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A pilot scale AG milling campaign was conducted at the AngloAmerican Platinum pilot plant in South Africa. Different blends of hard:soft (silicate:chromite) and coarse:fine particles in the AG mill fresh feed were tested. The effects of multi-component feed on the pilot scale autogenous grinding are presented in this paper, and can be used as a guideline for multi-component feed blends for AG milling. Preliminary modelling and simulation for the multi-component AG mill model are also included.

Jan 1, 2012

By H. Lawson

The Mine Safety and Health Administration (MSHA) issued Program Information Bulletin P09-03in April of 2008, providing formal guidance on using programs that model the redistribution of stress during underground mining of coal. A key part of this guidance is visual observation and mapping of ground conditions. If a correlation between ground conditions and model output can be established, the model is considered to be verified, and can be used to guide mine design in similar ground. A simple scale is recommended for ranking observed roof, rib, and floor conditions. This paper discusses optimization and implementation of a ground condition rating scheme in the gateroads of a deep underground longwall coal mine. Roughly 80% of each gateroad length deteriorated in a fairly uniform manner. However, this manner varied between gateroads, as did pillar size. The implementation of a ground condition mapping program, similar to that recommended in PIB 09-03, was successful in characterizing the ground response to mining in gateroads of a longwall coal mine.

Jan 1, 2012

By Scott Ellenbecker

Mining has evolved in recent years, taking steps forward in the way that the industry is considerate of the environment and the communities in which it operates. Technology plays a major role in that evolution. Osisko Mining?s Osisko Mine near Malartic, Quebec is developing a new way of doing business. One manager said, ?We are building the Osisko culture,? but the company is doing many things that could become industry changers. Much of the change is driven by mine ownership and management to offer a better workplace and better community relations. Mining equipment manufacturers are changing, too, by engineering products with more operator comfort, fuel economy, ease of maintenance and more cleanly designed machines. And for those drills working close to communities, smaller bore sizes and sound retention are just two changes for the better.

Jan 1, 2012

Critical safety tools to locate miners underground are featured by several exhibitors at MINExpo. Communication was the buzzword for health and safety products at the 2008 MINExpo, and it is still important in 2012. Products unveiled following the Miner Act in 2006 have been upgraded and improved. Saving lives and reducing injuries through better leadership, planning and practice is the goal of every mine professional.

Jan 1, 2012

In terms of throughput, product size and power draw, grindcurves provide a measure of the response of the mill performance to changes in mill operating parameters ? usually mill filling. Since presenting the principle in 2006, grindcurves have been applied to a wide variety of AG and SAG mills. Mill response has been carefully measured for variations in: mill fillings from 15% to 40%; throughput by a factor of two; power by 50%; feed blends; liner profile; and mill speed from 65% to 80%. The outcomes of this extensive program of work are presented as the measured grindcurves. How they have enhanced our understanding of mill operation and how they may be applied to practical daily mill control is discussed. It is proposed that this technique provides a viable and valuable mill control tool that may find extensive application in the industry.

Jan 1, 2012

By Edward Rybinski

Compañía Minera Antamina is a polymetallic mining complex that produces copper and zinc concentrates as primary products and molybdenum and lead/bismuth/silver concentrates as by-products. In 2007, Metso Process Technology and Innovation (PTI) was contracted to increase SAG mill throughput by integrating and optimising blast fragmentation, crushing and grinding for the harder M4/M4A (CuZn) ores. Following the implementation of recommendations provided by Metso PTI, the SAG mill throughput increased from 2750tph to reach an average of 3600tph for the remainder of 2007. Due to continued application of mine to mill integration and optimisation philosophy, by 2010, the concentrator consistently exceeded the target of 4400tph while processing harder CuZn ores.

Jan 1, 2012

By U. Thorley

This paper presents an overview of surface mining activity in the Canadian oil sands and how the mine operators interact with the province of Alberta's Mine Financial Security Program (MFSP), which took effect April 1, 2011. The MFSP approach to reclamation assurance results in the government of Alberta sharing a portion of reclamation liability through the majority of an oil sand mine's life. In order to determine the potential fiscal magnitude of this shared liability, an examination of the expected costs of oil sands reclamation activities through a study of corporate asset retirement obligation (ARO) liabilities and other corporate disclosures is presented. The province of Alberta's Environmental Protection Security Fund (EPSF), which formerly secured oil sands mine reclamation activities is discussed. Reclamation costs in the oil sands are poorly understood. The MFSP provides what it characterizes as a conservative estimate of C$75,000/ha, while corporate disclosures by Canadian Oil Sands Ltd. place expected costs at C$180,000/ha. There is significant risk associated with the apparent uncertainty surrounding reclamation costs.

Jan 1, 2012

The U.S. National Institute for Occupational Safety and Health (NIOSH) conducted a study to determine the effectiveness of a filtered air delivery system to reduce respirable dust exposure of roof bolter operators in underground coal mines. When performing roof bolting operations, roof bolter operators may experience exposure to high levels of respirable dust during a working shift, especially when working downwind of the continuous mining machine. While drilling and installing roof bolts, this filtered air system supplies a clean curtain of air over the roof bolter operator by means of a plenum mounted beneath the canopy. This experimentally designed air curtain, adapted for roof bolting machines used in this study, is based upon previous design prototypes, computational fluid dynamics (CFD) simulations and trial-and-error testing. Both the prototype and final designs were tested in the full-scale mining galleries at the Office of Mine Safety and Health Research (OMSHR) in Pittsburgh, PA before being taken underground for field testing. Test results of the system in both laboratory and field studies show reductions in operator exposure to respirable dust when the operator is positioned directly under the protected zone of the canopy.

Jan 1, 2012

By H. Cevizci

In this study, a newly developed plaster stemming method is studied and compared with the usual dry drill cuttings stemming method for surface blasting in mines and quarries. Drill cuttings are generally used in open pits and quarries as the most common stemming material since these are most readily available at blast sites. However, dry drill cuttings eject very easily from blastholes without offering much resistance to blast energy. The plaster stemming method has been found to be better than the drill cuttings stemming method due to increased confinement inside the hole and better utilization of blast explosive energy in the rock. The main advantage of the new stemming method is the reduction in the cost of blasting. In one series of blast tests, blasting costs per unit volume of rock were reduced to 16 per cent by increasing burden and spacing distances. Also, better fragmentation was obtained by using the plaster stemming method. Blast trials showed that plaster stemming produced finer material. In the same blast tests, +30 cm size fragments reduced to 5.4 per cent of the total, compared to 37.7 per cent in the conventional method of drill cuttings stemming. With this method of stemming, vibration and air shock values increased slightly due to more blast energy being available for rock breakage, but these increased values were small and under the permitted limit for blast damage criteria.

Jan 1, 2012

By Matthew S. Sanchez, Richard J. Lee, Matthew D. Zock, Drew R. Van Orden, Yumi Kamiya, Edward B. Ilgren

In many developing countries, asbestos is still used for friction products, insulation, and asbestoscement products. However, there is very limited modern data evaluating the airborne concentrations of asbestos fibers in operating asbestos plants. We have conducted an Industrial Hygiene survey, using state of the art PCM and TEM analysis, of a Bolivian asbestos cement plant that uses crocidolite during the production of roofing shingles and water tanks. The study is the first to use modern analytical measurements in an uncontrolled asbestos environment. Thus, this study offers insight into the historical airborne exposures at asbestos plants operating before modern dust control measures were introduced or airborne fiber levels regulated. The results suggest that fiber concentrations are far in excess of those for which current models would predict the onset of asbestos disease and mesothelioma. Significantly, the plant and community do not have an elevated incidence of asbestos disease or mesothelioma. Airborne fiber levels during comminution and fiber sizing ranged from 100 to as much as 1,000 f/cc. Fiber levels in the mixing, forming and finishing areas ranged from 0.5 to 9 f/cc. Based on the number of overloaded samples and estimates of their concentration, historical estimates of exposure may be underestimated by an order of magnitude. Also, an excellent correlation (1:1) between the PCM and TEM fiber concentrations (for fibers _0.25 um diameter) were obtained, raising questions about the conventional wisdom that the PCM systematically undercounts fibers. The results of this study further indicate that current models may overestimate the risk of asbestos disease and mesothelioma.

Jan 1, 2012

By P. Condori

Palabora Mining Copper has a unique ore body composition which unlike other copper ore bodies has three main components in significant proportions; these are copper bearing ore, magnetite and dolerite. The high content of dolerite, a hard barren material, creates a high proportion of pebbles which normally are recycled back to the mill. This action increases the mill bearing pressure and power progressively until corrective actions are taken. A logical action to solve the pebbles generation would be to incorporate a pebble crusher. This in fact was done however two fundamental issues were encountered; the high content of magnetite and existence of a cyclone classification section. Due to the high content of magnetite, metal detectors have not been able to work efficiently to separate tramp metal which causes damage to the pebble crushers. The existence of cyclones in the circuit had a detrimental effect on the final product when the pebbles crusher was online producing coarse sandy material. Due to the difficulties in treating pebbles via conventional procedures and the unique Palabora ore composition and characteristics, sorting technology was investigated at laboratory and pilot scale. It was found that a combination of optical and electromagnetic sorting could efficiently separate dolerite from the copper bearing and magnetite ores. This paper reports the findings of the laboratory and pilot scale work performed and discusses the additional benefits to the circuit.

Jan 1, 2012

By B. Caro Vargas

The Toulon South Tunnel in France is the second part of a project started 20 years ago. After the problems and delays suffered during the construction of the North Tunnel, due to a complex geologic context of highly fractured and soft rocks under a highly urbanized environment, a very dense automatic monitoring system was implemented to control the settlements of surface (more than 1000 points), the structures adjacent to the tunnel alignment and the underground galleries being constructed. The latest automatic instrumentation systems were installed, using for example AMTS capabilities in terms of ?automatic prismless settlement monitoring?. All the data (geotechnical, structural and geological) was gathered in a global automatic data acquisition system and continuously available on a web based interface. Three different threshold levels (notification, anomaly, alert) were set up, each one with a differential and an absolute value for settlements. Depending on the actual geological site conditions and the actual monitored settlements, different supporting systems and excavation techniques were used. Furthermore, the monitoring data was also used to predict and anticipate the future settlement, by comparing it continuously with the theoretical Peck settlement curves. This method allowed a better risk management by limiting the settlement on existing structures and helped to secure the Works progress schedule, for a project that lasts from July 2007 to March 2011. The implementation of this observational method application is presented in this paper.

Jan 1, 2012

By Michael D. Justason

"In January 2009, long-time competitors, Anchor Shoring & Caissons Ltd. of Toronto and Bermingham Foundation Solutions of Hamilton, joined forces to tackle one of the Greater Toronto area’s largest deep foundation projects: the West Toronto Diamond Rail Grade Separation. The two companies formed the “West Diamond JV” and succeeded in winning the contract from the Canadian National Railways. This deep foundations work was the first and most significant part of the $300-million-plus rail grade separation project. A big part of the job turned out to be dealing with local government regulations and citizens’ concerns with noise and vibration.The project is approximately 10 km (6 mi) northwest of downtown Toronto in an area of mixed-zoning including light industrial, commercial and residential buildings. The area is commonly called the “The Junction,” because of the heavy rail- traffic. The “West Toronto Diamond” refers more specifically to the railway junction where the North-South tracks of Canadian National (CN) Railway meet at a level crossing with the East-West tracks of the Canadian Pacific (CP) Railway. The goal for this part of the project was to convert the West Toronto Diamond into a grade-separated junction by depressing the CN lines under the CP lines, thus allowing commuter rail carrier, called GO Transit, intercity carrier VIA Rail, and CN freight trains to pass through the new underpass.Dawn Tattle, president of Anchor Shoring & Caissons says, “not only is the site in a densely populated area adjacent to homes and businesses, the crews worked adjacent to active rail lines with numerous trains passing daily. During the 7-hour working day, approximately 60 trains passed through the site in very close proximity to working crews.” Safety was paramount. While trains were passing through the site, it was a railroad requirement that all equipment and men stop working. In addition, at those times, all personnel were required to stay 6 m (20 ft) from the tracks and were required to face the tracks. For the faster commuter trains, this work interruption could last as little as 2-3 minutes, while interruptions caused by the slower freight trains could last as long as 25 minutes. The most disruption to the site occurred during the morning commute between 7 to 9 a.m., so work did not really get underway until after that time. Once work finally commenced the race was on to finish as much as possible before the afternoon commute – hence the shortened work day. The amount of disruption caused by the trains was a big unknown faced by the JV going into the project, but crews adapted quickly to the very unusual work environment"

Jan 1, 2012

By D. Sanguinetti, A. Consigny, M. Nodwell

"Alkali precipitation of dissolved metals is an inexpensive but non-selective means of treating mine wastewater. Alternatively, sulphide precipitation can treat to below parts-per-million concentrations while selectively recovering valuable metals. While technically feasible, sulphide treatment of dilute waste streams increases the size and cost of the plant relative to the metals loading. Ion exchange has been applied at two separate sites to pre-concentrate nickel containing wastewater prior to recovery in smaller and more cost effective sulphide precipitation circuits. The result is a dual-circuit system that can maintain high selectivity and reduce overall facility cost while meeting strict effluent regulations.INTRODUCTIONAlkali precipitation using lime is the most common method of treating mining effluents for dissolved metals removal. This method is generally sufficient for waste streams containing mixed metals of little value, and for meeting modest metal concentration limits in the final effluent. Due to the non-selective nature of the lime process, the produced metal hydroxide sludge is of little value. All metals are removed together in a sludge product which cannot be re-processed for further value recovery.By contrast, sulphide precipitation can be used to selectively remove and recover valuable base metals (such as copper, zinc, nickel and cobalt), since the sulphide will preferentially target these metals without reacting with less valuable metals (such as iron and aluminum). The low solubility of the metal sulphide solids also supports the removal of base metals to lower concentrations than can be achieved with alkali precipitation in addition to other benefits discussed more fully in a prior paper (Bratty, Lawrence, Kratochvil & Marchant, 2006). The corollary to this solubility feature is that sulphide precipitation can function on influent streams containing low (< 10 mg/L) metals concentrations to meet very low parts-perbillion final effluent concentrations. Reagent overdosing is also minimized when compared to alkali precipitation."

Jan 1, 2012

By Fabio Mielli

Encompassing between 20 and 40 percent of the typical mining operational costs, energy in mining operations is a growing concern for the industry. However, this concern is a complex, multi-faceted variable that involves government regulations, societal pressures, cost and competitiveness. Managing energy efficiency is becoming a keystone of successful companies. The suggested energy strategy in mining and mineral processing operations must follow a well-structured approach to include the following: ? Understanding where energy is being used and why. ? Recommending and implementing energy conservation measures. ? Driving visibility to targets and results. ? Leveraging the energy spent across the enterprise. ? Developing a robust energy and sustainability strategy. Additionally, it must ensure that all decisions support the financial and operational integrity of the business.

Jan 1, 2012

By C. T. Morley

The steadily increasing interest in high pressure grinding rolls (HPGR) as a legitimate alternative comminution technology for hard rock applications has led to a proportional increase in the demand for trade-off studies comparing HPGR with more established approaches, typically SAG-based but including AG and stage-crushing designs. The primary trade-off is between a) the higher capital cost typically incurred with HPGR-based designs and b) the higher operating costs of the more traditional technologies. However, if, through circuit design innovation, the capital cost penalty of HPGR circuits could be eliminated or reversed, then the need for trade-off studies would diminish.

Jan 1, 2012

Advanced process and equipment analytics have been around for a while. However, with accessible IT infrastructure and site maturity, it is possible to analyse, monitor, and control processing plants and equipment easily. These various disparate systems provide different reports requiring the involvement of various personnel and attention to different reporting platforms. For efficient harnessing of the systems? capabilities, as well as effective improvement and monitoring of process and equipment, a single point of entry is required. A process and equipment optimization solution was required at a concentrator in South Africa, focussing on the product stream of platinum group metal (PGM) concentrate from the UG2 Reef. The investigation of data to identify strategies for optimization was required to allow visibility into plant operations to guide operators, an easier method to identify process loop problems, identification of imminent equipment failures, and advanced process control to optimize throughput and stability. A collaborative effort between the client and General Electric Intelligent Platforms (GEIP) investigated data-driven solutions to each of the problems. With the focus on process optimization and asset monitoring, as well as equipment monitoring, a combination of approaches was utilized to address the various problem areas that were identified. Each was implemented separately in the control layer of the plant IT infrastructure. The integration was done in a centralized web-based reporting tool that integrated the detailed results from the various solutions. On the process control side, monitoring of control loops was included by calculating performance statistics that were reported daily to identify sub-optimally performing control loops and indicating potential problems. The advanced process control solution for this site includes a surge tank controller, stabilizing flow through the flotation banks, and preventing the surge tank from overflowing or running empty. Equipment monitoring was investigated, for preventative maintenance, by making use of statistical data models to indicate imminent equipment failure. These predicted alarm events included the cause for failure, drilling down, and allowing focus on a specific variable for preventative action. The results included a more stable flow through the mill, with fewer stoppages due to surge tank overflows or running empty. The causes for process drift could be identified and operators could react early. Alarms warning of equipment failure 2½ and 4 months in advance were identified in an offline analysis.

Jan 1, 2012

By Antonio Mendoza

El presente texto describe el sistema de manejo de agua y aire, las actividades integradoras, preventivas, de análisis y ejecución realizadas para describir la respuesta a los retos del futuro inmediato para alcanzar los objetivos ambientales en la mina Antamina.

Jan 1, 2012

By R. L. Bruening, N. E. Izatt, S. R. Izatt

"Rare earth elements (REE) are essential and unique components of many high-technology products without which functioning of modern society would be greatly impaired. Commercial deposits of REE are limited to a few geographical locations. Largely untapped sources of REE are available in endof- life (EOL) magnets, rechargeable batteries, and electronics. Presently, < 1% of REE in EOL wastes is recycled. Conversion of EOL wastes to liquid streams allows use of IBC’s Molecular Recognition Technology (MRT) process to selectively recover, separate, and purify target REE and associated metals at g/L to mg/L or lower concentration levels. The MRT process together with its applications to separations of REE and associated metals in recycling as well as in mining are described. Economic and environmental advantages of MRT are presented. INTRODUCTIONRare earth elements (REE) include the lanthanide series (La-Lu), Y, and Sc. These elements are not rare, but concentrated minable deposits are scarce (Cordier 2012; Haxel, Hedrick, & Orris, 2002). Over 95 % of the world’s supply of REE is controlled by China (Hanson, 2011a) where they are mined, processed, and the pure elements incorporated into a growing number of consumer and military products. The consumer products are marketed worldwide. Since REE are vitally important in consumer and military products, this situation has caused other nations to scramble to develop the capability to produce their own supply (Cordier, 2012).In the U. S., Molycorp has reopened the Mountain Pass REE mine in California and production has begun (Goldenberg, 2010). Development of a reliable internal source of REE is of high national priority in the U.S. (Hanson, 2011b; Hess, 2012: “Obama Announces”, 2012). These elements have in recent decades been incorporated into new consumer and military products that are essential to our economy and defense. These products range from wind turbines, high performance magnets, hybrid car rechargeable batteries, energy efficient lighting electronics, flat screen televisions, and smart phones to advanced weapons systems (Haxel et al., 2002; Levkowitz & Beauchamp-Mustafaga, 2010)."

Jan 1, 2012

By Carla L. Zenti

In recent years, considerable advances have taken place worldwide in the design and construction of first tunnel linings. With these advances, there is a tendency to move away from traditional support that includes heavy open profiles of rolled steel arches, to a lighter solution with the use of an optimized tubular steel cross section rib, and shotcrete reinforced with steel mesh and/or steel fibers, providing a continuous support (Lunardi, 1982). The development of tubular ribs has provided greater design options, increasing flexibility to engineers and contractors while providing a efficient and cost effective construction method. In this article, the authors describe numerical and experimental investigation on this problem, suggesting as a new first lining steel arch design approach by using tubular ribs cross section as new technical solution for first lining underground support.

Jan 1, 2012