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By S. Banisi, M Nesari, J. A. Finch, N. Nobari, H. Javani

"The flotation circuit of the Sarcheshmeh copper mine, which processes 40,000 t/d of ore at 0.9% Cu, consists of rougher, cleaning and recleaning stages. Mechanical flotation cells are used in all stages. To investigate the amenability of flotation columns in the plant especially for cleaning and recleaning stages, a column was designed, constructed, and installed at the Sarcheshmeh pilot plant. The pilot plant, which has an identical circuit configuration compared to the plant, can process up to 2 t/h of ore. The overall rate constant of the ore along with the target recovery of 94% were used to size the column. A 26 cm by 550 cm column with two filter cloth spargers and a submerged froth washing system using perforated tubes was constructed. To detect the interface level a 180 cm conductivity probe consisting of 1.5 cm diameter ring electrodes was installed. The tailings flowrate controlled by a variable speed pump was used as the main control variable. The initial testing program revealed that the optimum superficial gas and wash water flowrate were 1.5 and 0.3 cds, respectively. It was observed that the cleaning stage grade when using the column could increase by 2-3% at constant overall copper recovery.IntroductionThe Sarcheshmeh copper ore body which may rank as third or fourth largest in the world contains 1 billion tomes averaging 0.90 % copper and 0.03 % molybdenum. It is in located south-east Iran and has been processing 40,000 t/d of ore since 1982. After three stages of crushing, the ore with a F80 of 12.7 mm is fed to 8 parallel ball mills in closed circuit with cyclones to produce a product 70% finer than 75 microns. The concentrate of the first stage of flotation is reground and the tailings constitutes the main component of the plant final tailings. A concentrate with an average grade of 31% Cu (chalcopyrite and chalcocite) is obtained after cleaning and re-cleaning stages in mechanical cells. Total recovery of the plant varies between 83-87 % depending on ore type and operating conditions."

Jan 1, 2000

By L. C. Stilwell

Input-output analysis is a major branch of quantitative economics, and is used to analyse the flow of goods and services between production sectors in a national economy. Its purpose is to determine the relative value-adding capacity of each sector. The model has also, in recent years, found increasing use in assessing the environmental and ecological impact of development projects. It has, however, never been applied to individual production facilities, such as large mines, which themselves have complex economic structures, through which there is a flow of goods and services. Conventional cost and accounting systems, as used on mines, treat production sectors as separate cost centres, and do not determine the inter-relationships between them. This can lead to incorrect conclusions on the relative value of sectors and their impact on the total economic performance of the facility. This paper explains the basic principles of input-output analysis, and presents an example of its application to a simplistic model of a mine, which is used in the absence of any real data. The paper concludes that, by forcing definition of the value adding function of each sector, input output analysis will facilitate control of inputs, or costs. This will result in optimal application of resources and exploitation of ore reserves. The authors realise the model needs to be tested on an operating mine, and hope this paper will result in an opportunity to do so. The authors wish to thank the anonymous referees for their valuable comments.

Jan 1, 2000

Little knowledge is available that considers the effects of continuous miner position on the possible respirable dust exposure of the remote mining-machine operator. Such information could be very useful for increasing the awareness of the remote operator as to those parts of an extended cut that generate higher levels of respirable dust. This data could be used to develop guidelines for positioning the remote operator to reduce his potential exposure. This work details the effects of continuous miner position on dust levels measured on the machine and at the remote continuous miner operator location.

Jan 1, 2000

By Bingchen Chen, Zhitong Sui, Junwei Ma

"In the blast furnace slag, titanium disseminated in various mineral phases Titanium could be concentrated mainly in perovskite, which could be selectively precipitated and grown by optimizing the operation factors like the slag composition, temperature of heat treatment and additive agents. This study aims at establishing the titanium slag mineralogy and its distribution in the treated slag and the as-received slag, as well as the methods of perovskite separation. After heat treatment, the grain size was grown from 5 - 20µm to 80 - 200µm, the distribution of Ti02 in perovskite was increased from 48% to 81 %, the morphology was changed from snow-shaped grain to coarsening dendrites or equiaxed crystals. A concentrate were produced by gravity separation analyzing 35.25% Ti02 with a recovery of 68.28% and a tailing analyzing 9.53% Ti02 , and a possibility of flotation upgrading was discussed. I INTRODUCTION CHINA is rich in mineral resources of titanium, 92.4% of which is vanadium-titanium bearing magnetite. About 53% titanium were in iron concentrate after mineral processing, by which the blast furnace slag containing about 25% TiO2 were produced[11 • The content of TiO2 in such slag is too low to separate titanium dioxide, and it is also too high to produce slag cement[21. It has been accumulated to 50 million tons so far, which is still increasing at a rate of 3 million tons per year, and results in a waste of titanium resources and pollution of environment. Due to the dispersed distribution of titanium component in various mineral phases, very fine grain(<10µm) and complex interfacial combination, it is very difficult to recovery titanium component from the slag by traditional separating technique. In this paper, a novel technique to recovery titanium from the waste slags was proposed [3H4l, on which three continuous processes were involved: selective concentrating, selective growing and selective separating. Perovskite was designed as a titanium-rich phase, in which the most titanium was concentrated promptly, then perovskite could be selectively grown and coarsened by optimizing the heat treatment and the appropriate additives [ 5l[6l. The grain size of perovskite phase was larger than 80 µm, and the crystals appeared as coarsening dendrites or equiaxial grains like lump."

Jan 1, 2000

By D. H. Rubisov, V. G. Papangelakis

Sulphuric acid pressure leaching is the process of choice to recover nickel and cobalt from laterites with variable iron and magnesium contents. The latter influences the acidity levels required for effective leaching of nickel and cobalt, and during leaching, iron is rejected in-situ as hematite. Classical solid/liquid separation is performed via a CCD circuit, the performance of which depends upon the size and shape of precipitated particles. In this paper, precipitates obtained by acid-leaching of various lateritic feeds at 270°C are characterized using SEM/EDX and laser particle size analysis. It is shown that as acidity increases, the shape of the precipitates gradually changes from platelets to spheres, thus improving the S/L separation properties of the residue. The use of hydrogen ion concentration “at temperature,” calculated from a speciation analysis, allows the explanation of this change of morphology independently of the type of the ore feed. The possibility of precipitating magnesium sulphate “at temperature” is also discussed. In order to take advantage of this precipitation for scale reduction (as has been proposed in the past) without compromising the residue quality, [H+] “at temperature” must be controlled within an optimum range.

Jan 1, 2000

By P. -M. Tardif, S. Outalha, R. Le

"This paper proposes a new direction to implement an underground mine communication system. It presents actual underground communication systems and discusses their technological limits. A new system based on a wireless local area network (WLAN), together with its main systems characteristics, is then proposed. This paper also presents an experimental protocol for radio frequency propagation measurements. Finally, the paper describes the projected implementation of a WLAN in an experimental mine. IntroductionDuring the last decade, a number of Canadian mining companies have invested in modern communications systems in order to automate processes and reduce operational costs. Safety of miners is also a concern, regulated by health and safety regimes.Underground communication systems rely mainly on analog technology (especially the leaky feeder). Digital upgrades have been made to modernize this technology using a coaxial or fibre optic cable to transmit voice, documents, commands, controls, and video. Therefore, all wired equipment can benefit from an increase in efficiency from the digital technology.However, when it comes to mobile equipment, the only medium was, and is, still radio waves. With the advent of the wireless local area network (WLAN) standard, one can use a technology similar to that of the cellular phone to connect transparently different equipment. WLAN enables the transmission at rates higher than 2 M bits of voice, documents, commands, controls, identification, and of course, digital video. This technology was developed with inbuilding use in mind. Now, one can try to adapt it to underground mines."

Jan 1, 2000

By M P. Simpson, J L. Mauk

The Golden Cross, low-sulfidation, epithermal deposit shows a number of features that are directly or indirectly related to boiling hydrothermal fluids. Occurrences of lattice calcite and their quartz pseudomorph equivalents in veins, and occurrences of adularia in veins and in the surrounding altered rocks in the vicinity of ore, are both direct evidence of deposition in the presence of boiling hydrothermal fluids. Loss of carbon dioxide causes calcite deposition (platy variety) near the level of first boiling, while adularia deposits due to the attendant pH increase along the cooling flow path. Indirect evidence of boiling include crustiform-colloform quartz banding, late massive calcite veins, clay-carbonate alteration in the shallow and peripheral parts of the ore zone, and the restricted vertical interval of precious metal mineralisation. The colloform quartz banding strongly resembles the banding in amorphous silica deposits found in geothermal surface pipes. This implies that fluids ascending the Empire Vein structure were saturated in amorphous silica. If so, then they must have undergone phase separation, which initiated at considerable depth (e.g. =1000 m) and very hot temperatures (e.g. =300¦C). On the basis of stable isotope data, late massive calcite veins appear to have deposited from CO2-rich steam-heated waters. Calcite deposited along heating paths as these waters descended into the upflow zone during late stage collapse of the hydrothermal plume. In active systems, such steam heated waters form by deep boiling. The high CO2 contents of these waters promote hydrolytic alteration and the formation of clay-carbonate alteration. Reaction path modelling using CHILLER and a deep, Broadlands-Ohaaki water as an analogue, shows that minerals deposit along boiling flow paths over discrete spatial intervals. Calcite and adularia deposit near the site of first boiling, followed by gold and then by amorphous silica. For deep boiling starting at 300¦C, these minerals deposit over a path length that exceeds 1000 m. The distribution of banded quartz and gold at Golden Cross are consistent with such a boiling model. However, the elevation of first boiling must have fluctuated over 500 m to account for the coincidence of lattice quartz (pseudomorphs of platy calcite) and adularia, crustiform-colloform silica and gold over distances of a few centimeters in veins. We deduce that a downward propagating boiling front and expansion of two-phase flashing in a flowing water column occurred during episodes of high vertical permeability and fluid flux in the Empire vein structure.

Jan 1, 2000

Traditional fine grinding mills in mineral processing relied on the use of steel medium for particle size reduction. The successful development of the Isa Mill(a horizontal stirred mill with 3000 litres of net chamber volume and 1120 kW rated motor power)adopted a novel product separator design that has led to a major revision of medium use in fine grinding. The Isa Mill separator has also successfully operated with a wide variety of medium types such as silica sands, river gravel, smelter slag, run-of-mine ore fractions and steel shots, with size ranges from 0.5 to 10 mm. A great flexibility of the Isa Mill operations has been achieved for processing a feed as coarse as 120 um to a product as fine as 5 µm. This paper discusses the performance of two inert grinding media used in the Isa Mills in Mount Isa Mines of Australia for processing galena and sphalerite bearing ores to below 10 microns. They are the copper reverberatory furnace slag (CRFS)and the heavy medium plant rejects (HMPR). A methodology was also demonstrated for comparing the medium performance and for scaling up the Isa Mills from a 1.5-litre laboratory batch mill to a full scale 3000-litre mill.

Jan 1, 2000

By Joseph A. Dos Santos

The Expanded Conveyor Technology, a rationalization of the conventional conveyor technology, allows us to apply the theory and principles beyond the current (perceived) limits. This was first prompted by the writer&apos;s advancements in Sandwich Belt High Angle Conveyors. The introduction defines the Expanded Conveyor Technology and outlines the range of applicability for the wide variations in conventional and non-conventional conveyors. The writing deals with the theory and design of sandwich-belt, high-angle conveyors in the context of the Expanded Conveyor Technology, including the equations of friction, hugging pressure and the continuity of hugging principle; curvature constraints and criteria for tension, curvature, trough, and belt construction; and drive and tension analysis, load sharing and traction, including "derived load equivalents."

Jan 1, 2000

By D. N. Thompson, R. L. Sayer, K. S. Noah

Economical remediation of acid rock drainage (ARD) at secluded high-altitude western ore mines is difficult given the current treatment technology. Several passive-engineered systems that are based on wetland technology were tested in the laboratory with three western ore mine ARDs (Co, Cu and Fe mines) and with a copper leachate effluent. These systems used well-weathered lodgepole pine sawdust as the sole carbon source and mud from a pond at one of the mine sites as the source of sulfate-reducing bacteria (SRB). Simple one-pass flow-through systems removed 44% to 99% of the vari¬ous heavy metals front the Co and Cu mine ARDs and increased the pH from 3 to 7 after 28 days of SRB acclimation with a five-day residence time. Carbohydrate utilization rates were generally low, except for one 437-day run, which consumed 25%, 30% and 21 % of the cellulose, hemicellulose and lignin, respectively. Initial pH, amounts of toxic heavy metals and the degree of predegradation of the sawdust were found to significantly affect both remediation potential and acclimation time. Engineered SRB systems, alone or in combination with other passive technologies, offer promise for the economical remediation of western US ore mine ARDs.

Jan 1, 2000

By P SSrkkS

Mining is commonly seen as a typical basic industry with rough and even dangerous working conditions, heavy environmental load, and a low level of high-technology and automation with much manual work and operations. A mining operation (open pit or underground) is a very complex one consisting of many manual, physical, mechanical and logistical operations with different human interfaces and decisions. For this reason it is a demanding and potential area for all applications of automation and information technology: controlling difficult non-linear, time varying multivariable processes and machines; solving of ergonomic safety and environmental problems; automation of logistical systems; applying robotics, mechatronics, and information handling, etc. In addition to that, big economic sums are involved with these operations. On the other hand, automation technology has developed towards intelligent and adaptive systems including some from the above mentioned fields of automation. Connecting them with modern information and communication technologies makes the idea of an intelligent and unmanned mine more and more feasible in the near future. This requires intensive co-operation and co-ordination between the mining industry and manufacturers of mining machinery. This has been successfully accomplished in the five-year Intelligent Mine research and development program as well as the three years of subsequent implementation of its results in Finland. The basic elements of an Intelligent MineTM concept are:mine-wide information and data acquisition system; high-speed two-directional mine-wide communication network for real-time monitoring and control; computerised information management, mine planning, control and maintenance systems; automated and tele-operated machinery and equipment which are connected to the information system; and links to the public information networks. The degree of automation of an intelligent mine depends on many technical and economical factors. The basic precondition for such an approach is that it will improve the total economy of the mine. This paper will describe the Intelligent Mine Technology Program with the results. Also the implementation which took place during starting of a new underground mine (Outokumpu Chrome Oy Kemi Mine) will be described.

Jan 1, 2000

By R. E. Ray

In an effort to reduce the risks to underground miners of health hazards associated with exposure to high concentrations of diesel particulate matter(dpm), the Mine Safety and Health Administration(MSHA) published proposed rules in 1998 limiting dpm exposure in both underground coal and metal and nonmetal mines. The proposed rule for underground coal mines would require removal of 95% of dpm by mass, while the rule for metal and nonmetal mines would eventually limit total carbon exposure from dpm to 160 micrograms per cubic meter of air over an eight-hour shift. The comment period for both proposed standards ended on July 26, 1999.In this session, representatives from MSHA, the National Institute for Occupational Safety and Health (NIOSH), equipment manufacturers, labor and industry will discuss the impact of the proposed regulations on mine operations and worker health. Questions will be taken from the audience after brief presentations from each panelist. This paper provides a compilation of written summaries of each panelist’s opening presentation.

Jan 1, 2000

By P Heppner, J Schell, R Newell

The effect of various methods of conditioning on subsequent flotation performance was reviewed, where complex interactions involving attrition, aggregation, dispersion and surface cleaning were discussed. The present study focussed on the influences of standard laboratory cell conditioning, ultrasonic dispersion and high intensity conditioning on copper mineral flotation characteristics. The effect of substituting demineralised water for the WMC plant water was also examined. It was found that higher copper concentrate grades were often obtained using demineralised water, however the use of high intensity conditioning in mill water gave the highest copper recovery and highest flotation rate constant. This process should be considered if copper grade and recovery in this section of the plant drops, especially if the drop is due to surface oxidation of the copper minerals. Other methods of conditioning (cell and ultrasonic techniques) improved the rate of copper flotation above that obtained in the virtual absence of conditioning, showing the importance of conditioning on subsequent flotation operations.

Jan 1, 2000

By William R. Yernberg

A conference on coalbed and coal mine methane was held March 27 and 28, 2000, in Denver, CO. The conference, organized by the Strategic Resource Institute, was attended by leaders in the coal mining and gas energy industry. The conference focused on the recovery of methane from coal beds as an energy resource and the removal and utilization of coal-mine methane (CMM) related to underground coal mining. The two-day conference discussed methane resources around the world, methods of recovery, methane markets, underground coal mining, health and safety issues and environmental issues related to methane. The consensus among the presenters is that the future looks promising for coal bed methane (CBM) and CMM.

Jan 1, 2000

By M. L. Young, M. S. Klima

Hindered-settling columns are used throughout the minerals industry for both size and density separations. In this study, the performance of a continuous laboratory-scale hindered-settling column was evaluated for various particle systems. The test variables included solids composition, water rate and column height. Column performance was evaluated using partition curves and corresponding performance parameters.

Jan 1, 2000

By T. M. Ruff, W. G. McCoy, M. J. Beus, S. Iverson

Monitoring conveyance position and wire rope load directly from the skip or cage top offers several significant safety and production advantages. The Spokane Research Laboratory of the National Institute for Occupational Safety and Health (NIOSH) developed a shaft conveyance monitoring system (SCMS). This system consists of position and guide-displacement sensors, a maintenance-free battery power supply and a new sensor, which is mounted on the wire rope with a Crosby Clip, to measure hoist-rope tension. A radio data link transmits sensor output to the hoistroom. A state-of-the-art automated hoisting test facility was also constructed to test the concept in a controlled laboratory setting. Field tests in full-size shafts are now underway.

Jan 1, 2000

By T Cutts

Since 1989 Kalgoorlie Consolidated Gold Mines has managed the Kalgoorlie gold operations of joint venture partners Normandy Mining Ltd and Homestake Gold of Australia Ltd. Current production from the Fimiston Open Pit is approximately 650 000 ounces per annum. The mine incorporates a multitude of narrow shear hosted, subvertical lodes, predominantly within Golden Mile Dolerite. Traditionally KCGM has used blasthole based grade control in the Fimiston pits. A single sample is taken from vertical production blastholes, drilled on ten metre benches. This process was improved with the addition of infill drilling along blasthole rows to provide additional samples across strike. However the limitations of adequately defining subvertical mineralised structures with vertical blastholes remain. In 1997 the first of two trial areas were drilled with close spaced, inclined Reverse Circulation (RC) drilling. These tests indicated that RC based grade control had the potential to provide significant advantages. These include:improved delineation of mineralised structures, particularly across strike; reliable short-term mine schedules based on the advance data available from drilling over three benches; and the angled RC drilling is capable of providing samples of near stope and stope fill material which often remains unsampled by blasthole drills due to the safety constraints around unstable underground openings. Based on the success of this initial work RC based grade control was gradually implemented across production areas commencing September 1998. Some of the many challenges faced include:development of effective procedures and systems for the planning, logging, interpretation and modelling of the RC data; obtaining adequate drill coverage due to mine scheduling constraints and restricted access around underground openings; requirement for integrated systems to handle either blast hole or RC data; and development of effective methods to evaluate the performance of RC grade control. RC based grade control is delivering significantly improved lode definition, grade estimation and subsequent ore classification.

Jan 1, 2000

The operations management system at Olympic Dam has evolved over a two-year period to the state described in this paper. This evolution has been driven largely by the requirements of the recent expansion of the Olympic Dam operation from three to nine million tonnes of ore per year. Such a change process demands an holistic approach to mine management and several techniques have been employed including XPAC, Mine Works Planner as well as a basic philosophy of æjust-in-timeÆ completion. The philosophies, software and tracking mechanisms for managing a large tonnage operation are described, outlining a fully integrated scheduling system from shift to shift detailed activity planning to a 20 year production plan. Moreover, the vision of production exceeding the current limit of nine million tonnes means that there are to be further developments to this state-of-the-art system in use at the Olympic Dam mine.

Jan 1, 2000

By Claude Deveau

"With ever decreasing feed grades, finer mineralogy and increased demand for product, it became obvious that a major step in equipment performance was required to reduce operating costs and increase production. Offsite testwork indicated that a Centrifugal separator was capable of recovering fine tantalum and that the newly developed C Series Falcon concentrator would be capable of replacing many pieces of aging equipment and provide improved performance. Further investigation led to the rental and the purchase of a Falcon C20 concentrator followed by a C10 to maximize circuit performance.Falcon Concentrators Inc’ s practice of working with the customer mirrors Tantalum Mining Corporation of Canada’s (Tanco) philosophy of continuous product development. This synergy honed valve design for continuous operation in a highly abrasive ore environment.Tanco has recently purchased two more Falcon concentrators for the recovery of additional tantalum from its spodumene circuit. These new units have additional user friendly operating features partially based on developments made at Tanco.The Falcon C Series units have enabled Tanco to maximize recovery of tantalum that was otherwise lost while using the original conventional gravity circuit."

Jan 1, 2000

Modelling and simulation are important aspects of flotation research, which may assist in the design of new circuits and the optimisation of existing ones. Flotation research in the AMIRA P9 project has developed a methodology for flotation plant modelling based on determination of cell (pulp) characteristics. froth characteristics, and ore floatability (using floatability components). The implementation of this methodology requires the determination of ore floatability, to which end a small flotation pilot plant known as the Floatability Characterisation Test Rig (FCTR) has been designed and then built and kindly made available to the AMIRA P9 project by Baker Process. The FCTR has a 2 tph capacity and consists of six 130 litre rougher/scavenger cells and six 50 litre cleaner/recleaner cells. The Mintek FloatStar pulp level control system is used to control the pulp level in all cells. A number of experimental procedures have been developed for using the FCTR to obtain the data required for the P9 flotation models. These procedures include how to determine the floatability parameters, Pi and mi, the bubble surface area flux, Sb, the mean residence of the pulp in the cell, t, water recovery. Rw, froth zone recovery, Rf, and the degree of entrainment, ENT. The flexibility of the FCTR allows it to be used in numerous flotation studies such as stream characterisation, reagent testing, grinding experiments, power studies, oxidation studies, and scale-up and simulation studies. This paper will describe the design and operation of the FCTR and the procedures that will be used to obtain data from the rig for modelling purposes.

Jan 1, 2000