. These studies allow consider performance, costs and operational risks relationship in the decision make process. The Asset Management approach support these studies in order to observe the whole asset life cycle, understand value chain through all company process and optimize the asset economic life. In this context, the present technical work has the purpose to support asset management decision making regarding ArcelorMittal Vega cold rolling drive motors, through the motors fail behavior modelling and estimated the risks involved in asset management decision. Through the Reliability, Availability and Mantenability (RAM) analysis, simulations were performed considering the failure, repair cost data and investments to build options to mitigate the operational risks.

Oct 9, 2019

By W Valery, A Jankovic

A growing demand within the minerals industry for sustainable development and the introduction of carbon taxes have resulted in a significant focus on improving the energy efficiency of comminution circuits. However, in this drive for improved energy efficiency the role of classification has been overlooked. Inefficient classification and large recirculating loads reduce circuit capacity, result in over-grinding and higher specific energy consumption.It is well understood that classification increases mill capacity; therefore, closed ball mill-cyclone circuits have become an industry standard. However, due to limitations in cyclone classification efficiency, the optimum recirculating load is limited to about 250 per cent. A simple relationship quantifying the effect of classification efficiency and recirculating load on grinding circuit capacity is presented in this paper. The possibility of improving the capacity of ball mill circuits by improving classification efficiency is discussed, considering the current practical limitations of classification equipment. Simulation tools were used to evaluate circuits with cyclones and with high frequency screens to identify opportunities to improve energy efficiency. The investigation also identified potential benefits to flotation recovery due to a reduction in over-grinding.CITATION:Jankovic, A and Valery, W, 2012. The impact of classification on the energy efficiency of grinding circuits - The hidden opportunity, in Proceedings 11th AusIMM Mill OperatorsÆ Conference, pp 65-70 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Oct 29, 2012