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By Brett Schug, Caelen Anderson, Sohail Nazari, Carlos Cristoffanini

"The Haile gold mine in South Carolina is increasing the automation level of its processing plant in order to improve operational stability. One step toward this goal is the application of a digital twin concept to provide virtual instruments. Haile has engaged Andritz to implement virtual instruments at its grinding area hydrocyclones and at its tailing thickener underflow pump. These virtual instruments provide density values in a traditionally difficult location for reliable slurry density measurement. The digital twin is a first-principles integrated design engineering with advanced simulation (IDEAS) simulation model, connected in real time to the control system. Results have been promising, with the virtual instrument values matching the physical instrument under normal operating conditions and showing better prediction under upset conditions. Haile plans to use the virtual instruments as optional process control parameters.OceanaGold’s Haile gold mine is located near Kershaw, SC, about 80 km (50 miles) southeast of Charlotte, NC. This location was first mined in 1827 and has produced gold through several operating periods since then, including a heap leaching operation from 1985 through 1992. In October 2015, OceanaGold acquired Romarco Minerals, the previous owner of the Haile operation.The current operation began in 2017 as an openpit mine with additional underground resources. The nameplate throughput is 5,760 t/d (6,350 stpd) ore, and 2017 production was 3,345 kg (118,000 oz) gold, with 3,968 to 4,384 kg (140,000 to 155,000 oz) gold expected in 2018. Proven and probable reserves exceed 85 t (3 million oz) gold at a grade of 2 g/t (0.06 oz/st) gold. The process, as shown in Fig. 1, includes a primary jaw crusher, comminution with a semiautogonous grinding (SAG) mill and ball mill circuit, flash flotation, rougher flotation, regrinding, pre-aeration, carbon-inleach leaching, carbon elution and regeneration, cyanide recovery, electrowinning and refining. The Haile operation’s inaugural gold pour took place Jan. 20, 2017. Mine life is expected through the year 2030."

Dec 1, 2018

By Nicolas Denies, Gust Van Lysebetten, Bart Lameire, Jan Maertens, André Vervoort, Noël Huybrechts, Flor De Cock

"Abstract Originally developed for ground improvement works, the deep mixing method (DMM) has increasingly been applied in recent years for the realization of soil and water retaining structures and as alternative to traditional foundation solutions. From practice, there is a real need for practical guidelines dealing with the execution, the design and the control of such applications. With the aim of developing such guidelines, the BBRI ‘Soil Mix’ project was initiated in 2009. Within this research project, deep soil mix (DSM) material from 38 Belgian construction sites has been tested. In spite of the large advances in the mechanical characterization of the DSM material, one major issue remains the representativeness of the typical core samples in comparison with the real scale behavior of the soil mix elements. There is among others the question of the influence of the unmixed soft soil inclusions on this behavior and the issue of the scale effect which must be considered in the design. In order to investigate these questions, 8 large scale UCS tests and 17 large scale bending tests have been performed on excavated soil mix elements. The present paper discusses results of this experimental campaign, presents some research perspectives and highlights different aspects related to the design of soil mix elements for the realization of retaining wall or foundation solution.INTRODUCTIONSince several decennia, the deep mixing method (DMM) has been used to improve the strength and deformation characteristics of weak soils. In recent years, deep mixing has increasingly been applied – in Belgium and in other countries – for the realization of soil and water retaining structures and alternative foundation concepts. With regard to the execution of the DMM, one can refer to the European standard EN 14679 on deep mixing (2005) that was elaborated under the umbrella of CEN TC 288 “Execution of special geotechnical works”. However, from practice, it has been experienced that this execution standard does not provide enough pragmatic information and guidelines, in particular for the more recent applications of the deep mixing method (with retaining and bearing functions). The same need by the sector for guidance rules linked to design aspects in the context of Eurocode 7 was experienced as well. With the aim of developing such guidelines and in order to provide feedback to the European standardization platforms, the Belgian Building Research Institute (BBRI) has initiated the BBRI ‘Soil Mix’ project (2009-2013) in collaboration with the KU Leuven and the Belgian Association of Foundation Contractors (ABEF), the Belgian branch of the EFFC. Within this research project, deep soil mix (DSM) material from 38 Belgian construction sites, with various soil conditions and for different execution processes (CVR C-mix®, TSM and CSM), has been tested (Denies et al., 2012)."

Jan 1, 2014

By J. Chretien

The ability to continuously monitor the air quality within a mine has become instrumental in becoming a low cost producer. The many considerations involved in monitoring air quality include sensor type, hardware placement, as well as data storage medium. BESTECH has had the opportunity to gain insight into these air quality monitoring considerations through deployments of NRG1-ECOTM, a minewide energy consumption optimization system. This paper explores the particular challenges overcome through these installations, and provides a set of guidelines for mines that want to maximize data capture while minimizing costs. It provides a view of additional benefits of air quality monitoring, such as ventilation control, reporting and trending.

Aug 1, 2013

Computer software has been developed to link real-time information generated by underground mine ventilation airflow monitoring sensors into a network simulation program to undertake network simulations and allow interpretation of key system data and operational changes. Results were used in the development of a computerised monitoring and simulation system to provide immediate or real-time data on air behaviour within each branch of an underground mine ventilation network through linking of sensors to the ventilation network simulation software. The outcome of the project is an online system that can report changes in the mine ventilation system, allow causes of changes to be isolated and rectified, improve balancing of available air throughout the mine, allow improved approaches to regulator setting and dispense with much of the labour used for underground ventilation measurement. The work activities in both coal and metalliferous Australian mines have involved examination and modelling of regulators, software modification and considerable mine site testing and optimising activities. There is some discussion on approaches to control of flow through ventilation systems with increased information. New systems will be part of a total mine information management system. They will have to be cost effective and justified by gains in productivity. New systems will need to provide simulation of contaminant production such as diesels, vehicle heat, strata heat, radiation, blast fumes and other gases. More robust real-time ventilation simulation systems will be required. Personnel and vehicle identification and production tracking will be collected to provide integrated ventilation system monitoring and control. This paper examines a study to gain greater understanding of computerised real-time airflow monitoring and control within the mine production system to provide immediate simulated information in each branch of an underground ventilation network and to allow interpretation of key system data and operational changes. A case study implementing a real-time airflow monitoring and control is discussed. Approaches to control of flow through ventilation systems with increased information are discussed. The concept of a system that can be linked to or be part of a total mine information management system is developed. Such a system can form the base for mine automation that allows mines to incrementally and cost effectively implement monitoring and control to further seek gains in productivity.

Jan 1, 2005

By Bora Okumusoglu, Devon K. V. Mothersille

"AnchorTest is an innovative software package, specifically developed for tablets, that permits ground anchor test data assessment and management in real time. The solution has two components: a front-end tablet app runs on the Apple iPad platform, and a back-end Cloudbased system running on Amazon Web Services with an online cross-platform website, which can be accessed from any PC, tablet or even mobile smartphone. This tool provides full data analysis and data management capabilities and portability to create greater efficiency in the anchor testing process. AnchorTest is programmed to accommodate the major international anchor testing codes and incorporates an intuitive user interface, which is revolutionary compared to conventional engineering software designs. The use of this tool creates an environment where the testing of ground anchors has effectively become a paperless exercise with greater efficiency and access to instantaneous feedback on the performance of anchors in relation to established acceptance criteria.Historically, project personnel record and analyze the results from anchor load tests using spreadsheets and a laptop computer and/or on predesigned paperbased test sheets (usually as a backup of the testing). In addition, the processing of the test results is not typically performed in real time as the testing progresses — the calculations and analysis are performed either afterward while still on site (if a field office is available) or after returning to the office. Undoubtedly, on larger projects containing numerous anchors where multiple anchor tests may be performed at the same time, processing, analyzing and accepting the load test data and results can be especially time consuming, which could cause delays to the construction schedule.DevelopmentThe need for a more automated and digitized approach to record, process and analyze the data from anchor load tests was highlighted at a deep basement project for a mixed-use development complex in Moscow, Russia. The diaphragm wall supporting the structure was approximately 1,970 ft (600 m) in perimeter length and about 148 ft (45 m) deep, with an excavated depth of about 82 ft (25 m), which required six levels of single bore multiple anchors (SBMAs). This project provided a challenge to recording, processing and signing off on the data generated from some 3,600 3-unit SBMAs. More specifically, for this project, three hydraulically synchronized stressing jacks were used to stress and proof test each 3-unit SBMA, which resulted in nearly 10,800 data plots of the load-extension tests being generated. This project served as the main impetus in the conceptual design and optimization of AnchorTest."

Jan 1, 2017

By X. Wu

Tunnel Boring Machines (TBMs) are widely used for tunneling in urban areas because of their high advance rate, precise as-built profile and minimal impact to buildings and traffic on the ground. For a tunnel built by a TBM, there are strict requirements on alignment control and safety. To meet these requirements, it is important to monitor the position of the TBM. In the current practice, the TBM position data, including advance distance and line and level deviations, are reported manually to the managers on a daily basis. To interpret and analyze the position data, the managers also need to refer to various construction drawings. This practice is untimely, inefficient, and error prone for decision making. To improve the current practice, an automatic approach for real-time as-built tunnel product modeling and visualization is proposed, based on TBM position and orientation data autonomously sourced from the Virtual Laser Target Board (VLTB) TBM Guidance System developed at University of Alberta. Related information of the tunnel project, such as the as-designed alignment, soil layers, the ground, existing utility lines, is also visualized together with the model of the as-built tunnel. The modeling algorithm is presented step by step. Its application in a real-life drainage tunnel project is discussed and limitations are also identified.

Aug 1, 2013

By E. J. Sun

The ADS system was developed to reduce accidents related to haul trucks operating under low visibility conditions in surface mining and construction sites, which is based on the GPS, mesh-wireless networks, and the Google-Earth 3D graphic engine as the graphic interface and mine-mapping server. This system has the capability to pin-point and track vehicles in real time using a 3D interface, which is based on user-based AutoCAD mine maps using the Google-Earth graphics interface. All equipped vehicles are shown in a 3D mine map stored in a local server through a wireless network. When low visibility conditions are present, the system indicates available exit/escape routes for driver safety. The research results indicate that the ADS system potentially increases reliability and reduces uncertainty in open pit mining operations by customizing the local 3D digital mining map, constructing the truck 3D models, tracking vehicles in real time using a 3D interface and indicating available escape routes for driver safety.

Oct 1, 2009

By Milan Yekich, Emanuele Cauda, Justin Patts, Cody Wolfe

A worker’s personal exposure to respirable dust in occupational environments has traditionally been monitored using established methodologies which entail the collection of an 8-hour representative sample that is sent away for laboratory analysis. While these methods are very accurate, they only provide information on the average exposure during a specific time period, generally a worker’s shift. The availability of relatively inexpensive aerosol sensors can allow researchers and practitioners to generate real-time data with unprecedented spatial and temporal granularity. Low-cost dust monitors (LCDM) were developed and marketed for air pollution monitoring and are mostly being used to help communities understand their local and even hyper-local air quality. Most of these integrated sensing packages cost less than $300 per unit, in contrast to wearable or area dust monitors specifically built for mining applications which have been around for decades but still average around $5,000 each. At the National Institute for Occupational Safety and Health (NIOSH), we are leveraging the power of high-volume data collection from networks of LCDM to establish baseline respirable hazard levels and to monitor for changes on a seasonal basis as well as following any application of control technologies. We have seen the effective use and advantages of monitoring live data before, during, and after events like shift changes, operational changes, ventilation upgrades, adverse weather events, and machine maintenance. However, many factors have prevented a systematic adoption of LCDMs for exposure monitoring: concern for their analytical performance, the complexity of use, and lack of understanding of their value are some factors. This contribution outlines a one-year case study at a mine in Wisconsin USA, covering the installation, maintenance, data visualizations, and collaboration between NIOSH researchers and the industrial hygiene professionals at the mine.

Feb 1, 2024

By R. Spring

Artificial intelligence, and especially expert systems, are currently receiving considerable attention. Of interest to the control engineer is the utilization of these tools for real-time process control applications. To evaluate this technology, a real-time expert control system was implemented in one of the grinding circuits at Brenda Mines Ltd. The performance of this micro computer based expert system compared satisfactorily to the proven supervisory control system currently in use. The study confirmed the expectations that expert systems have potential for real-time, supervisory control of mineral processing operations.

Jan 1, 1989

By J Moffatt, T Payten, N Spooner, L Teixeira, L A. Balzan, G Wilkie, G Tsiminis

Fluorine is a penalty element due to its reactive nature. In acidic environments many fluorine minerals dissolve to form hydrofluoric acid (HF), changing processing conditions. When smelted HF can be released, causing negative effects to nearby people and the environment, as well as potentially damaging the smelter. Sale of ore with high fluorine levels elicit a financial penalty or are banned outright. Real-time sensors create the opportunity for instantaneous decisions on ore processing due to changing conditions. A fluorine sensor would allow rises in fluorine concentration in a processing stream to be flagged, and decisions on processing conditions or diversion to stockpile before processing could be undertaken. As fluorine is a light element, it is difficult to detect with in-field XRF devices and does not work well with PGNAA. There are currently no existing sensors to quantify the presence of fluorine in real-time, and thus decisions based on fluorine grade cannot be made at minute- or even hour-scales. Sensors designed to measure the presence of minerals that contain fluorine are a possible avenue to enable the real-time detection of this element. Mineral-based sensing may also give an added advantage of additional information about how the fluorine will react under different processing steps. The authors were given a grant under CRC ORE II (project number P1–005) to search for mineralspecific signatures suitable for real-time analysis. The work focused on novel regimes and applications of fluorescence as a means to detect specific minerals. The aim was to exploit fluorescence responses unique to minerals of interest in mining systems in order to produce sensors that address gaps in existing capability. After the successful discovery of signatures specific to two major fluorine minerals an additional grant (P1–014) was funded to develop the research into a prototype on-belt sensor, in partnership with Scantech International Pty Ltd. This paper details the development of a sensor package through multiple Technology Readiness Levels (TRLs) through collaboration with government/industry grant schemes, academics from university, and a sensor-focused Mining Equipment and Technology Services (METS) company. We give a brief description of the new sensor technique and provide a case study of multi-disciplinary collaboration.

Aug 24, 2022

By A. F. van der Merwe, R-D. Taylor, M. Jacobs, F. H. Conradie

Total bound moisture (TBM) is a typical quality indicator of industrial-grade gypsum. This gypsum is comprised of three distinct phases, namely anhydrite, dihydrate, and hemihydrate, of which only the latter is of much industrial use. TBM analysis is a lengthy laboratory procedure, and an artificial neural network (ANN) TBM inference measurement is proposed as a fast and online alternative. An ANN inference model for gypsum TBM based on plant data was developed. The inputs to the network were primarily focused on the plant's calciner, and different network topologies, data divisions, and transfer functions were investigated. Furthermore, the applicability of the TBM value as a quality indicator was investigated based on a gypsum phase analysis. A strong correlation between TBM and the gypsum hemihydrate and anhydrite content was found, validating the plant target TBM of 5.8% as a quality indicator. A network topology consisting of one hidden layer with logarithmic-sigmoid (logsig) and pure linear (purelin) transfer functions showed the best performance (R > 90%).

Oct 3, 2023

By T Belligoi

Diamond cores and drill chips provide the only direct physical evidence for ore containing rocks. Early characterisation of cores and drill chips is important as it provides critical information for downstream processing. Traditional characterisation techniques include visual logging by a geologist or analytic and spectroscopic methods but they are time consuming and can miss some important textural or geomechanical features.The goal of this work is to evaluate the application of image analysis to iron ore cores and drill chips and to suggest improvements to existing core-scanning and chip monitoring systems. Two samples of massive ore differing by their mineralogy and texture, as well as two different batches of drill chips, have been imaged and analysed. Results are compared in function of the imaging system and the classification algorithms.As a conclusion, despite the necessity for more testing and improvements in calibration and lighting, it is obvious that image analysis technologies can bring a lot of useful information in the perspective of a geometallurgical mapping of the deposit.

Jul 11, 2011

By Hao Zhang

Site inspection is an important component of safety management system. In current practices, the inspectors evaluate the safety condition on a construction site with the assistance of a standardised checklist. However, the checklist emphasizes on evaluating the implementation of safety management system, but provides limited task-specific check items for assessing whether the individual construction tasks are conducted under safe condition and in a safe manner. To address this issue, the research presented in this paper aims to provide safety practitioners with comprehensive and taskspecific safety information to promote effective risk identification and facilitate strategic risk control during site inspection. Specifically, this research first builds a project-specific safety information database, which stores potential risks and control measures for each construction task. The research team then develops a mobile decision support tool to retrieve information from the database and support safer decision-making on site. The tool supports users in two ways: one is to provide daily risk checklists and risk control strategies to guide step-by-step inspection alongside the project schedule; the other is to let users input any safety-related keywords during the safety inspection process and the tool returns relevant safety information by applying text mining algorithms. It is ongoing research. This paper presents an overall research framework and discusses the progress in developing safety database and data retrieval concepts. The outcome of the project will help enhance safety management practices and reduce possible risky working conditions on a construction site.

Aug 1, 2013

By Kevin L. Gering

A detection method and apparatus have been developed to perform real-time measurement of aqueous free cyanide, C-. A laboratory prototype can measure cyanide ranging from 5 micrograms ,per liter to 100 milligrams per ?liter for analysis times as short as 2 minutes per measurement. Sample size per measurement is typically only a few mI, thus? minimizing the waste volume produced from spent samples. The basis for this detection device is a quantifiable, stable affinity between the electrode material and free cyanide in the sample; The electrode exhibits piezoelectric behavior, allowing it to be used as a microbalance. This technology 'has experienced two generations of laboratory prototypes, and has been thoroughly tested to determine the operational sensitivity toward process variables such as pH, competing reactions, etc. The speed and ,accuracy of this method make it superior to conventional wet chemistry methods used for quantifying cyanide levels in water. A device based on this technology could be useful in areas involving process monitoring and environmental compliance, .particularly in the cyanide-based leach mining industry. Interest for this detector has been shown by the gold mining industry and others. Patent application is in progress.

Jan 1, 1998

By Pierre Gouvin

This paper describes the design, installation and monitoring of a state of the art real time geotechnical/structural instrumentation monitoring system to facilitate tunnel construction under Interstate route I-5 in Seattle, Washington, USA. The project involved removal of existing highway foundation substructures on both North and Southbound lanes as well as the underground reversible high occupancy vehicle lanes. The system utilized state of the art 3-D pulsed laser scanning, wireless sensor networks, automated robotic total stations, tilt beam sensors, narrow angle tiltmeters, and in-place inclinometers. Dedicated real time data loggers, with a web based graphical interface, provided 24/7 access to critical measurements. In addition to the instrumented sections of wall and roadway subsurface which monitored physical measurements at known points, the pulsed laser scanning allowed complete site monitoring coverage where physical sensors were not located. This data allowed post processing at any location enabling the contractor and designer to respond to unforeseen structural responses to construction. Use of the instrumentation system resulted in the early detection of wall movement, and provided feedback to the designers to facilitate construction process changes in order to minimize further movement.

Jan 1, 2010

By J. P. McDonald

Exposure to particulates containing metals and metal fumes (PCMMF) is a potential concern in ore refining and smelting. Some metals of primary interest are arsenic, cadmium, copper and lead, which have been linked to various adverse health effects. The current National Institute for Occupational Safety and Health (NIOSH) sampling method for metals in particulates requires the use of a filter, precision airflow pump and laboratory analysis. A major concern with this method is the one-to-two weeks? wait before laboratory results are available for use in determining if additional controls are needed to assure adequate exposure protection for workers. Particulates containing these metals were sampled during sixteen sampling events at a copper smelter using the traditional NIOSH methods. Monitoring of particulates was simultaneously conducted using a TSI 8520 Dust-Trak real-time aerosol monitor with a 10-µm-cutpoint sampling inlet. NIOSH analytical methods related to particulates and metals (methods 0500, 0600 and 7300) were used to determine particulate mass and individual mass contributions of metals on sample filters. Linear regressions with y-intercepts forced to zero were developed to determine the relationship between the PM10 measurements recorded by the DustTrak and laboratory-reported total particulate mass, PM10 and respirable arsenic, cadmium, copper and lead concentrations. These linear regressions yielded correction factors that can be applied to DustTrak readings to obtain total particulate mass, PM10 and respirable concentration estimates for each of the four metals. The R2 (coefficient of determination) values from the linear regressions ranged from 0.65 for total lead to 0.91 for total copper. These results suggest that the DustTrak may produce real-time data useful in providing estimates for airborne concentrations of arsenic, cadmium, copper and lead in copper smelter particulates.

Jan 1, 2011

By Wilfred Lus

Meaningful and real time environmental monitoring of marine tailings placement is a clear sign of deeper commitment to the people of PNG in regard to impacts of mining on coastal environment and marine life. Today daily mine wastes and tailings are increasingly being delivered to the seabed offshore of project sites in Misima and Lihir islands. Ramu and Simberi mining projects also plan to dispose tailings out at deep sea. As tailings leave the tailings pipe and come out into the seabed, concentrations of the cations and other potential harmful particles in the tailings stream need to be quantifiably monitored each day during the life of the refinery. For continuous monitoring of the tailing?s true chemical characteristics submarine cables connected with ocean floor observation systems consisting of deep-sea underwater video, and cation sensors and electrodes will be laid. Power transport to the tailings site and data transfer from the tailings site will be via opto-electric cables. Various data center instruments will record and manage the collected data. Observation data will be transferred in real time to stake holder?s data centers via a dedicated line from on-land stations, and then distributed to company offices and government establishments. Japan Marine Science and Technology Center, Telikom PNG, and Australian Institute of Marine Sciences will be the key advisers in this project. The main role of the observatories is to monitor and collect background seabed geochemical data prior to start of tailings disposal, during tailings disposal period, and after the life of the refinery.

Jan 1, 2001

By Adrian Moore, Alan Richards

A real-time system for prediction of the effect of meteorological conditions on airblast overpressure levels has been established in the Hunter Valley Coalfield in Australia. Real-time meteorological data from continuously operating sounding equipment and a predictive meteorological model is input to an atmospheric refraction model that enables the effect of meteorology on airblast overpressure levels in the area surrounding the blast site to be evaluated. Graphical outputs from the model, which are superimposed over a scaled airphoto of the mine and surrounding area, show the extent that airblast levels will be increased. When combined with inputs that quantify the effect of blasting specifications, the airblast levels that will result in the surrounding area from the combined effect of blasting specifications is determined. The model permits those responsible for blasting to make more accurate decisions on suitable times that blasting may take place to conform with applicable airblast limits.

Jan 1, 2009

Safety remains a critical priority for the Australian mineral resource industry and will receive increased focus in the future. This is particularly evident in underground coal mines where reserves are becoming deeper and more hazardous to extract. The CSIRO, through its Exploration and Mining Division, have recently delivered on two projects aimed at providing step-change capabilities in real-time risk management and hazard control. This paper describes the key outcomes of these projects.

Jan 1, 2005

By F. Vahdatikhaki

Simulation techniques have offered significant boosts toward a cost-and-time-optimized planning of construction projects by enabling project managers to effectively comprehend the behavior of projects. Using historic data from projects of like nature, simulation considers uncertainties involved in a project through accommodating the stochastic modeling parameters. However, the heavy reliance on the statistical data and not taking into account the context-specific features of the project cause the degradation in the realism and accuracy of the simulation models. Similarly, the extent to which a historic pattern could be retrofitted to new projects will decrease in line with the growing uniqueness of the projects and the novelty of construction methods. Furthermore, the existing real-time simulation frameworks are not capable of distinguishing the transient environmental changes, with minimal long-term impacts on the productivity, from the influential changes that will greatly impact an operation. In addition, existing simulation tools are devoid of location awareness, resulting in the inability to consider safety threats in their representation of the project. To address these issues, this research proposes a framework based on the integration of new tracking technologies used in Automated Machine Guidance (AMG) with simulation-driven 4D modeling methods. The proposed framework automates the adjustment of the simulation model based on the updated data from the site, and thus transforms simulation from a predictive tool used at the planning phase to a proactive monitoring platform usable throughout the planning and construction phases. A prototype is developed to test and demonstrate the effectiveness of the proposed approach.

Aug 1, 2013