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By Juliana Colacioppo

La voladura es un procedimiento que está diseñado para obtener pilas a través de una fragmentación adecuada para el carguío y transporte, aumentando así la productividad de las palas y camiones y asegurando la estabilidad de los taludes y condiciones del piso de los bancos en la mina. Asimismo, el diseño de la voladura debe optimizar las operaciones posteriores tales como chancado, zarandas, clasificación, molienda, flotación y lixiviación. En ese sentido, el presente texto describe la metodología de optimización de procesos de la miina Antamina hasta la oncentradora a través de la recolección de datos de campo, caracterización, modelación matemática y simulación de las operaciones, donde además se utilizan sistemas de rastreamento de minerales y de análisis continuo de imágenes.

Sep 9, 2007

By Beer G

The recent re-emergence of an Integral Pressure Stripping system which operates with both cell and column in closed circuit at elevated temperature and pressure, requires no cyanide in the eluate solution and has greatly reduced carbon reactivation requirements in seen as a progressive step in this area. Several of these re-configured IPS systems have been placed in service in Australia and overseas in the last three years, with the first of the new generation units constructed and commissioned by Como Engineers Pty. Ltd. at Mt. Fisher in the East Murchison of W.A. in September 1987. This plant was relocated to a new ore body at Darlot W.A. in February 1989. Use is made of a data base of raw plant performance figures from both Mr. Fisher and Darlot and its performance compared with other operating plants. Initial commissioning difficulties of the Mt. Fisher prototype and dis- cussed together with the modifications and operational procedures required to overcome these problems. Stripping times of less than 6 hours at 145 degrees have been achieved with barren carbon values less than l O ppm from loaded carbon values above 3000 ppm and with cell pass efficiencies reaching 90 per cent.

Jan 1, 1991

By B Mil, D P. Adhikary, M S. Craig, P Rutzou

As shallow coal reserves with easier mining conditions are exhausted, future deep coal mining with difficult mining conditions may face significant economic, technical and environmental challenges. Moreover, due to increased coal production capacity with the new generation longwall systems, predicting adverse mining conditions has become more important than ever before. The potential impact of these difficult conditions is an increase in mining risks and costs. Reliable prediction of rock mass deformation, mine stability and mine water inflow is not only essential for improving mine safety and reduction of coal production costs, but it is also important for the assessment and management of the environmental impact of mining. This paper briefly describes an integrated approach to mine groundwater simulation and prediction. Central to this integrated approach is a three-dimensional computer code called COSFLOW, developed by CSIRO of Australia in collaboration with NEDO and JCOAL of Japan to address the pressing issues of mine water management. COSFLOW incorporates unique features that make it ideal for the simulation of coal mining and examining the interaction between rock fracture, aquifer interference and water flow. This paper also presents an example of an application of the integrated approach and COSFLOW in water inflow prediction at Springvale Mine in New South Wales.

Jan 1, 2006

By Esaki M, Nishimura K

This paper describes the results of the field application tests at Miike Colliery on the integrated automatization of the longwall mining system for medium thick coal seam. The purpose of the research is to develop an automatic longwall mining system which can be controlled accurately from outside of the face, and the ultimate goal is an eliminate of men from the face. Presently, the field test is being conducted in Yotsuyama mine following to a success in the performance test on surface. Remote Batch Control System for shield supports has been adapted to operate all supports from the control panel located at the entrance of the face. Remote monitoring and control system of the drum shearer has also been tested. The system makes it possible to operate the shearer either at the main gate or full automatic. Productivity and safety will be substantially improved as those systems enable to eliminate all workers from the face under the severe working conditions with high ground pressure and hot and humid atmosphere due to increasing mining depth. So far, we have been satisfied with the results of the field test and those system will be an effective countermeasure to operate the face with a high risk of rock-burst.

Jan 1, 1987

By A. v. E. Conradie, I. Nieuwoudt

Comminution and flotation circuits are frequently perturbed by disturbances, such as feed particle size variations, ore hardness and varying mineral liberation, which can have a significant impact on the recoveries and grades. Although advanced control strategies can neutralize many of these disturbances, few such systems have been implemented at present. One reason is that it is only recently that the requisite sensor systems have been developed and used to control froth flotation systems. Another is owed to the complexity of these non-linear interactive systems. In this paper, a plant-wide control strategy is considered, wherein both unit operations have a single overall control objective. The automated design of the controller is based on an advanced evolutionary algorithm viz., Symbiotic, Memetic Neuro-Evolution (SMNE), for developing neural network controllers in a reinforcement learning framework. A rigorous phenomenological comminution and flotation model was used to develop suitable neurocontrollers, which used all possible sensor inputs and available manipulated variables. The neurocontroller managed to identify optimal or near-optimal operating conditions consistently and showed robust performance in the presence of significant disturbances. The results suggest that evolutionary reinforcement learning offers a very competitive approach towards the development of integrated non-linear controllers for mineral processing plants. Keywords: neural networks, control, flotation, comminution, evolutionary reinforcement learning

Jan 1, 2003

By Oyku Selimoglu

The key to successful mine production plan and subsequent operation is efficient mine layout design and optimization. Pit layout design and optimization allow the delineation and extraction of mineable reserves and the minimum waste subject to slope stability, economic, quality and quantity constraints. Many design and optimization software packages have been developed to aid this intensive and challenging process. These packages include VULCAN, SURPAC, DATAMINE, GEMCOM, MICROLYNX, MEDSYSTEM and MINESIGHT. These software packages are developed as integrated computer-aided systems used for database creation, survey, geological and geostatistical modeling, mine planning and production optimization and environmental modeling. In Turkey, many mining companies still plan and design mine layouts with traditional hand methods. In this study, VULCAN has been used to design and optimize the Eti-Bor A.S. Kestelek Boran Open Pit Mine in Western Turkey. The main objective is to show the company the superior advantages of mine planning software for designing and optimizing mine layouts over the traditional hand methods. Drill hole data used by the company to estimate the reserves for planning are used in this study. The ore grade varies between %1,04 B2O3 to %47,33 B2O3. The pit toe and crest strings are projected using variable batter angles and berm distances. On the north side, batter angle is 180 and berm distance is 25 meters, on the south side, batter angle is 320 and berm distance is 15 meters. In addition to that open pit bench height is 10 meter. The concepts of block modeling are applied to the Kestelek open pit mine with detailed ore grade modeling for each block. The Lerchs-Grossmann?s algorithm is used to optimize this mine based on the block model, the economic block values for each block and the underlying field constraints. The results from VULCAN were similar to the estimates by hand. The reserve estimates from VULCAN is 13,192,870 tons compared with the hand estimate of 13,200,000 tons, overburden estimates of 15,622,889 m3 compared with 15,000,000m3 obtained by hand with a stripping ratio 1.18:1 (m3:ton) from VULCAN versus 1.14:1 (m3:ton) from hand estimate. Vulcan improves the efficiency, speed and reproducibility of the planning results. It provides mining engineers, geologists and surveyors with a cost-effective modular system for assessing and planning the mine layouts. Furthermore, Vulcan?s specific modules allow efficient access and manipulation of databases, open pit mine design, block models, optimized 3D mine layouts, and more. However, for competitive business in Eastern Europe, VULCAN should improve its software support. Effective training, help desk support systems and nearby distributors with just-in-time solutions to company problems will generate competitive business for VULCAN.

May 1, 2007

By Scoble M, Peck J

This paper reviews the instrumentation and monitoring of blasthole drills and electric mining shovels at a surface coal mine in western Canada. The drill monitoring component involved the development and implementation of microprocessor-based hardware on Bucyrus-Erie 45R and 60R drills. Over a two year period 3800 metres of blasthole drilling were monitored The drill data was subsequently correlated with core and geophysical logs towards identifying unique and reproducible ranges of performance parameter data for the different rock types penetrated. Using this technique, the geology of the study area benches was characterized in detail. Once these same benches had been blasted, the performance of a P&H 2800XP shovel was monitored as it worked through the blasted ground. In this regard, the influence of different digging conditions on shovel performance were identified in a range of blast and geological environments within the study area. The precise nature of these environments was confirmed by a correlation with the interpreted drill monitored data and muckpile size distributions obtained from a digital photo-analysis study. The excavation of 500 000 bcm of waste was thus monitored and a digging index derived which reflected variations in muckpile diggability. The paper concludes by proposing an integrated monitoring approach which, as a first step, uses interpreted drill data for explosive loading. This capability would permit greater accuracy in explosives loading ie. charge placement within higher strength lithologies, while avoiding weaker units. The performance of an instrumented shovel would then be monitored as it works through the resulting muckpile. Interpretation of the shovel performance data would determine the overall quality of the blast in terms of a digging index (DI), providing an indication of the relative digging effort and the effectiveness of the blast design.

Jan 1, 1990

By Sergei Decterov, Peter Hayes, Evgueni Jak, Taufiq Hidayat, Denis Shishin

Copper smelter operations around the world are under sustained pressure to reduce costs and increase output. Through the provision of reliable data on fundamental properties of the chemical systems the opportunities for improvements of industrial copper production can be identified. Experimental and modelling studies on phase equilibria, thermodynamics of copper slag/matte/metal/gas systems have been combined into an integrated research program undertaken at PYROSEARCH. Experimental phase equilibria studies involve high temperature equilibration in controlled gas atmospheres, rapid quenching and direct measurement of compositions of equilibrium phases with electron probe X-ray microanalysis (EPMA). Thermodynamic databases development and modelling is undertaken using the computer package FactSage in conjunction with advanced models used for complex solution phases. Progressive development of these research methodologies has brought significant advances in characterisation of these complex systems, including a new optimised thermodynamic database for the copper-containing slag system Cu2O-Al2O3-CaO-FeO-Fe2O3-MgO-S-SiO2.The new data and models can now be applied to assist in improvements of the processes. The effects of changes to chemistry and process conditions within the smelting reactor can be examined. Several examples of new descriptions of the phase chemistry of the Cu2O-CaO-SiO2 and Cu2O-FeO-Fe2O3-SiO2 systems in equilibrium with metallic copper showing calculated and experimental data are presented.

Jan 1, 2014

By V. Prostakova, M. Shevchenko

The copper smelting gas / slag / matte / metal / solids system with the Cu-Fe-Ca-Si-O-S major elements has been a long-term focus of the present overall research program using integrated experimental and modelling approach for the phase equilibria characterisation and development of a thermodynamic database. A systematic investigation of phase equilibria of slag systems in equilibrium with Cu metal is providing information for systems where copper coexists in slag with lead, zinc, and aluminium oxides as major components. Experimental studies involve high-temperature equilibration of synthetic samples; rapid quenching; and measurement of the compositions of equilibrium phases using electron probe X-ray microanalysis (EPMA). Particularly important feature of the present study a wide range of temperatures (660-1670°C) being characterised that reveals major inconsistencies in the existing thermodynamic description of the multicomponent system, and allows to establish the thermodynamic properties from phase equilibria in a reliable way. FactSage-based thermodynamic modelling is integrated with experimental research. Initial thermodynamic assessments are used to identify priorities for experiments, planned to provide specific data for thermodynamic optimisation. Significant improvement in the accuracy of the phase equilibria description is achieved, in particular in the PbO-Cu2O-SiO2, ZnO-Cu2O-SiO2, and Cu2O-CaO- Al2O3 systems in equilibrium with metallic Cu. INTRODUCTION Slags high in lead and copper are generated in primary metal production in the smelting of lead sulfide concentrates and in pyrometallurgical metal recycling systems. The compositions of these slags are varied due to increased fraction of recycled materials in the feed as well as introduction of previously unused chemical elements to modern technology. Therefore, their processing becomes chemically more complex; in that way they contain a large number of different metals. These slags form complex non-ideal solutions (with possible formation of several immiscible slags) that can coexist with stoichiometric solids, solid solutions, mattes and molten metal depending on the bulk composition and process conditions. Predicting the outcomes of smelting and refining processes is becoming increasingly difficult. To assist in the optimisation of these metallurgical processing operations, a comprehensive research program is underway to develop accurate thermodynamic databases for these non-ferrous process systems.

Jan 1, 2019

By Jarvensivu M, Ylinen R, Jamsa-Jounela S-L

The paper presents a new integrated system for control of concentration processes. The system is based on cluster-based modelling taking the ore quality into account and a new on-line particle size analyser capable also for reliable measuring of particle size distribution of concentrate. A metallurgical precontrol audit was performed at the Hitura concentrator in order to design the control strategy of the integrated grinding and flotation control. A new analyser PSI-200, was used to the measurement and control of the distribution of nickel in the total particle size range. An expert control system using the cluster model together with a new control strategy for decision of necessary control actions is outlined. The method has been tested to real data from mineral processes. The results are in good correspondence with empirical process knowledge. KEYWORDS: Cluster analysis, expert control, flotation control, mineral processes, modelling, particle size.

Jan 1, 1993

By T. Gerritsen, R. C. Delgado, J. Janzen, E. R. Veloza

The paper describes the components of an Integrated Furnace Control system for covered-arc (shielded arc) smelting with results from the recently started 75 MW Cerro Matoso Line 2 Furnace. The paper starts with a review of the mechanisms of power and feed input and heat losses in the shielded-arc smelting process, and describes how the details of the control system are tailored to the process. The control modules of a covered-arc smelting furnace are described including measured results and screen captures. This paper focuses on Integrated Furnace Controls tailored to shielded-arc smelting, but similar approaches have been recently applied to other furnace processes including immersed-arc smelting.

Jan 1, 2004

By H. E. Urtubia, C. W. Bailey

"BHP-Billiton’s Minera Escondida Limitada is one of the world’s largest copper producers. It treats a combined 88 million tons of copper ore per year through its two concentrators: Los Colorados and Laguna Seca. Over the past three years, metallurgical sampling has been performed at the Laguna Seca concentrator to calibrate both the JKSimMet and JKSimFloat grinding and flotation simulators. In the past, the calibrated simulators have been used to predict the effect of changes in operating conditions in the grinding and flotation circuits separately. To assist in the development of future processing options, predictions were required of the effect of changing grinding circuit conditions on flotation performance. This was achieved by using an integrated grinding and flotation simulation. The grinding circuit performance was predicted under different operating conditions (such as tonnage rate and product grind size) using JKSimMet, and these results were then used in JKSimFloat to predict the flotation performance for the new grinding circuit product. This combination of the simulators allows both the effects of residence time and grind size on flotation performance to be investigated.This paper presents the first combined grinding and simulation modelling and simulation case study using JKSimMet and JKSimFloat. The modelling and simulation methodologies for the grinding and flotation circuits are discussed along with the circuit simulations that were performed. The simulator predictions are presented in conjunction with independent laboratory results of the new operating conditions. The ability to predict flotation circuit performance based on changes in grinding circuit performance is also discussed. This methodology provides improved predictions of flotation circuit performance when grinding circuit changes (including grinding capacity increases) are made.INTRODUCTIONOver the past decade, the grinding and flotation research groups at the Julius Krutschnitt Minerals Research Centre - JKMRC (Brisbane, Australia), University of Cape Town (Cape Town, South Africa) and McGill University (Montreal, Canada) have been developing a methodology for optimising grinding and flotation plants using actual plant data together with semi-empirical sub-process models. The project is being conducted as part of the Australian Minerals Industry Research Association (AMIRA) P9 Project, titled “The Optimisation of Mineral Processes by Modelling and Simulation”. The project first commenced in 1962 and is currently in its “Nth” phase."

Jan 1, 2007

By Shosei Serata

The application of conventional rock mechanics methods to complex ground is very difficult. Yet. In most underground mining, the ground is complex. Therefore. conventional methods are not only difficult to apply but are also generally ineffective in improving underground operations. Similarly, conventional rock mechanics instrumentation has not significantly contributed to improvement of mining practice. Rock mechanics instrumentation in underground mining operations is often considered to be" merely an expensive nuisance. A new system of mine instrumentation is changing this traditional view. The new instrumentation method, called the SPDR method, was originally devised by Dr. Shosei Serata to meet the specific requirement of establishing the Stress Control Method of mining upon a solid quantitative foundation. This instrumentation method has contributed substantially to the widespread success of Stress Control mining under widely varying ground conditions in different types of underground mines (1.2.3.4). The instrumentation method provides an effective means for optimizing Stress Control mining patterns, simultaneously achieving reduction in production costs and substantial improvements in safety (5). The principles and methods of the new instrumentation method are described below, with field examples.

Jan 1, 1986

By L Avalos, F Melo Miranda, J Misle, M Ingwersen

"Los Pelambres, majority owned by the Chilean company Antofagasta Minerals, is one of the leading producers of copper and molybdenum in the country. It is located high in Andes Mountains, over 3000 metres above sea level, 316 km from the nation's capital, Santiago.The maintenance service supplied to Los Pelambres over the past 13 years has evolved to the point that FLSmidth now provides an integrated service crucial to the management of their customer's assets. The contract initially involved specialty mechanical, electrical and instrumentation maintenance and has developed to encompass maintenance planning and plant control systems.The integrated partnership has delivered excellent results in the areas of improved availability, reliability and return on investment. The operation is now amongst the industry leaders in plant availability.The integrated maintenance service has delivered: An increase in plant availability from 93%, in the first year, to 96.5% today, generating approximately $50 million additional income per year, Quality work procedures, Process and equipment improvements, Major shutdown planning involving more than 700 personnel, 6000 parts and over 2 000 discrete activities.The ongoing success of the partnership requires a high level of understanding between both companies. A commitment to maintain a long term sustainable relationship, based on a ""win - win"" culture, is the key to this success. In this regard Los Pelambres has been a pioneer in establishing and developing such relationships.This case study will share the lessons learnt, the measures taken to improve performance and the best practices adopted during the 13 year evolution of the maintenance service partnership.CITATION:Misle, J, Melo Miranda, F, Avalos, L and Ingwersen, M, 2013. Integrated maintenance services at the Los Pelambres Mine in Chile - The lessons learnt and best practices developed from a long-term sustainable relationship, in Proceedings MetPlant 2013 , pp 296-331 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Jul 15, 2013

If you are to be and remain competitive in the mining industry, it is vital that your company management systems are efficient. An integral part of today's competition in a ruthless market is to keep internal costs to a minimum. Integrating our core and parallel management systems is becoming an essential strategy to ensure efficiencies are maintained to the highest level, allowing the maximisation of profits, and to maintain that leadership status within our industry. The uniquely designed Integrated Management Process provides the path to develop, implement, and monitor an Integrated Management System in a simple but highly efficient and effective manner.

Jan 1, 1997

By M Armstrong, S J. Coward, A Galli

Mine management is often expected to make rapid evaluation decisions at different stages of projects based on limited and uncertain data. The challenge is exacerbated by having to distil technical complexity into a financial model that is usually designed to produce only one or two key indicators, eg net present value (NPV), internal rate of return (IRR). Mining is a complex environment with many sources of uncertainty ranging from sampling to economics. In order to optimise investment decision-making, an appropriately structured evaluation framework must be utilised. An evaluation framework should be designed to encapsulate and integrate the complexity across the evaluation cycle, ie sampling, resource estimation, mine planning and treatment, and financial and economic modelling. This complexity is diverse and ranges from sampling support, scale effects to understanding the impact of variability, uncertainty and flexibility on operational efficiency and economic viability. These complexities, combined with time and capital constraints, usually do not allow all facets of evaluation to be integrated into the model. The model must strike a balance between simplified estimation techniques and sufficient incorporation of aspects of the project that will make a material difference to the investment decision. This paper demonstrates the impact of the scale of measurement on the valuation of a mineral project. Comparisons are made between global estimation averages using a top-down approach and local estimates using a bottom-up approach. Three sampling campaigns were conducted on a virtual orebody to compare the relative NPV accuracies. Stochastic forward models were run on foreign exchange rates and are compared with the results from a fixed foreign exchange rate model.

Jan 1, 2006

By F. Carew

Accurate knowledge of what mass and grade is to hand and where it is stored is key to mine efficiencies and overall profitability. In order to make the right decisions and align production with stockpile capacity, feed and contract demand, a clear and accurate view from production through blending and processing is required. The use of a mine production management solution can provide you with a high degree of confidence in and visibility into validated data as well as auditable and traceable material movements, activities and surveys. A robust calculation engine enables mass and grade changes to propagate to material movements and stockpiles to ensure you are getting the most accurate view at all times. Tracked changes in material balances can be readily incorporated in revised production schedules to close the loop. The availability of accurate, timely information, coupled with predictive trend indicators, is a significant advance in narrowing the gap between claimed and planned production that is common to many mines, regardless of commodity. This paper provides an overview of a Mine Production Management System (MPMS) and explains how the system helps address the challenges listed above.

Jan 1, 2011

By P L. McCarthy

To design and operate a successful mine the technical specialists must agree on what is ore, what is not ore, and how quickly the orebody is to be mined and processed. These seemingly simple questions defy easy analysis and can push mining engineers, geologists, metallurgists and others to the limit of their capabilities. The questions are rarely addressed adequately in feasibility studies or in operational planning. To optimise the mine and processing plant requires proper determination of cut-off grades or values, prediction of feed variability on an hourly, daily or longer basis, right-sizing the mining rate for optimum product quality, understanding the cost of capital and the expectations of investors, and many other considerations that involve geology, geotechnical engineering, mining, metallurgy, environmental effects and economics. This paper addresses the key matters that should be considered as inputs to the practical issues of metallurgical plant design and operation.CITATION:McCarthy, P L, 2015. Integrated mining and metallurgical planning and operation, in Proceedings MetPlant 2015, pp 35–45 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 7, 2015

By C. O?Connor

With ever-increasing global demand for mineral resources, numerous mines are moving towards developing and mining deeper, more complex and lower grade ore bodies. In many cases, mass mining methods (e.g. block caving) are being considered to deal with deeper, lower grade deposits. The body of practical knowledge, however, related to the impacts mass mining methods have on the surface environment in terms of rock mass response, subsidence, etc., is limited, imposing both economic risks to the mine and safety risks to mine personnel. This paper presents the framework for and preliminary results from a large collaborative research initiative between Diavik Diamond Mines, Rio Tinto, the University of British Columbia (UBC) and Simon Fraser University (SFU). The project involves the integration of available subsidence, rock mass, mine operation and monitoring data, together with the advanced application of combined finite/discrete-element modelling codes capable of simulating fracture behaviour, cave propagation and surface subsidence above block cave mines. The main objective of this work is to develop advanced numerical modelling methods to characterize complex rock mass behaviour above block cave mines. The research will also include the study of rock deformation mechanisms associated with the transition from surface to underground mining and the potential interaction between simultaneous open-pit and underground mining operations.

May 1, 2007

By D. Schleiss

Reduced access to knowledgeable workers is creating challenges for operations. We are doing more 4D Operations - dirty, dull, dangerous, and distant. Personnel costs in these environments are high, and it is not always possible to get the people where you need them. Integrated Operations is a strategy to integrate people, process, and technology for faster and better decision making. Adopting an integrated operations approach can help to relocate personnel, improve collaboration, and align objectives to deliver reduced costs and improved performance. In this paper, the authors will highlight the required infrastructure to enable an Integrated Operations platform. Key decision points for enabling this technology for both Greenfield projects and existing mines will be discussed. Furthermore, the benefits and improved return on investment that result from deployment of an Integrated Operations strategy will be presented.

Jan 1, 2014