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"With the globalization of the mining industry, many companies are now seeking to invest in underground diamond mines, with the purchase of small diamond pipes being seen as particularly attractive. However, recent experiences in South Africa have shown that many projects fail due to a lack of awareness of the hazards associated with diamond mining. In this paper three significant hazards are dealt with — mud rushes, block crushing, and implementation of an inappropriate mining method. Measures that assist in the prevention of these three hazards are given.IntroductionFor over a hundred years, South Africa has been seen as the centre of the diamond mining industry, possibly having the largest number of operational underground diamond mines in the world. Despite the fact that this industry has been dominated by large mines of De Beers Consolidated Mines Limited, many small underground mines have operated profitably for a number of years, exploiting diamondiferous fissures and pipes. In the last decade there has been renewed interest in these small operations from international companies. However, many of these projects have not realized their full potential owing to a lack of appreciation of the hazards inherent in the operation of a diamond mine.Hazards Associated with Diamond MiningIn the development of a diamond mine, the mining company must be aware of the hazards associated with diamond mining. There are three main hazards: (1) mud rushes; (2) block crushing; and (3) selection of an inappropriate mining method (not a natural hazard, but a planning induced hazard). Each of these hazards will be dealt with in turn in the following sections."

Jan 1, 2000

By C. Ciriello

Six Sigma methodology, as applied within Xstrata (formerly Falconbridge and Noranda), involves a disciplined approach to managing projects, solving problems, improving performance, and leveraging information. The four (4) cornerstones of Six Sigma are the use of Philosophy (customer driven, desire to improve and discipline), Metrics (measurement systems), Methodology (scientific method and sequence of deliverables), and Tools (such as statistics, change management, and root cause analysis). This paper will outline the general steps of the Six Sigma methodology and demonstrate how each phase directly applies to a real plant metallurgical project aimed at reducing nickel losses of the rougher flotation circuit at Raglan. The main concepts of Six Sigma are described, along with the specific challenges, successes, and deliverables related to the project. It is also the authors' aim to demystify the basic Six Sigma principles.

Jan 1, 2007

By P. Espinoza, I. Yutronic, J. Olivares

"Compañía Minera Doña Inés de Collahuasi's (CMDIC) Concentrator Plant is located at 4300 meters above sea level, approximately 2000 kms north from Santiago, Chile. The concentrator has three grinding lines. Each one, Lines 1 and 2, have one SAG mill at the primary grinding stage followed by a secondary grinding and classification stage consisting of one ball mill, two hydrocyclone batteries and a sump with two pumps. Line 3 has one SAG mill (Gearless Mill Drive), followed by a secondary grinding and classification consisting two ball mills, four hydrocyclone batteries and a sump with four pumps. Average throughput for these three lines is 150 Ktons per day. Peak values of 180 ktons per day have been achieved.Since late 2008 and throughout 2009 and 2010, Operations and Automation areas developed an optimization program for the grinding process, considering the implementation of Model Predictive Controllers (MPC) for the three SAG mills, and later, extending MPC to the secondary grinding and classification stages. The implementation of a MPC solution was based on stability considerations (high variability of the SAG process, high interaction between sump level control and classification efficiency, etc), requirements for an automated and consistent operation, the need to maximize throughput under timevarying scenarios and, in the long term, optimization of grinding process considering Specific Energy Consumption, among other parameters. MPC solutions had proven control robustness and strong optimizing capabilities in terms of helping in discovering new operational points and so achieving all of the aforementioned goals.On the first stage of the program, MPC implementation considered identification of dynamical process control models based mainly on historical data, in order to know the impact of a group of Manipulated Variables over Controlled Variables. Also, the impact of measured Disturbance Variables was modeled in order to take into account the high impact and interaction of these variables over the processes. At the end of this stage, 4 controllers were successfully operating for the 3 SAG mills and the secondary grinding and classification process. In response to challenges made by the working group, the second stage of the development of control applications in the grinding process required to achieve a design and implementation of a solution capable of governing the milling process, in addition to stabilization and optimization of both processes (SAG milling and secondary grinding), to integrate from a point of view of process control and automation. Therefore, in the second stage, MPC performance was continuously monitored and optimized through advanced tuning, inclusion of more process models (with proper step tests), redefinition of specific optimization criteria and adjustment to new process needs.Finally, successful MPC implementation at Collahuasi has proved that fast development and deployment of process control solutions is possible and allows immediate process stability, higher throughput, specific energy consumption reduction, and successful product size control, among many others."

Jan 1, 2012

By H. A. Kishawy, S. Kannan, M. Balazinski

Metal Matrix Composites (MMCs) are new generation engineering materials that possess superior physical and mechanical properties compared to nonreinforced alloys. However, the presence of abrasive ceramic reinforcements in the ductile matrix causes severe tool wear and premature tool failure. Flank wear was found to be the dominant wear mode while the main wear mechanism was abrasion. Analysis of the cutting tools using scanning electron microscopy has shown that both two body and three body abrasion are operational during machining MMCs. A methodology for predicting the tool flank wear progression during bar turning ofMMCs was presented in an earlier paper [1]. In the proposed model, the wear volume due to two body and three body abrasion mechanisms was formulated. Then, the flank wear rate was quantified by considering the tool geometry in 3D turning. The main objective of this paper is to investigate the contribution of two body and three body abrasion towards the tool wear volume during cutting MMCs.

Jan 1, 2006

By Helmut Lerchs

An open-pit mining operation can be viewed as a process by which the open surface of a mine is continuously deformed. The planning of a mining program involves the design of the final shape of this open surface. The approach developed in this paper is based on the following assumptions: 1. the type of material its mine value and its extraction cost is given for each point; 2. restrictions on the geometry of the pit are specified (surface boundaries and maximum allowable wall slopes); 3. The objective is to maximize total profit-total mine value of material extracted minus total extraction cost. Two numeric methods are proposed: A simple dynamic programming algorithm for the two-dimensional pit (or a single vertical section of a mine), and. a more elaborate graph algorithm for the general three-dimensional pit. ASURFACE mining program is a complex operation that may extend over many years, and Involve huge capital expenditures and risk. Before undertaking such an operation, it must be known what ore there is to be mined

Jan 1, 1965

By Tao Cheng

Previous research and applications in construction resource optimization have focused on tracking the location of material and equipment. There is a lack of studies on automated monitoring of the interaction between workers and equipment for safety purposes. This paper presents a new approach for measuring the safety performance of construction personnel particularly when they work in very close proximity to moving equipment as well as static hazards such as chemical and flammable substances. A method of generating hazardous zones according to the geometric and kinematic characteristics of the considered hazard is introduced. The spatio-temporal relationships between the hazardous zones and workers? positioning data collected by real-time location sensing technology are automatically analyzed. This approach has been validated in a controlled test bed environment that simulates a construction site. Results indicate that worker?s safety performance of selected activities can be automatically and reliably measured using the developed approach. Furthermore, a heat map is generated for visualizing proximity related issues in the test bed using the computed results.

Aug 1, 2013

By J. A. Reid

THE views and observations expressed herein on this old but constantly recurring question are our own, no effort having been made to align them with standard texts. Therefore, while they may find general acceptance amongst fellow engineers, they must stand as personal opinions and as such are open to debate and discussion. In order properly to consider the subject, it should first be 'set in proper perspective. Why are Prospects Examined? Prospects are examined to determine whether they may contain economic concentrations of metals or minerals, the legitimate mining business being run, pretty largely, to make money. Next to food and clothing, modern civilization is based on metals, with which are included in this discussion minerals, oils, and fuels. A constant and increasing demand for the common metals requires the location of replacements for depleted orebodies, while the use and appreciation of new metals brings increasing demand for them. Aluminium is a good example of a metal which has, within recent years, made great progress. Today, we are becoming increasingly aware of magnesium, chromium, tungsten, thallium, and other lesser known, metals.

Jan 1, 1945

By Bradley Stoughton

The magnetic oxide of iron, F eO4 , contains a theoretically larger amount of iron ( 72.4 per cent.) than any other commercial ore. It is probable that it has originated in many cases by the prolonged exposure of the hydrated oxide, ZF e20 a + 3H20 to heat and pressure which converts it first into hematite, F e20 3, and then into magnetite. It would thus appear as if nature had already done part of the work of removing all the oxygen and that magnetite should be relatively easy to reduce. That it is, in fact, less reducible than either limonite or hematite, is due chiefly to its dense and compact physical structure, which makes it less pervious to the furnace gases, and also to its characteristic action in resisting crushing to a uniform size, with consequent irregularity in reducing conditions within the furnace. The net result is that the magnetic oxide requires more fuel and more time for its reduction in the blast-furnace than any other iron ore of similar iron content and physical condition. There is another very important reason why the smelting of magnetite is more costly than that of hematite, and its treatment viewed with a great deal of adverse prejudice by blast furnace operators, namely, that magnetite decreases the proportion of heat developed by the fuel in the stack of the furnace, and increases the already excessive heat requirements of the heart.

Jan 1, 1924

By Terry McNulty

"Previous papers (McNulty 1998 and 2004) have dealt with the causes of successful and less successful achievement of design production rate by new processing plants in the minerals industry. Examination of many case histories has allowed the construction of curves or profiles that represent projects with similar characteristics that equate to differing degrees of care exercised during the project development phase. Simplistically, decreasing care is reflected by increasing risk and a heightened likelihood of poor technical and/or financial performance.This contribution provides an update, including recent case histories, and presents a modified Series 1A curve that includes the best 23 case histories, out of a total of 81 examined, or 28%. This is done to show that some very carefully developed and executed projects can ramp-up quickly and that owners of new projects should avoid being too pessimistic in projecting early cash flow if they are certain that they have done their homework. The role of metallurgical process development in the reduction of project risk is discussed and several financial analyses are presented that express the potential monetary value of a well-designed and professionally executed metallurgical program."

Jan 1, 2014

By W. Beres, R. E. Miller, B. Shiari, L. R. Zhao

A dynamic multiscale simulation method has been developed to study the material scratching processes on nanoscale single crystals. The model simultaneously captures the atomistic mechanisms near the free surface and the long range mobility of dislocations and their interactions, without the computational cost of full atomistic simulations. The method also permits the simulation of system sizes that are approaching experimentally accessible systems, albeit in 2D. Simulations are performed on single crystal aluminum to study the atomistic details, surface evolution, and generation and propagation of dislocations for a variety of scratching depths at room temperature. Simulations demonstrate the power of the developed method in capturing both long-range dislocation plasticity and short-range atomistic phenomena during tool advance. Variations of scratching normal and tangential forces are investigated and related to plastic deformation and dislocations generation during the simulation process.

Jan 1, 2006

"During the development of a mining project, samples are taken for metallurgical tests. The sample can be a composite sample made of material from a selection of various drilling products or a sample from a mining test. It can be also a sample from an existing plant in order to investigate process enhancement. This sample can represent several tonnes of material which are analysed and split for use in various tests.In the current case, a composite sample of gold ore is dedicated to a Gravity Recoverable Gold (GRG) test. The properties of interest are the head grade of gold, the size distribution of the material, and the gold assay per size class. The sample is mixed and a sub-sample is taken to measure the feed properties: the size distribution and the gold assay per size class. The remaining material of the sample is subject to the first stage of concentration using the laboratory Knelson concentrator. The concentrate is analysed in its entirety, while a sample of tailings is taken for the same analysis. The remaining part of tailings is subject to grinding to feed the second and third stages of concentration. Similar sampling is performed at each stage.The concentration performances are analysed in light of these measurements. But what is the accuracy of the measurements of the properties? Pierre Gy’s theory of sampling, associated with a heterogeneity model built using the GRG test results, will answer this question. The current paper presents, through a real example, the calculation of the errors of the measurements of size distributions and gold assays performed during the GRG test. The uncertainties of the concentration performances and liberation size estimate are then calculated and their impact on the results interpretation is analysed.INTRODUCTIONDuring the development of a mining project, samples are taken for metallurgical tests. The sample can be a composite sample made of material from a selection of various drilling products or a sample from a mining test. It can be also a sample from an existing plant in order to investigate process enhancement. This sample can represent several tonnes of material which are analysed and split for use in various tests. In order to take into account the ore variability in terms of gold deportment, it is recommended to perform variability studies (Dominy, Murphy, & Gray, 2011, Dominy, 2013) using samples representing various horizons or years of production. But for a given ore type, it can be necessary to perform many tests with different operating conditions (Brochot, 2012a). In that case, the variability of the samples is not due to the heterogeneity of distribution of the deposit, but only on the heterogeneity of constitution of the primary sample. The level of confidence associated with the estimated performance parameters is directly linked to the overall error (including sampling error) of the measurements performed during the tests."

Jan 1, 2016

By R. B. Kaunda

One fundamental requirement for surface and underground rock engineering is the ability to characterise the rock mass. An accurate characterisation of the rock mass allows rock engineers to optimize designs safely and economically. A number of classification systems have been developed in the past 50 years to help characterise rock masses such as RMR, Q system, Rmi, and several others. The challenge in developing rock characterisation schemes is often practicality, i.e. creating systems with relatively simple inputs for the everyday practitioner. A second challenge is the degree of subjectivity often inherent in commonly used classification systems. These challenges are especially exacerbated in weak rock or densely jointed rock masses. This paper introduces a new approach to characterise densely jointed rock mass using artificial neural networks and principal component analysis, based on principles commonly used in the geotechnical engineering of rock fills and waste rock dumps. Thirteen input parameters are dimensionally compressed using principal component analysis. Using a global database with more than 100 case histories, an artificial neural network is developed to conduct the rock mass characterisation. The advantage of this approach is less subjectivity as commonly used engineering (quantitative) terms are put to use. A further advantage is that given that the method is site-data dependent, it allows for ‘fine tuning’ of the model for a specific site.

Jan 1, 2015

By Yasuo Iizuka

We have had studied CO oxidation on unsupported Au powder (mean particle size, ca.100nm) manufactured by evaporating ultra high purity gold metal (>99.99%) in inert gas and reported that it showed some activity after oxidizing pretreatment in O2 at 423 K?453 K. However, recent XPS analysis of the Au powder revealed that it contains much amount of impurity metals such as Ag and In at levels which far exceed those expected from the impurity level of raw gold metal in the bulk. Several samples of Au powder containing different amount of impurity metals were prepared to examine whether the activity depends upon the existence of surface impurity or not. Activity measurements were performed at 273 K after undergoing the powder under various pretreatment conditions. Although the activity of Au powder varied to some extent according to the pretreatment condition, it is strongly correlated to the surface concentration of Ag. Such dependence was not found for In, indicating that the activity of unsupported Au powder is mainly due to the existence of Ag in the surface layer. The activity attributable to ?particle size effect? was not recognized for Au powder with a mean particle size larger than 80 nm.

Oct 1, 2003

By Jean-Luc Collins

"This paper shows how simple reliability concepts such as mean time between failures and mean repair time can be used efficiently to help increase equipment availability and so reduce the economic losses associated with unreliability.More specifically, the paper shows how these simple concepts can be used in maintaining an appropriate balance between fleet failure and repair rates and how they can be used for setting up priority repair rules f or queuing equipment.IntroductionA profitable mining operation must handle large quantities of ore and waste at the lowest possible cost. To achieve this objective, the operation must optimize the productivity of its fleets of equipment by efficient management of the time element. Figure I shows some basic equipment activities in an open pit operation while Figure 2 shows a tree diagram describing some time elements of these activities.It should be noted that the only time a piece of equipment can generate a profit is when it can be found in the operating status. In order to maximize this time element, the sum of the other time elements must be minimized because the total time is always fixed.This paper shows the application of simple techniques capable of reducing the waiting time for repair (maintenance delay) by using simple reliability concepts."

Jan 1, 1988

By Eric D. Marks

Fatalities resulting from ground workers colliding with objects and construction equipment accounted for approximately 18% of the total construction fatalities experienced in 2010. Current injury and fatality measuring methods have proven to be inadequate due to their use of passive measures of safety rather than a more active approach, such as the use of leading indicator data (also called near misses) of hazardous proximity situations between ground workers and heavy equipment on construction sites. The objectives are to create and evaluate the effectiveness of a reliable algorithm for collecting and analyzing the resulting leading indicator data from hazardous proximity situations. Numerous experiments emulating typical interactions between workers-on-foot and heavy equipment are used to evaluate the proximity sensing and detection technology. Safety leading indicator data (also called near misses) generated by the proximity sensing and detection technology during the experimental trials are used to create and assess the resulting algorithm. Results from the experiments indicate that leading indicator data generated from these systems can be processed and analyzed to identify hazardous proximity situations and incidents on construction sites.

Aug 1, 2013

By Craig Faulkner

Discharge cones for large Semi Autogenous Grinding (SAG) and Autogenous Grinding (AG) mills are subjected to high wear as significant volumes of ground ore and slurry exit the mill. With the larger diameter mills of 32ft to 40ft in size becoming the norm, very high, concentrated wear is highlighting the limitations of conventional discharge cones and frequent changes are subsequently required. This paper outlines the advances made in the design of the Bullnose discharge cone. Superior wear materials to increase wear life over conventional rubber or chrome-moly steel discharge cones and the introduction of key design features to reduce reline times and improve fit and safety during installation, offer significant opportunities for the mill operator. Collated from multiple case studies, the wear data and reline history from 2004 to present clearly illustrate the way in which superior component longevity has reduced the frequency of relines over the life of the product to increase mill availability and effectively increase the tonnes milled in a period.

Jan 1, 2012

By Yugo Mitani, Tatsuya Kato, Chiharu Tokoro, Abdullah Al Mamun

Acid mine drainage (AMD), which is a major source of mining pollution, often contains ferric and/or ferrous ions together with several toxic elements. The ferric and ferrous ions in AMD precipitate in several mineralogical forms after neutralization, and the ferric/ferrous precipitates become the main component of the sludge generated after AMD treatment. The precipitates are also good absorbents for several toxic elements. To avoid generation of voluminous sludges and the re-dissolution of toxic elements from the sludge, it is very important to generate well-draining and efficiently adsorbing sludges by controlling the mineralogical form of the ferric/ferrous precipitates. Green rust, which is ferric and ferrous hydroxide, is a double layer hydroxide which is able to sorb several toxic elements. The green rust transforms to goethite or lepidocrocite by rapid oxidation, whereas it transforms to magnetite at ambient temperature by slow oxidation. The magnetite is also good absorbent especially for toxic cations and it makes a compact sludge due to its magnetic properties. We investigated the magnetite generation process at ambient temperature in detail. The magnetite generation process can be divided into three steps; (i) oxidation of Fe(II), (ii) Fe(II) surface complexation to Fe(III) hydroxide, and (iii) crystallization of magnetite. More magnetite can form when the oxidation rate is slower than the crystallization rate, and optimum conditions for its formation are at pH 9.5 with mild agitation. Ferrihydrite is the most common precipitate and it is able to sorb many different toxic elements. However, it drains badly and its solid/liquid separation properties are poor. We investigated the removal mechanism of several toxic elements by co-precipitation with ferrihydrite. We confirmed that the removal mechanism by co-precipitation partly involved surface precipitation when the initial ratio of toxic elements to ferric ion was high, although the main mechanism was always surface complexation. When surface precipitation occurred, highly efficient toxic element removal with ferrihydrite could be achieved.

Jan 1, 2016

By Y. M. Shneerson, E. E. Zhmarin, E. M. Vigdorchik

One of the Gipronickel Institute activities is research and development of customized leaching technologies. The work is performed in several steps. Leaching kinetics are studied on a lab-scale according to a special procedure. Experimental data are processed using mathematical models of batch and continuous processes. Reliability of kinetic data and preliminary calculations is verified experimentally in laboratory reactors of various capacities. If necessary, certain parameters of the mathematical model are adjusted after pilot plant tests in continuous mode ( 4-reactor train, each with 25 L capacity). The specified kinetic characteristics along with the mathematical model are used for further development of industrial leaching technology.

Jan 1, 2005

By K. E. Harley, M. J. Whiting, T. J. Sabin, E. M. Ryan, J. F. Watts

"Wire and Arc Additive Manufacturing (WAAM) has the potential to enable a very significant reduction in buy-to-fly ratio compared to conventional manufacturing through the ability to build near-net shape components. Components manufactured from AA 2319 by WAAM can exhibit significant levels of porosity. There is also a variation in the physical appearance of the surface deposit sometimes found on such components. This deposit is similar to those observed on aluminium joined by MIG and TIG welding processes. It has been suggested that both the bulk porosity and the surface deposit are caused by hydrocarbon-based lubricant on the feedstock wire. An established correlation between surface deposit and porosity would offer valuable insight into WAAM products and enable early interventions in quality control or process monitoring based on visual examination. The relationship between the nature of the surface deposit and porosity has been studied for AA 2319 WAAM components manufactured using different wire batches. Evidence is presented to support the assertion that (i) there does not appear to be a relationship between surface deposit coverage and porosity, (ii) batch-to-batch variability in feedstock wire affects porosity. This study has led to a better understanding of the cause of porosity in WAAM components.INTRODUCTION There is a high cost associated with conventional, subtractive manufacturing because of the high ‘buy-to-fly’ ratio, a measure of the initial material bought compared to the material found in the finished part (Allen, 2006; Yilmaz & Ulga, 2016). A typical aerospace product may have up to 90% of the purchased billet of forging machined away which is cost inefficient and high in material waste. Wire and Arc Additive Manufacturing (WAAM) has the potential to reduce costs and lead time. Robotically controlled weld torches rapidly deposit feedstock wire in layers to build large near-net shapes with mechanical properties similar to those of conventional manufactured parts (Sequeira Almedia & Williams, 2010; Martina et al., 2012; Ding et al., 2015; Williams et al., 2015). A high level of porosity variation has been observed in aluminium WAAM parts (Cong, Ding & Williams, 2014; Gu et al, 2016) which can result in a range of material properties (Rudy & Rupert, 1970). This leads to difficulties in regards to standardisation and qualification of process and parts. In order for WAAM to be used commercially, porosity will need to be understood, monitored and reduced to a reproducible acceptable level or eliminated."

Jan 1, 2018

By John E. Udd

"In this paper the author presents the results of the 1992 CIM survey of graduates in minerals and technology programs in Canadian post-secondary institutions. As usual, the trends are out-of phase with the economic state of the industry. People who chose a minerals career in the prosperous days of the late 1980sare now entering a labour market in recession.The cyclical nature of enrollments is illustrated in a series of figures showing the trends since the CIM survey Wa5 begun in 1956 (and even earlier for mining engineering).In the survey, the respondents were asked to provide comments on their perceptions of the problems specific to minerals education in Canada. The large number of responses have led the author to the conclusions and recommendations given in the final part of the paper."

Jan 1, 1993