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Ravensthorpe Nickel Operation (RNO) is a major new mine and processing plant currently being constructed by BHP Billiton in a ?green field? site near the small town of Ravensthorpe, about 150 km west of Esperance and six hours drive from Perth in Western Australia. Ensuring that the project has a positive overall impact on the surrounding region and that this extends well beyond the life of the operation will be a major challenge for RNO, state and local government, and the local community. For the last two years, the Centre for Social Responsibility in Mining (CSRM) has been assisting RNO management and the RNO Community Liaison Committee to develop a community sustainability monitoring framework for the project. This paper reports on the process that was used to develop the framework, describes the main elements and briefly discusses key learnings from the exercise.

Jan 1, 2007

By Osvaldo A. Bascur

The implementation of continuous quality improvement is the confluence of Total Quality Management, People Empowerment, Performance Indicators and Information Engineering. The supporting information technologies allow a mineral processor to narrow the gap between management business objectives and the process control level. One of the most important contributors is the user friendliness and flexibility of the personal computer in a client/server environment. This synergistic combination when used for real time performance monitoring translates into production cost savings, improved communications and enhanced decision support. Other savings come from reduced time to collect data and perform tedious calculations, act quickly with fresh new data, generate and validate data to be used by others. This paper presents an integrated view of plant management. The selection of the proper tools for continuous quality improvement are described. The process of selecting critical performance monitoring indices for improved plant performance are discussed. The importance of a well balanced technological improvement, personnel empowerment, total quality management and organizational assets are stressed.

Jan 1, 1995

By George D. Haley

This report will be given in two sections. The first sec¬tion outlines techniques and equipment to form almond shaped fluorspar briquettes by means of briquet presses, and the second section outlines techniques of the balling disc. PART I - BRIQUET PRESSES Fluorspar has been briquetted for a number of years and the so called "peach pit" briquet is known to many steelmen. Present production is estimated at over 100,000 tons annually. Slide 1 shows an assortment of various sizes and shapes of briquettes. It is possible to form fluorspar into almost any configuration of briquet. For safety on the melting floor, pillow type briquets are preferred. Ease of mechanical handling and durability of the product are facil¬itated by an almond shape. The dimensions of the almond can vary from 1-in. to 1-1/2-in. in length, from 13/16-in. to 1-in. in width and from 1/2-in. to 1-in. in thickness. The type of equipment to pro¬duce almond shaped fluorspar briquettes is shown in Slide 2. Here we have a Komarek-Greaves and Company 300 ton briquettor equipped with almond rolls. This machine is capable of producing fluorspar briquettes at a rats of 30 tons per hour with power consumption of 35 hp per ton par hour.

Jan 1, 1969

By L. A. Weakly, D. A. Weiss, R. B. Crookston

A presentation of experience gained from using mechanical and conventional equipment for excavating shafts, raises, tunnels and other openings in various Colorado oil shale mining properties.

Jan 1, 1983

By G. R. Giuliani

Hanna Mining Company's Groveland Mine is located in the Upper Peninsula of Michigan. The low grade iron ore deposit consists of a mixture of magnetite and hematite with chert, jasper, quartz and various iron silicates (1). The ore is beneficiated by magnetic separation and anionic flotation of the iron minerals with chemical depression of the silica. The magnetic concentrate makes up about 75% of the concentrate. The concentrate is pelletized at the rate of 2.0 million LTPY of pellet production. The concentrator facilities were started up in 1959 and the concentrate was marketed as sinter feed until 1963 when the concentrator was expanded and the pelletizing plant was added. The pellet plant now consists of regrinding, elutriation, filtering, balling and induration. The pellet machine is a straight grate which employs updraft drying and cooling and downdraft drying, preheat and firing. It is necessary to regrind the concentrate before pelletizing. The con-centrate is 60% passing 325 mesh, with a surface area of ±lOOO cm2/Gm, and must be ground to about 83% passing 325 mesh, 1600 cm2/Gm blaine surface area, for pelletizing. The energy for regrind has been reduced from 12.5 KW per LT to 8.80 KW ate of 2.0 million per LT. This was the result of changes made in the concentrator where originally a coarse spiral concentrate, instead of the magnetic concentrate which is screened on fine screens to reduce the coarse fraction and prevent overgrinding before flotation, was produced. Also in 1968 an additional concentrating line was added to the concentrator which employs more grinding power than the other three lines. The demand for a high iron grade and lower silica pellet resulted in the investigation of different schemes of upgrading the reground concentrate which had more iron values liberated during grinding for surface area. The reagentized material presented many problems, mainly in selectivity trying to flot the iron and with high reagent consumption having to dereagentize the concentrate for amine silica flotation, in the various flotation systems tried. Tests were then conducted with elutriation (2) which proved satisfactory by removing the lower specific gravity, fine gangue material from the heavier material with the

Jan 1, 1977

By Michael J. Feltes

In mining operations, conveyors hold one of the most important keys to productivity. Sudden belt or belt-splice failures and extended repair downtimes can contribute to low material-handling system availability. Consequently, operations and maintenance personnel should have a thorough understanding of the available splicing and repair alternatives and how each method can affect the productivity and cost-effectiveness of their operation. The two primary methods of joining belt ends - vulcanization and mechanical fastening - affect the likelihood of sudden failure and repair times in different ways. The time-honored method of vulcanization remains popular in many conveyor-intensive underground and above-ground mining operations around the world. At first, vulcanization may seem attractive because, when done properly by trained and experienced craftsmen, it can match the original belting fairly closely and give the splice a smooth, continuous surface with no edges or seams to invite snagging.

Jan 1, 1993

By N. E. Norman

A great deal of effort has been put forth in recent years to arrive at accurate projections of the demands for tunnels in this decade. In reviewing the statistics presented by various study groups, it appears that during the decade from 1960-69, there were some 1,335 miles of rock and soft ground construction tunnels excavated throughout the world. These statistics indicate 645 miles of rock tunnel and 689 miles of soft ground tunnel were excavated during the last decade. This is expected to increase to 3,000 miles in the 1970's according to projections made by various authorities in the field of construction tunneling. I point out the above statistics to emphasize two main points: (1) The demands for tunneling in this decade alone are staggering. (2) There is a fairly even distribution in the amount of rock tunneling and soft ground tunneling being excavated. Unfortunately, available statistics do not answer many important questions about tunneling which are of great importance to the contractor and to boring machine designers. For example, how many of the projects completed in the past decade involved both soft ground and rock tunneling? How many projects involved tunneling in conditions where both rock and soft ground were contacted at the same face. While the answers to these questions remain unanswered, I am sure most of you can think of numerous examples of projects where mixed face conditions are prevalent. Many of you are probably familiar with the Austin Crosstown Interceptor which was bid last month in Austin, Texas. Here is a project involving 57,000 feet of tunnel where limestones and clay shales are expected to be traversed. Another project, the Tonner Tunnels No. 1 and No. 2, near Los Angeles, involve some 22,000 feet of tunnel where mixed soil and rock conditions are expected. A large majority of the projected tunnels for this decade are to

Jan 1, 1997

By H. W. Hitzrot

Introduction Mechanical classifiers consist of a settling tank with parallel sides and a sloping bottom equipped with a mechanism which continuously agitates the pulp and removes the settled solids. The functions served by mechanical classifiers include the following: (1) allow the particles larger than the desired size to settle in the tank and provide an overflow product with a minimum of oversize particles, (2) produce an overflow product of sufficiently high solids content to meet the requirements of the subsequent processing steps, (3) agitate the pulp and permit separation of the entrapped undersize particles so they can report in the overflow product, and (4) drain and remove the underflow solids from the settling pool. Various types of mechanisms have been used to agitate the pulp and remove the settled solids, which include: (I) endless belt and chain drags, (2) reciprocating rakes, (3) helical flights mounted on a rotating shaft which extends through the settling pool, (4) helical flights inside of a rotating drum which contains the classifier pool, (5) troughed conveyor belts forming the settling pool in the concave curve of the belt closely following the tail pulley, and (6) low-speed impellers agitating the underflow settled in the apex of cone-type mechanical classifiers.23 The principal use of mechanical classifiers has been in closed¬-circuit wet grinding; however, this application has been widely displaced over the past few decades by the hydrocyclone. The hydrocyclone installation, including its feed pump, offers lower capital costs and requires less floor space. Nominally it produces an overflow prod¬uct of higher solids content, compared with a mechanical classifier, for comparable classification size up to 400µm (35 mesh). However, these advantages of the hydrocyclone are being gained at the sacrifice of some of the advantages of the mechanical classifier. The mechanical classifier requires less power and has lower maintenance costs than the hydrocyclone and its feed pump. The underflow product from the mechanical classifier can have a higher solids content and contain less entrapped undersize particles than the comparable product from the hydrocyclone. Consequently, it is capable of operating at a higher classification efficiency. A reduced circulating load24, 25 results under these conditions in a closed-circuit grinding application. Other applications for mechanical classifiers include desliming, dewatering, and washing operations. Sand-slime separation may be achieved using one or more stages of mechanical classifiers. Typical applications would include washing and deslimining of concrete aggre¬gate or sand; glass sand; abrasives; oyster shells; phosphate rock; iron, nickel, and chromium ores; alumina; zeolites; solar salt; and precipitates from chemical processing. As an example for the latter, Bitzer26 recommended the use of mechanical classifiers for countercur¬rent cementation-in-pulp of copper from the leach liquor. Similarly, mechanical classifiers are used in uranium processing27 for separation of the barren sands from the pregnant leach solution. Depending on the particle size and the effectiveness of the sand¬slime separation, the sand product from mechanical classifiers may be drained to solids content approaching 84%. Thus, mechanical classifiers are frequently used as dewatering equipment for various applications, such as: 1) Make a product having suitable solids content for subsequent transport by belt conveyor. 2) Provide a drained product to reduce cost of drying. 3) Provide a drained, washed, heavy sand product for return to the circuit. 4) Recover fine values from dilute plant effluents from coal, sand, phosphate-rock, and iron-ore washing plants and from steel-mill flue¬dust scrubbers. 5) Drain residual reagents of a preceding process stage prior to conditioning with reagents of different characteristics, e.g., cationic¬anionic flotation of phosphate rock, iron ore, etc. Design and Operating Features The proper selection of mechanical classification equipment re¬quires that the properties of the solids and liquid are adequately de¬fined. The following descriptive information regarding the solids is desired: feed rate, chemical and physical composition, density, tem¬perature, size analysis, and desired separation size. For the liquid used, the following data would be needed: feed rate, density, viscosity, pH, and temperature. Settling Area. The pool area required to permit a particle larger than the separation size to settle depends on the density and shape of the particle and on the density and viscosity of the pulp within the classifier pool. These criteria of the solids and pulp determine the settling rate which, in turn, determines the settling area required. Determination of the settling rate by long-tube batch tests can be used to calculate the settling area. A theoretical approach for estimat¬ing the settling area requirements is discussed in Chapter 1, Classifica¬tion Theory. This procedure can be used when neither test data nor empirical data from similar operations are available. Data on settling-area requirements and settling rates have been compiled by the manufacturers of mechanical classifiers. The approxi¬mate settling area required for a particular separation size can be estimated by using the curve shown in Fig. 65. This curve applies for closed-circuit grinding applications. For dilute velocity classification in open circuit, desliming, the length of the overflow weir, W, multiplied by the weir's mean distance from the feed opening, E, is used as the design criterion, instead of the settling area, in sizing the classifier. The area requirements, W X E, for dilute velocity classification can be expressed in terms of volumetric flow, Q, and settling rate, Rs, as follows: W x E = Q/(18.06 Rs) where W and E are feet, Q is gallons per minute, and Rs is inches per second. Overflow Weir. The hydraulic head, and thus the velocity at which the overflow crests the overflow weir, is one of the factors controlling the particle size of classification. Consequently, the length of the overflow weir must be designed to provide the overflow velocity which allows the particles larger than the desired size of classification to settle in the working area of the pool. Obtaining the necessary

Jan 1, 1985

By Jacques L. Mauboussin

The EUROPEAN ORGANIZATION for NUCLEAR RESEARCH (CERN) has undertaken the construction of a LARGE ELECTRON POSITRON COLLIDER (LEP), near GENEVA (Switzerland). The facility includes the main 27 km long tunnelled ring, 18 shafts, 20 experimental caverns and many auxiliary galleries. Roughly 800 000 cu.m were excavated in the molasse at 50-140 m depths, using roadheaders for caverns and auxiliary tunnels and 3 WIRTH, 4.5 m diameter, fullface TBMs for the main circular tunnel. Each TBM performs 25-30 m/day. Provisory lining behind them uses either precast concrete elements or shotcrete. Works a e being carried out by a joint-venture of European contractors led by FOUGEROLLE (France).

Jan 1, 1987

By William J. Gregg

Mechanical testing results on oriented Devonian gas shale core throughout the Appalachian basin show a preferred fracture direction perpendicular to bedding. The preferred direction is generally parallel to the Allegheny Front, but is only coincidentally parallel with in-situ stresses in some areas of the basin. The strength of the preferred orientation of induced fractures decreases with distance from the Front. It is suggested that strain related to Paleozoic deformation is responsible for this mechanical fabric and thus the direction of induced fractures in laboratory tests may not be of use as indicators of in-situ stress orientations as previously suggested.

Jan 1, 1986

By Vernon R. Degner

The past two decades has seen the application of the mechanical flotation machine, originally developed primarily for metal1iferous ore beneficiation, increasingly applied to cleaning coal in the 28x0 T. Mesh size range. Internal cell hydrodynamic studies of mechanical flotation machines of all sizes, as well as computer aided modeling studies of flotation kinetics has, within the last five years, established a basis for optimizing coal flotation circuit design and machine operation, and has a1 so pointed a way toward improvements in mechanical flotation machine design for the future. Consideration of the trend toward increased fines produced by current mining techniques, as well as the environmental need for a progressively cleaner product, lends support to basing the design of the mechanical coal flotation machine of the future on finer feed; below 100 microns in size. Future types of mechanical flotation machines, which may satisfy the fine coal cleaning requirements for a significant improvement in product grade while maintaining the combustible recovery levels of current technology, are discussed.

Jan 1, 1988

By Levent Ozdemir

The advantages offered by mechanical mining have been demonstrated in the underground mining of coal, evaporites and other soft minerals. Mechanical mining and the advancements in automation technoloogies have been the principal drivers towards the realization of enhanced productivity in soft rock mining. For past two decades, emphasis has been placed on developing mechanical mining technology for hard rock applications, to achieve similar productivity improvements and cost reductions. The benefits of mechanical mining are numerous, particularly in an industry where market conditions continue to dictate higher production and lower costs while maintaining high safety standards. Other benefits of mechanical mining include reduced ground support and labor requirements and the elimination of blast and diesel fumes. These benefits further make this technology an attractive alternative to drill and blast for hard rock mining. Mechanical mining is conducive to full implementation of remote control and automation technologies that are under development to achieve further productivity and safety improvements in underground mining. Mine development has been the main focus area for mechanical miners by manufacturers and mining companies. Potential applications include ore body access, haulage and ventilation drifts, undercut and exploration drifts. The economic use of this technology in mine production is still considered many years away. It would need a major technological breakthrough that would make mechanical rock fragmentation competitive with the large-scale, low-cost production blasting operations.

Jan 1, 1998

By Eckart Schneider

PROJECT The Walgautunnel is the heart of a new hydro scheme in Western Austria, which is supposed to go into operation in 1984. With it's length of 21,4 km, a bored diameter of 6,25 m and an internal operating pressure of 13,5 bar it will be the largest water conducting tunnel in Austria. Even compared with some of the country's world-famous highway tunnels like 'Tauern' or 'Arlberg' it has to be regarded as a major tunneling project. Owner is the Vorarlberger Illwerke AG, a power corpo¬ration founded in 1924. In the course of the past 6o years this company developed the 'Werksgruppe Obere Ill - Lünersee', consisting of 6 major power plants and 4 large reservoirs. The installed capacity is 1.114 MW in the generating and 529 MW in the pumping mode. The total power output amounts to 1.916 GWh. The water for power generation comes from the glaciers of the Silvrettagroup, as this corner of the Austrian Alps between Vorarlberg , Tyrol and Switzerland is called. The Walgauwerk utilises all the water accumulated by the existing schemes as well as the so far unused run-off water, passing by in the river Ill. The intake to the Walgau-Tunnel is situated right beside the lower reservoir of the recently completed pump-storage plant 'Rodund II' at an elevation of 64o m above sea level. Though the head is a mere 162 m, 1 billion m3 of water will generate 356 GWh per annum. The power-output of the two Francis turbines is 86 MW.

Jan 1, 1983

By Cherie M. Tilley

The Stillwater Mining Co. of Nye, MT, is operating a platinum-palladium mine that requires an extensive system of footwall laterals to facilitate mine production. The 10-year mine plan calls for more than 48,300 lineal m (160,000 lineal ft) of footwall lateral. A rapid tunneling and raising system is necessary to sustain mine production schedules and achieve production goals. This article describes the results of using a Robbins 4.1-m-diam (l3.5ft-diam) tunnel boring machine (TBM) to develop the footwall laterals and a Robbins RBM-6SP raise boring machine to develop raises at the mine. The Stillwater Mining Co is a partnership between Chevron Resources Co. and Manville Corp. Chevron Resources is the managing partner. When the mine began production in September 1986, the owners were primarily concerned with the actual production of platinum and palladium, the grade minable and the amount that could be mined. As mine development and mine production proved feasible, the owners considered higher production levels. The Stillwater Mine is developed by a system of adits (known as footwall laterals) that are driven parallel to the ore bearing zone. This led mine officials to consider using a mechanical boring machine in the primary mine development. Previously, tunnel boring machines have not been used successfully in mining applications. Therefore, the owners decided to purchase a used machine to reduce the potential risk.

Jan 1, 1991

By Richard E. Gertsch

A century of experience with mechanical excavation machines is beginning to pay dividends to the mining industry. Mining is moving from mechanical excavators to mechanical miners. These mechanical mining systems are poised to make a significant impact on hard-rock mining, both underground and surface. Mechanical mining machines have had a long and successful career in coal and evaporites ("soft-rock") mining. Unlike most mechanical hard-rock mining, these systems actually mine ore. For example, the most productive underground method has been, arguably, longwall mining. Mechanical excavation machines are mostly used in civil tunneling or in driving mine openings such as vent shafts. Civil tunneling is a notable mechanical excavation success. Even with its high capital cost, a tunnel boring machine (TBM) can drive kilometers (miles) of tunnel at very low cost. In hard-rock mining, mechanical excavators bore tunnels, raises and shaft openings in the mine, but rarely mine ore. Like the soft-rock miners, their contribution to mining is important and their development must continue. Generally, they are used as excavators not miners. Current trends guarantee development of true general-purpose hard rock mechanical mining machines. Mechanical miners will become a complete mining system and will determine the design of the mine. Mechanical methods will reward the operator with lower costs and high productivity.

Jan 1, 1992

By R. J. Robbins

The mechanization of hard rock underground mines offers a large potential for reducing cost, improving efficiency, and increasing profitability. However, in spite of serious efforts by quite a number of equipment developers and mining company initiatives, the industry has achieved little real progress. The task is difficult and the blasting alternative to mechanical excavation is an effective and well-developed method, which continues to improve in spite of its inherent limitations. A large number of machines have been built and tried. Only a few developments have succeeded to make a major impact on underground hard rock mining. It is certain that hard rock mines would be laid out and designed quite differently if the mining engineers knew they had available continuous mechanical excavation machines. In the absence of the machines, mines will be designed for excavation by traditional methods. It is not easy to utilize mechanical excavation in a mine which is designed to operate with normal drill and blast excavation. This is certainly an impediment to machine development. But what if an ore body cannot be mined conventionally, simply because the mining company cannot get permits to satisfy the ever increasing strict EIS requirements of the general public and governmental agencies? This may provide the incentive necessary to develop the equipment that will be needed by a new mining method that will have almost no impact on the environment.

Jan 1, 2001

By Richard E. Gertsch

Mechanical mining holds great promise for the mining industry. Realizing this promise depends on developing the tools needed to mechanize a mining operation with a reasonable expectation of success. Mechanical mining entered the 1990s with new machines, new operating methods and new ideas for the future. Mechanical mining can provide higher production, increase safety, reduce roof support requirements, create smoother openings for better ventilation, substitute continuous production for cyclical drill-and-blast procedures, and create opportunities for automatic and teleoperated control. The full promise of this important technology still lies ahead. Obstacles include: • Long-term production prediction: Mechanical systems have a high capital cost. Although recouped by lower operating costs, the tradeoffs are not always clear to mine operators. • Cutting tools for hard rock: Rock of more than 103.4 MPa (15,000 psi) cannot be cut by flexible mining machines. • Machine designs: Many machines cannot convert the required power into rock cutting capability. • Engineering: Better use of the machines in the mine is needed.

Jan 1, 1994

By L. Gertsch, R. Gertsch

Mechanical mining is steadily gaining usage in the mining industry. A variety of machines currently finds employment: tunnel boring machines, roadheaders, continuous miners, surface miners, and augers. These machines have advantages compared to drill and blast mining methods, including increased safety, lower cost, uniform muck size, and accurately sized openings. A century of experience with mechanical methods has already paid dividends to the coal industry. Current trends guarantee eventual development of true general-purpose hardrock mechanical mining machines. Mechanical miners will become integrated mining systems and will determine the design of mines, when several significant challenges have been met.

Jan 1, 2001

By R. E. Gertsch

Mechanical mining holds great promise for the mining industry. Realizing this promise depends on giving mine operators the capability to evaluate the higher production, the lower costs, and safety enhancement that comes with mechanical mining. The opportunities for low cost and high production must outset the high capital costs associated with mechanical excavation. Giving the mining industry the tools to effectively evaluate and successfully implement mechanical methods defines the challenges and directions of the mechanical mining industry.

Jan 1, 1994

By L. Gertsch, R. Gertsch

Mechanical mining is steadily gaining in usage in the mining industry. A variety of machines are now being used, including tunnel boring machines, roadheaders, continuous miners, surface miners and augers. These machines have advantages compared to drill-and-blast mining methods, including increased safety, lower cost, uniform muck size and accurately sized openings. A century of experience with mechanical methods has paid dividends to the coal industry. Current trends guarantee eventual development of true general-purpose hard-rock mechanical mining machines. When several significant challenges have been met, mechanical miners will become integrated mining systems and will determine the design of mines.

Jan 1, 2002