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By S. K. Pan, R. Venugopal, L. A. Kumaraswamidhas, Rakesh Prasad, Chandan Pandey

Cold compressive strength (CCS) and apparent porosity (AP) of pellets are essential properties regarding the burden of blast furnaces. The optimal required values for industries are 2.5 KN CCS and 21% AP. Blaine fineness and firing temperature are the decisive parameters analyzed here. During firing, microstructure phases such as silicate, hematite, and pore are formed. The phase’s grain density during induration influences the pellet’s CCS and AP. The influence of the factors over the response is evaluated by I-optimal (response surface methodology) design. Blaine fineness, firing temperature, pore phase grain density (PPGD), silicate phase grain density (SPGD), and hematite phase grain density (HPGD) affect the CCS and AP of pellets. The RSM-I-optimal predicted responses with a coefficient of determination (R2) of 0.89 for CCS and 0.91 for AP of iron ore pellets. Optimal conditions were Blaine no. = 1668 cm2/g, 1250 °C firing temperature, PPGD value 90 no/mm2, SPGD value 250 no/ mm2, and HPGD value 490 no/mm2, with 4.5 KN CCS 27%. The induration processes were investigated through statistical design of experiments for process optimization. Statistical analysis indicated the direct and interactive influence over CCS and AP. In this study, RSM-I-optimal modeling is used for iron ore pellets processing. The I-optimal prediction could be applied to make the process economical because information is obtained through fewer experiments.

Aug 18, 2020

By Y. Zhang, M. Yekich, C. Zhou, C. Jobes, J. Galanko, D. Tuchman, J. Srednicki, J. Carr

The continuous personal dust monitor (CPDM) is an essential instrument for working in hazardous environments, is used to monitor real-time coal dust exposure, and is mandated by the Mine Safety and Health Administration (MSHA) for underground coal mines. Researchers from the National Institute for Occupational Safety and Health (NIOSH) found that it is possible for electromagnetic interference (EMI) between a CPDM and a proximity detection system (PDS) to occur. Various approaches have been taken by researchers and manufacturers to address this EMI issue. Administrative controls were recommended to keep the CPDM six inches away from the wearable PDS device. Shielding pouches were made to contain the electromagnetic (EM) emission from the CPDM. Metal shielding was added to major EM emitting components. EMI filtering with large capacitors was introduced to mitigate EMI. Most recently, a novel magnetic-field-cancellation-based approach was developed and achieved remarkable results. In this paper, we provide a comparison between these approaches. The pros and cons of each approach are presented and discussed, so that mining device manufacturers and operators can best evaluate the technology and controls that improve the health and safety of mine workers.

Feb 1, 2023

By Samir Kumar Pal, Rajasekar Rathanasamy, Gobinath Velu Kaliyannan, Moganapriya Chinnasamy, Sathish Kumar Palaniappan

The research examines the performance of uncoated and coated tungsten carbide-cobalt rock cutting bits. It aims to optimize process variables (cutting speed, depth, coating material) considering multiple output responses (cutting forces, specific energy, wear rate, material removed, angle of reaction forces). The study uses a hybrid optimization technique combining Taguchi design, grey relational analysis, and fuzzy logic. The optimal parameter combination was found to be cutting speed: 200 mm/s, cutting depth: 6 mm, and titanium aluminum silicon nitride coating.

Apr 24, 2022

By W. R. Reed, J. D. Potts

This study tests the ability of a new air nozzle system, located under the drill deck shroud, to improve the dust capture of the drill deck shroud. The system consists of three air nozzles supplied with regulated pressurized air and located midway down the shroud in the off-inlet corners of the shroud. Laboratory testing produced operating curves for the system that showed an optimum operating point of 207 kPa (30 psi) and generated respirable dust reductions of 48% to 52% from the drill deck shroud.

Jan 1, 2009

By Bernd Hagenah, Katie Theis, Cristina Lauzon, Petr Pospisil

Lidding over or tunneling existing transportation infrastructure is currently under review in several U.S. cities. The main reasons for this are the use of the created space for urban development, the reduction of noise and exhaust fumes for the residents, and, thus, a significant increase in the quality of life. The main aspects to be considered during the planning process are (1) total investment and operational costs, (2) impact of construction works on current traffic, (3) safety and fire protection, and (4) socio-environmental issues. The paper presents some basic planning principles, and experiences of recent urban highway coverages are shared.

Jun 23, 2024

By Roger M. Buckeridge, Charles D. Reese, Silvio M. Martino, William T. Carey, Ansel H. Graham

FUNCTIONS OF RAIL HAULAGE SYSTEMS The principal application of rail haulage in under¬ground mining is in the movement of ore or coal pro¬duction from near the mining areas out to a processing plant. In some cases, such production haulage may end at a shaft pocket or slope belt conveyor transfer station, depending on the type of mine and the geo¬logical placement of the mineral being mined. Main-Line Haulage The basic reasons for choosing main-line rail haul¬age are high-tonnage production per shift and long haulage distances. The choice between rail and other systems, such as belt conveyors, is not easy and requires an integrated study of many factors: tonnage, distance, grade, product size, number of producing areas, ore reserve, safety, capital cost, operational and maintenance cost, and the mining system. Projecting a main-line rail haulage system for com¬parison with other systems requires a choice of many variables which are interrelated. The project must start with consideration of the mining system, tonnages per day, distances and grades, and loading and dumping conditions. Rail mine cars of different sizes and types are studied. High tonnage demands consideration of wider track gages. A suggested minimum for metal mines is 914.4 mm (36 in.); for coal mines, 1066.8 mm (42 in.). The choice of the train size should be governed by tonnage per shift, physical factors of loading and dumping, cycle time, and the number of trains that can be operated and safely controlled. After the size of the train is determined, the type, size, and specifi¬cations of the locomotive can be selected. The loco¬motive may be trolley, battery, or diesel; selection guides are discussed elsewhere in this chapter. The advantages of rail main-line haulage are high tonnage capacity, flexibility, reliability, safety, low operational and maintenance cost, and dual usage of the system (supply haulage, for example). The dis¬advantages are high capital investment, high installation cost, the requirement for more maintenance facilities, and restriction to certain ore reserves and mine pro¬jections. Supply Haulage Supply haulage is a basic requirement of any mine, but the type and volume of supplies vary with the type of mineral being mined, the mining methods, and the size of the mine. A mine developed for rail main¬line haulage gains supply haulage through the addition of a secondary track system to extend the main line closer to the producing areas. Additional haulage equipment, generally smaller, is also added. It is neces¬sary to design into the rail system more switch bypass points and train control systems. The track system standards demanded by rail main-line haulage con¬tribute to the reliability and efficiency of the supply haulage function, whereas a supply track system to supplement other haulage systems often suffers from poorer track and installation standards. When belt conveyors are chosen for production haulage, a rail supply haulage system is often installed rather than using rubber-tired vehicles for supply haul¬age. The conditions of the seam or ore body create these items for consideration: haulage grade of more than 6% favors rubber-tired vehicles; longer haulage distances favor rail; difficulty in maintaining a smooth roadway favors rail; and movement beyond the end of a rail system generally requires rubber-tired vehicles, making a single system rather than a dual system attractive. Although operation of a supply haulage system may be concentrated on a single shift of a multiple-shift mining operation, proper planning and supervision are required if the haulage is to be efficient. Often the newer personnel at a mine are assigned to supply haul¬age which may add to the difficulty of obtaining maxi¬mum efficiency. Supply haulage by rail offers the advantages of high reliability, lower maintenance, and high efficiency over long distances. The disadvantages are less flexibility, high installation costs, and rubber-tired vehicles for use beyond the inby end of track often required. Personnel Movement The efficient and comfortable movement of the miner to and from his work area has a significant effect on his daily output. Minimizing man-trip time also becomes more and more important as hourly wages increase. Personnel are generally moved over a rail system by one of three methods: a specialized personnel carrier to which a certain number of men who work in a certain area are assigned; a combination vehicle, used to carry personnel but also capable of being used as a light supply/utility locomotive during a working shift; and man-trip cars towed by a supply locomotive. The first and second methods are used in coal mines where long distances make speed and comfort important. The third method is more common in metal mines. Equipment Movement As mining equipment technology has advanced, many mining machines and their subcomponents have grown in size. This trend requires careful planning for adding specialized carriers to handle the movement of larger equipment. Continuous miners, longwall equipment, raise borers, and ventilation equipment are examples of machines which may be difficult to move and which require special handling. The selection of the weight, speed, and operating characteristics of supply locomotives used to move equipment is important. Larger mines may often justify a special group of loco¬motives for this application.

Jan 1, 1982

By Steve Kral

The Prospectors and Developers Association of Canada (PDAC) was established in 1932 in response to proposed regulations that would have threatened prospectors in Ontario. From there, the association grew to represent the interests of Canada?s mineral exploration and development industry. The PDAC?s mission statement reads: ?The PDAC exists to protect and promote the interests of the Canadian mineral exploration sector and to ensure a robust mining industry in Canada. The PDAC will encourage the highest standards of technical, environment, safety and social practices in Canada and internationally. ?Today, the PDAC?s 6,000 individual members include prospectors, developers, geoscientists, consultants, mining executives and students. In addition, the association?s membership includes 950 corporate members, representing senior, mid-sized and junior mining companies in addition to organizations that provide services and equipment to the mining industry. In 2010, the PDAC adopted its e3 Plus principles, a framework to guide its membership in responsible exploration.

Jan 1, 2011

By Richard Snyder

Secretariat of the Coal Mining and Mining Executive Committees' of the National Safety Council (NSC) and Manager of the memberships to both Mining Sections; Senior Consulting Safety Engineer, NSC; member of several committees for consensus Standards of the American National Standards Institute (ANSI); a Certified Safety Professional (CSP) of the Board of Certified Safety Professionals of the Americas, Inc. and a chief proctor for CSP testing and certification procedures, et al. It appears that the tunneling trade is merging into its own renaissance for the decade of the 1970s', and most likely on past the year 2001. Federal interest in underground excavation, and more specifically, rapid excavation expertise has been on the upswing since the latter part of the 1960's, mainly due to the pressing national needs for more raw materials based on the rise for material goods and the projective gloom of possible power shortages. On the pure tunneling side the national needs encompass, in the mainstream of priorities, rapid transportation and water supply excavation as the two top contenders. For instance, the estimates for tunnel mileage for the period 1968-1975 are:(1) Subways---85 miles Urban Highways--- 123 miles Intercity Highways---210 miles Water Supply Routes---528 miles at a total of 946 miles of tunnels. The estimated cumulative underground excavation demand in dollar amounts for the period 1970-1989 are:(1) Construction Oriented Demand--- $35 billions Mining Oriented Demand---$34 billions (which includes the coal-oriented demand on the order of 26 billions.

Jan 1, 1997

By Connor Langford, Murray Gant, Ken Massé

For public organizations, preparing accurate project cost estimates is a critical component in capital project planning. Project delivery methods provide a structured approach to moving projects through the design and construction lifecycle, and typically use cost estimates as key inputs at each stage to determine if the project will advance. As design stages can occur years or even decades before construction contracts are awarded, estimates need to make reasonable assumptions about how the work may be executed (means and methods) as well as potential future market trends so that appropriate values for material pricing, labour costs, escalation, and owner’s costs can be included. This process is challenging enough during stable markets, as historic trends can often be misleading and require a suitable understanding of economic factors to use appropriately. When you mix in the market volatility that has been observed since 2020, developing accurate project cost estimates becomes even more challenging. In cases such as this, having a structured approach to cost estimating that includes an adequate risk-based reserves cannot be overstated as it provides the basis for ongoing project decisions. This paper explores some of the historic and more recent market trends that have impacted key aspects of project cost estimates for capital project planning. It also provides recommendations on how to develop cost estimates for infrastructure projects, with examples from Metro Vancouver, which plans for and delivers regional-scale services to 2.6 million residents. A brief commentary on the use of escalation clauses in contracts is also presented.

Jun 13, 2023

Since it was first introduced, the Coal Mine Roof Rating (CMRR) has been widely accepted as a tool for geologic characterization and mine planning. This paper discusses the application of the CMRR to another practical ground control problem. Extended cuts (cuts greater than 6 m (20 ft) in length) are commonly used with remote control continuous miners. Extended cuts can greatly increase productivity, but they have been associated with a number of fatal roof fall accidents. When extended cuts are attempted in weak roof, the roof may collapse before it can be bolted, causing hazardous conditions. Until now, it has not been possible to predict where conditions may not be suitable for extended cuts. In this study, data on the CMRR and extended cut experience were collected at 36 mines in 7 states. It was found that when the CMRR was greater than 55, deep cuts were routine in nearly every case. When the CMRR was less than 37, extended cuts were almost never taken. Between 38 and 55, extended cuts were feasible sometimes but not others. The data also shows that extended cuts are less likely to be stable if either the entry span or the depth of cover increases.

Jan 1, 1998

Diesel engines are used in underground mining 1 throughout the world. Exhaust gases from those engines contain toxic components. To protect quality in underground mines, diesel emission control was introduced decades ago, many years before the first surface applications. Today, emission controls, such as catalytic converters, are standard on underground diesel engines in countries concerned with occupational safety and health. Nett Technologies manufactures a range of diesel emission-control devices for underground mining. Emission problems are not the same at each mining operation. And there is no universal control technology. The selection of exhaust aftertreatment technology depends on raw exhaust emissions, particular emission problems, fuel quality and economics. Some of the technologies that have been used in underground mining to control diesel emissions include catalytic converters, diesel filters, fume diluters and water scrubbers. Table 1 compares the effectiveness of these technologies to control the particular components or aspects of diesel emissions.

Jan 1, 1997

By G. B. McClurg

China was nota factor in the supply of fluorspar to the United States until the early 1980's when it shipped in its first package of Metallurgical lump, that not only was higher grade than the Mexican Metallurgical spar but was also about $30.00 a ton cheaper landed at Burnside. Representatives of the Mexican Fluorspar Institute and several producers made trips to see the Chinese operations supplying their once reserved market place. China, an enigma to most Westerners suddenly became the new contender, with prices that were disgustingly low or so thought the other exporters. Of course China has been mining, producing, consuming and exporting from 400,000 to 500,000 tons per year of various grades of fluorspar but until the first partloads came to the U.S., very little attention was paid to their exports by American-continent producers or consumers.

Jan 1, 1986

By Walter R. Hibbard

Precipitation in the northeastern United States, Florida, California and in many industrialized areas of the world is now more acidic (lower pH) than can be accounted for by natural causes. At the same time, the acidity of many lakes and streams in the northeastern United States has been measured and found to be similar to that of actual rain. These facts have led to conclusions that the two conditions are related. Coal burning utilities, 700 to 1000 miles upwind, have been accused of being the cause, leading to proposals for strict emission controls on the alleged offenders. The costs of these controls would place an estimated $10 to $15 billion capital burden on utility customers in about 15 states plus $2 to $6 billion annual operating costs. There appears to be no direct well-established scientific evidence that the accused are guilty but that the indictment is based largely on circumstantia1 evidence. This study examines the evidence, describes the situation and proposes what must be done to reduce the acid precipitation in an orderly cost beneficial manner. It is interesting to observe that studies by the different adversaries on the acid precipitation issue come to different conclusions largely because they do not read the same literature, but selectively develop evidence to support their own points of view, This study will try to review the issues impartially and reach a position of scholarly balance.

Jan 1, 1982

By Robert Hochscheid

A patent issued to J.N.J. Leeman (1957) described the change in performance that takes place when a cyclone is installed in the horizontal position rather than the vertical position. Although this patent was directed more toward improvements that could be realized in the heavy medium cleaning of coal, it contained specific references to reducing the quantity of fine solids that would report in the underflow, and an example for fine sand classification is also included. The three cyclone installations for which data is given in this paper demonstrate that horizontal mounting of large cyclones can improve classification efficiency, eliminate some operational difficulties, and reduce cyclone maintenance requirements in closed circuit grinding installations. Cyclone Experience at Serrana S.A. Each of four grinding circuits at the Serrana S.A. de Mineracao Apatite flotation plant in Brazil have a 2.7 X 4.6 meter (9 X 15 foot) rod mill and each originally operated in closed circuit with two vertically mounted Model D20B (500m nominal diameter) Krebs Cyclones. New feed size is 25mm. The Apatite is liberated at a relatively coarse 35 to 28 mesh grind, but the 500mm cyclones had to be fed at 66 pct. solids in order to obtain an overflow analyzing 12 pct. coarser than 42 mesh. Because dilution water in the cyclone feed had to be limited, classification was inefficient, and there were other significant circuit difficulties as summarized in a recent article by C. A. Busnardo (1984):

Jan 1, 1985

By M. C. Stuttle

MDL Rock Lasers has undertaken successful mapping trials of abandoned mine workings using its underground cavity scanning system. The work was being performed for Kalgoorlie Consolidated Gold Mines (KCGM), Australia's largest gold producer. MDL Rock Lasers supplies underground surveying systems to the mining and quarrying industry KCGM's Fimiston Super Pit, located in Kalgoorlie, Western Australia, is Australia's largest open-pit gold operation. Fimiston's final pit design is expected to be 3.7 km (2.3 miles) long, 1.5 km (0.9-miles ) wide and 540 m (1,770 ft) deep. During the early days of Australian mining, underground operations were labor intensive. Mining was selective and generally narrow stopes were mostly backfilled. Improved processing technology and mine mechanization during the 1970s and 1980s has permitted larger scale operations to adopt less selective underground-stope operations. The "super pit" concept was a logical step for mining companies working toward economies of scale. However, the industry recognized that there was no precedent for excavating a 500-m- (1,640-ft-) deep open pit through ground previously affected by old workings. To appreciate the geotechnical challenge facing KCGM, it is necessary to consider that under the pro¬posed area at the open pit, stoping reached a level of 1 km (0.6 miles) and was supported by more than 2,000 km (1,240 miles) of development headings. The company was fortunate because plans were available for the Golden Mile underground operations. The existing plans were interpreted by the mine's geotechnical team and computer models were constructed of the underground workings. These models can be imported into three-dimensional mine planning packages, such as the Vulcan's Unix-based software, Envisage, to assist analysis and design. This prior knowledge of the workings provided the focus for investigating and confirming ground conditions using probe drilling. After several iterations of drilling, followed by detailed analysis, several decisions were made relating to the nature of the ground and the mining approach to be taken. It was recognized that the stope models were not perfect due to hu¬man error, lack of original survey information and progressive deterioration in ground conditions. It also became apparent that the sole reliance on probe drilling was inefficient in terms of time and quality of information. This was particularly true in complex areas where stopes are in close proximity. A major concern was the presence of open stopes (voids). In many cases, stopes consist of combinations of filled and void sections. The condition of pillars within these underground workings is extremely important. In time, pillars collapse and voids will propagate in upward and lateral directions. So systems needed to be developed that allowed rapid and accurate verification of ground conditions. KCGM was introduced to MDL Rock Lasers while investigating technology for underground mining. The two companies decided to use the C-ALS, MDL Rock Laser's underground laser, cavity scanning system, to improve the management of mining through affected ground. This system was to be used in conjunction with probe drilling and void mapping activities. A field test in one area of the Fimiston Mine verified the capability of the C-ALS system to quickly and efficiently assist in this decision making process. The C-ALS scanner features lightweight, carbon fi¬ber alignment rods from Measurement Devices Ltd.'s (MDL) Boretrak MKII. This is a borehole deviation system that stops the two axis measurement head rotating and lowers the system down a borehole. The scanner is deployed by a 110-mm (4.3-in.) borehole, up, down or sideways. The operator can then carry out vertical and horizontal plan section scans at any user specified ARC (an angular increment of 2°) or the distance between two points on the ARC (CHORD) increments. Windows '95 software enables the operator to control the cavity scanner remotely, surveying the area in real time. The system makes data quick and convenient.

Jan 1, 1999

By Clark B. Risler

Conveyors constitute a critical artery, essential to the successful operation of most ore processing plants. Technological progress is permitting the recovery of metal from low grade ores which previously could not be worked economically. Significant in this progress are improved material handling techniques highlighted by the frequent and successful application of conveyors. From the standpoint of the plant manager the successful conveyors are those he never hears about. They continue to economically transport the loads applied to them, requiring only routine maintenance attention. When such conveyors are subjected to closer scrutiny you will find that they have been carefully selected and engineered to perform the required function under the anticipated conditions. Among the primary elements in a conveyor drive are the electrical motor and the speed reducer. The selection of these elements can be aided by the systematic consideration of several factors. These factors which focus attention on the critical operating conditions, will be individually evaluated and their effect upon the selection of the electrical drive system and speed reducer analyzed.

Jan 1, 1958

The latest resource estimate for the Caspiche gold/silver/copper project in the Maricunga region of Chile was released by gold explorer Exeter Resource Corp. The resource is low grade, but bulk minable and drilling to date has shown a NI 43-101 compliant inferred resource of 1,117 Mt (1.23 billion st) grading 0.55 g/t (0.016 oz/st) gold, 3.81 g/t (0.111 oz/st) silver and 0.22 percent copper. Exeter said these findings make the in situ metals amounts of 609 t (19.6 million oz) of gold, 4.4 kt (137 million oz) of silver and 4.84 billion lbs of copper, which the company relates as 33.7 million gold equivalent ounces using assumed metal prices of $23.33/g ($800/oz) for gold, 35 cents/g ($12/oz) for silver and $2/lb for copper. The deposit is almost midway between Barrick?s Cerro Casale gold deposit and Kinross? Refugio Mine. In a statement Exeter chairman Yale Simpson said ?This updated resource estimate places Caspiche firmly among the world?s largest gold-copper discoveries in recent years and clearly supports our decision to aggressively drill the property, despite the global economic decline. ?We expect that the very substantial copper and silver credits will be extremely important, and will markedly impact the potential viability of Caspiche. Specifically, using metal prices of US$2/lb copper, $23.33/g ($800/oz) gold and 35 cents/g ($12/oz) silver, the 4.84 billion lbs of copper and 4.2 kt (137 million oz) of silver are equivalent to 376 kt and 62 t (12.1 and 2 million oz) of gold, respectively. ?Our recent drilling has defined what appears to be a coherent higher grade central zone associated with a definable early stage diorite intrusion. We expect this zone will be important in developing various mining and economic models for the project,? Simpson said. Exeter is still drilling the deposit to expand the re-source estimate further to the southeast and at depth and to upgrade the higher grade central zone to the indicated category. Simpson said, ?Exeter intends to enhance the value of Caspiche by continuing to de-risk the project through ongoing exploration, metallurgy, engineering, water and environmental studies. These studies will continue through the next 12 months and will lead to a conceptual development study. A timeline for the release of that study is being formulated. The project budget for the next 12 months is C$14 million.? Mineweb reported that Caspiche is likely too big of a deposit and at too high of altitude for Exeter to handle alone. Exeter will be looking to other majors, or perhaps the Chinese, to help develop this huge orebody. But, in the meantime, it also has its high grade Cerro Moro deposit in Argentina, which could be brought to production relatively quickly and at relatively low cost.

Jan 1, 2009

"One of the major issues that the Rare Earth Elements Mining Industry has to deal with is the legislation vacuum that exists in many countries around the world. Among these, are countries which have long history and tradition in mining. In many cases the lack of direct legislation for REE mine management as well as for other potentially polluting industries can be a barrier to sustainable development. Moreover, the case of lax legislation in China has led to environmental pollution problems and extended smuggling of rare earth elements. This paper looks into the current regulatory status on the mining of REEs, identifies the loopholes and suggests some elements for a new global legislation framework for sustainable development in the REE mining industry. The setting of this regulatory framework will be in line with the present and future challenges of the rare earths market as well as with the policy strategies that are defined internationally. The aim of such a legislative framework will be to strengthen the global rare earth elements supply chain, appease social concerns and ensure the preservation and conservation of the environment. INTRODUCTION The general public received their first introduction to rare earth elements (REEs) in 2010, when the previously inconspicuous commodities became the subjects of front-page headlines. It was when China created a furore in global high-tech markets after imposing an embargo on Japan following a minor marine dispute (Barakos et al. 2015b). Soon enough the Chinese embargo was extended on REE export restrictions all over the world and thus aroused concerns to many countries over potential supply disruptions. The world had suddenly realized that these wonder materials underpin products that they care about. Governmental and industry executives, policymakers and material scientists voiced concerns and conducted numerous reports stating the situation and the risks of a supply crisis. The price spike of 2011 intensified the crisis and the public turmoil, yet the drama did not last for long as the prices declined significantly in 2012. Nevertheless, the world was nonplussed by the fact that China has the total control of the market with more or less the 90% of the global production. More potential entrants became interested, thus initiating an exploration boom during the recent years that has resulted in a significant increase in known global REE reserves that could have potentials for exploitation."

Jan 1, 2016

By S. H. Amini, A. Noble

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

Jan 1, 2017

By Theophilus Mensah, Kwame Awuah-Offei

Engineers face significant challenges when determining what geometry provides the most profitable and safe stope for extraction. Several techniques and optimization algorithms have been developed in recent years, but most fail to find optimal solutions because they are heuristic or LP-based without efficient geometric constraints. This paper presents a two-dimensional binary linear programming (BLP) model for determining the optimal combination of blocks in a stope that maximizes the economic value of the layout of stopes for a sublevel deposit. The work draws from Queyranne and Wolsey’s (2017 & 2018) formulations of tight constraints for bounded up/down times in production planning problems to formulate novel and efficient geometric constraints along with geotechnical and grade constraints for the BLP stope layout optimization problem. Results from the model indicate that it is possible to formulate efficient shape constraints in LP-based approaches. The model used for the numerical example contained 144 valuable blocks out of 774 blocks, which translates into an economic value of $53.21M. The BLP model selected 60 valuable blocks and 13 waste blocks that met all constraints translating into a maximum economic value of $34.4M in 1.83 hours within a gap tolerance of 0.00%.

Jun 25, 2023