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By Liz Diaz, Tacio Ferreira

Capstone Copper’s Pinto Valley Mine faced challenges in recovering rock and ore on final walls because of geotechnical constraints that require restrictions on methods for loading blastholes adjacent to the pit boundaries to preserve wall stability. The operation had been using the same drill and blast designs for years. With changing geology, such as harder rock, as mining progressed, material was being left unmined in final walls because of poor breakage. The amount of unrecovered, unprocessed ore was estimated at approximately 380,000 tons a year generated from an average of 60 final wall blasts performed annually. The engineering team from Capstone and Dyno Nobel engaged to minimize the amount of material left on the final pit walls. This paper presents how we collected data, reviewed design standards, and found opportunities to improve ore recovery from pit final walls without increasing drilling and blasting costs. The results collected from implementing the new design on two benches showed the potential for extra revenue of approximately $3.6 million generated annually from reducing final wall unrecoverable underbreak by nearly 71% on the mine’s highwalls.

Feb 1, 2025

By Daniel Saramak, Agnieszka Saramak

A big issue in crushing and grinding operations in raw materials handling is high energy consumption and low breakage effectiveness. According to the Legendre [7], only 10% of energy input is directly consumed on the feed material breakage, while the remaining portion is dissipated in the form of heat and noise [8]. In the industry of limestone powder production, the grinding operations constitute integral part of technological circuits, and the energy consumption in operations of industrial comminution consume as high as 2% of world energy [14]. High-pressure grinding is the technology with proved energy benefits both in ore processing circuits and in limestone grinding. The promising results concerned mostly the achieved energy savings and good results of material breakage were achieved and demonstrated in numerous investigations [1,3,12]. However, it appears that a proper selection of operational parameters of the press devise, determination the feed material characteristics and adjustment of process course san be of a key-significance in improving an effectiveness the HPGR operation. Operational parameters of devices and process course should be verified towards the characteristics of the feed material, which mainly applies to the particle size and shape of the feed material and its moisture, and also mineralization in case of ores [2,4,9]. There are various investigations concerning an impact of the operational pressing force on comminution results which mostly refer to the determination of energy consumption and crushing ratio [5,6,10,13]. Investigations on the moisture content are less common, however their results suggest that, in general, the HPGR feed with higher moisture shows the tendency to higher comminution intensity, while the energy consumption increases together with increasing of feed material moisture. Investigations on olivine sand feed [11] showed that crushing ratio decreases for higher moisture, especially when the material is crushed at higher pressing force. HPGR devices, however, shouldn’t be regarded as a unique and perfect solution for comminution of each type of material. But they indeed may bring technological and economic benefits, comparing to conventional crushing and grinding machines, resulting in more favourable breakage of material particles and lower consumption of energy per unit mass of processed feed material.

Feb 1, 2025

By Robert Kimutis, Lihong Zhou, Mark Mazzella, Jim Addis

Due to the surge in shale gas production, a substantial number of unconventional shale gas wells have been drilled across U.S. coal reserves. Gas breaches resulting from damaged wells pose a considerable safety risk to miners. This paper investigates how a ventilation system can effectively manage breached gas through a network-based numerical model and laboratory-scaled physical model. Several hypothetical gas breach scenarios in a longwall area are simulated, exploring factors influencing gas mitigation. The study establishes correlations between breached gas inflow and gas concentration at critical locations. The findings in this study provide valuable insights for managing mine ventilation systems and enhancing coal miner safety.

Feb 1, 2025

By Sahendra Ram, Priyadarshi Onam, Abhishek Kumar Singh

A numerical simulation study is carried out for assessment of stability of coal pillars having dirt bands by varying its size and depths. Physico-mechanical properties of dirt bands including thickness and its position in pillar system are varied in the simulation study. Results of the simulation study are correlated with the available empirical approaches of pillar strength are validated with field observations. It is observed that the presence of weak dirt bands significantly influences the strength of pillar. An attempt is made to develop correction factor for the available empirical approaches, which are developed without considering the weak dirt bands in pillar system. The findings of the study will be helpful for suitable design of different size of coal pillars at different depths and stages of depillaring operations.

Feb 1, 2025

By Muhammad Azeem Raza, Samuel Frimpong

Underground mining environments are inherently hazardous and can lead to emergencies where effective rescue and self-escape become critical. Missouri University of Science and Technology is pioneering new technologies for effective self-escape. The rescuers and miners need to be trained in these new technologically driven environments. Previous research in fields like aviation, medical surgery, and oil and gas drilling has demonstrated the effectiveness of virtual simulation training, but the mining sector has yet to fully adopt advanced tools such as eye-tracking and immersive training modules. This research proposes a comprehensive training infrastructure incorporating these technologies to enhance situational awareness and decision-making during emergencies. The novelty lies in the application of advanced miner escape and communication technologies, specifically designed to monitor and enhance cognitive responses in high-stress situations. By leveraging these technologies, the proposed training infrastructure aims to prepare the next generation of underground miners and operators, by equipping them with the necessary skills to manage emergencies effectively.

Feb 1, 2025

By Daniel Amponsah-Berko, Palas Kamlakar Borkar, Kwabena Boafo, Neha Sharma, Timothy Eisele

A series of iron-leaching experiments were conducted to test the ability of metal-reducing anaerobic organisms to reduce iron from Fe3+ to Fe2+ to dissolve it from iron ore tailings. This bioleaching process involves the fermentation of biomass from Typha latifolia (a common wetland plant) to generate organic compounds, which, along with metal-reducing organisms, reduce and dissolve iron. The concentration of dissolved iron over time was studied for one year. Iron concentration above 1150 mg/L was achieved at a pH range of 3.95–5.36. Tailings from multiple locations were examined.

Feb 1, 2025

By Angela Binder, Mareike Schubert, Yichen Jiang, Sandra Nowosad, Oliver Langefeld

GermanyINTRODUCTIONThe mining industry is currently characterized by various factors such as environmental impact, resource scarcity, social responsibility and geopolitical uncertainty. The production of minerals required to meet the demand for renewable energy is expected to increase by 500 % by 2050, particularly for critical minerals such as graphite, lithium and cobalt 1. Easily accessible deposits are often depleted, meaning that deeper and more complex deposits need to be developed. Furthermore, investors’ value systems have shifted towards more sustainable practices. Alternative approaches to solving this problem are therefore currently being developed, such as the Modular Mining Systems concept for scalable and adaptable mining projects 2. Many mining companies have also taken important steps to become more sustainable, implementing measures such as proactive closure strategies, restoration programs and the development of renewable energy projects. In the European Union, laws such as the Critical Raw Materials Act and the Net Zero Industry Act support the mining industry 3,4. They see it as important for the energy transition and promote more sustainable ways of working in the industry Particularly negative environmental impacts such as land degradation, scarcity of local water resources, water pollution and greenhouse gas emissions are ingrained in society’s memory. Despite these efforts, the public image has not yet changed. To change this perception, the industry must strive to better communicate its sustainable practices and the steps it is taking towards a more responsible and sustainable future, promote transparency and build trust.Digitalization, automation and electrification are driving the digital transformation in mining. However, their implementation can lead to higher capital expenditure, limiting their adoption across the industry. Furthermore, implementing new technologies can be a daunting task for any organization. Change management comes into play when introducing such disruptive technologies. It involves preparing an organization for change, potential resistance and establishing effective communication. This helps to ensure that the implementation is successful and the benefits of the new technology are maximized. Digital transformation requires well-trained, young mining, electrical, mechatronic and software engineers with a deep understanding of information systems. Unfortunately, the industry faces the enormous challenge of attracting this younger generation, who have little interest in the extraction of raw materials. The need for action is compounded by an aging active workforce heading into retirement and the forecast of increasing demand for critical minerals.In this challenging environment, the concept of Blue Mining with its constant further developments represents a promising approach. This implies a shift from a linear to a sustainably oriented circular economy. For the mining industry, this specifically means the introduction of innovative technologies, the increased recovery of materials from waste and the consistent questioning and application of circular principles along the entire life cycle of a mine. Such a change can not only reduce the environmental impact, but also contribute to economic resilience and increased social acceptance of mining.

Feb 1, 2025

By Philani Larrance Ngwenyama, Ronald CW Webber-Youngman

Through-the-Earth (TTE) communication systems were developed to provide post-accident communication in underground mines. Unlike primary tracking systems, they do not require any major infrastructure installations underground. Instead, they use the Earth’s overburden as the medium or channel for the transmission of electromagnetic waves between surface and underground. Under ideal conditions, TTE communication systems should be able to provide full-duplex, two-way voice, text and data communication. However, this will depend on the design and optimization of the different types of TTE communication systems (that is, antenna and electrodes), and understanding of the rock properties and their influence on the transmission of signals. This can help simulate and model the transmission efficiencies and predict the possible range and data rates. Being able to optimize the performances of these systems can enhance rescue missions, improving the chances of saving trapped miners, and ultimately reduce fatality rates across the mining industry.

Feb 1, 2025

By R. Chandramohan, Landon Jackson, C. Meinke

Understanding constraints within the raw battery material supply chain is essential for making informed decisions that will ensure the battery industry’s future success. The primary limiting factor for long-term mass production of batteries is mineral extraction constraints. These constraints are highlighted in a first fill analysis which showed significant risks if lithium-ion batteries are used to fully support vehicle electrification and intermittent energy storage. Nickel, lithium, cobalt and graphite reserves risk 100 percent depletion with significant consumption of known resources. Furthermore, more than 700 new critical mineral mines will need to be developed to meet the required production rates for decarbonization by 2050. Demand for critical minerals will outpace mine development timelines even as improvements are made to battery energy density and compositions. Governments and the private sector need to align themselves on decarbonization goals to establish cooperative agreements on the critical mineral supply chain by reducing the barriers to entry and increasing exploration efforts. Additional measures must also be taken to reduce the demand for critical minerals. Policy such as incentivizing public transportation and biking infrastructure can be exploited to drastically reduce the mineral demand placed on the mining industry.

Feb 1, 2025

By Hilal Soydan, H. Sebnem Düzgün, Jurgen Brune

In this study, with the primary goal of capturing ongoing digital transformation and automation impacts on the mining industry and its workforce, we conduct several interviews with mining industry experts in the United States and analyze our survey reports qualitatively and quantitatively through exploratory analysis. After the interpretation of the insights of industry experts, we proceed to generate a personalized and customized data analysis through a novel metric based on skills, knowledge, competencies and occupational requirements, which quantifies the job similarities for occupations in the mining industry based on the publicly available database of the U.S. Department of Labor. We use text analytics to tokenize and classify the interviews to capture a better understanding of major response categories. The temporal analysis shows that the critical competency needs in the data science and autonomy category increases from 28 percent in current demands to 43 percent. In defining our metric, we also calculate Kullback–Leibler (KL) divergence for each job profile that enables determining whether and to what extent that job is transitionary in our test set based on the mean, standard deviation and kurtosis of each job of interest. Our analysis reveals that the in-group job transitions are significantly easier than the between-group transitions, proving our initial assumptions and common sense. The generated heat maps provide the opportunity to present the gap between the current job and desired job profiles that provide feasible career change options, among others, offering individualized career paths for job seekers and promoting potential job transitions. Through the collection of industry-specific individual employee data, the AI system is envisaged to continue to learn as end users engage with the system, thus creating a central data hub specifically for the future workforce in the mining industry. Although the study has limitations on generalizability for qualitative assessments, it presents itself as a valuable application of how qualitative and quantitative approaches could be of value for future worker training in the mining sector.

Feb 1, 2025

By Isabel F. Barton, Eytan Bos Orent, Mark D. Barton

A new examination of tabular uranium (U)-vanadium (V) deposits within the La Sal district places mineralization in the context of the complex fluid flow history that has occurred in the Paradox Basin and Colorado Plateau. As the only currently producing district of this deposit type in the region, the La Sal district provides excellent opportunities to study deposit- and district-scale features that can serve as exploration guides where exposure is limited. The absence of major structures along a narrow and elongate mineral trend that runs E-W across the southern part of the Utah-Colorado border indicates a regional lithologic control. The trend was likely influenced by Jurassic drainage patterns, as indicated by paleocurrent directions shown in Fig. 1. Fluvial sandstone host rocks in the Jurassic Morrison Formation contain significant evidence of multiple superimposed fluid systems that have progressively changed local mineralogy. Apart from the presence of ore minerals, remnants of fluid systems are preserved as cements including quartz overgrowths, compositionally distinct carbonates, and sheet silicates. New geochronology methods provide constraints on the timing of initial mineralization and later remobilization. U-Pb ages of calcite associated with ore minerals provide evidence for Early Cretaceous mineralization, whereas textures and K-Ar ages show that early-formed V-minerals were replaced at the expense of V-bearing micas and clays during the Eocene. The paragenesis of minerals in U(-V) deposits of the La Sal district reflects the complexity of a sedimentary

Feb 1, 2025

By Amy McBrayer, Vladislav Kecojevic, Juan David Valencia Quiceno, Dragan Bogunovic

The mining industry’s commitment to innovation reflects a history of adopting technological advancements to enhance workplace safety, environmental sustainability and vocational training. The objective of this research was to develop an augmented- reality (AR) system for heavy-equipment operators (HEOs) in surface mining. The developed system has the potential to enhance mine safety, training and data-driven decision- making, which presents a significant step toward a more sustainable, effective and technologically driven mining training, contributing to the industry’s evolution and growth. The AR training system leverages Microsoft’s Power Platform and HoloLens 2 capacities to provide operators with detailed and immersive training guides for three mining equipment, including bulldozers, motor graders and haul trucks. AR guides combine speech controls, 3D objects, informative images and explicative videos in the real working conditions to enhance the operator’s learning process. The system has the potential to modify the training structure based on user performance and provides an efficient approach to data collection during training. This project was developed and applied through a case study in a surface mine in the Southern United States.

Feb 1, 2025

By Jeffrey W. Lin, Larry B. Weston, Jonathan D. Abbott, Jordan L. Arthur

Hydrocarbon fuel oils are one of the main components of ammonium nitrate-based explosives, including ANFO (Ammonium Nitrate-Fuel Oil) and emulsions. While a wide variety of fuels can, and have, been used in the manufacture of ANFO and emulsion products, No. 2 diesel, particularly dyed, off-road diesel, is widely used due to its ready availability and use in fueling mining equipment. However, a number of alternatives to standard diesel have been introduced over recent years, namely, biofuels, ‘high-performance’ diesels, and renewable diesels. The pressure to adopt these alternative fuels come from a variety of sources, such as initiatives to reduce carbon footprints, increased lifetime of equipment, and cost-advantages from tax credits. While these factors may provide a very real benefit to the mine site, a consideration that is often missed is how the use of these fuels can impact the formulation and characteristics of the ammonium nitrate-based explosives. Herein will be presented a discussion of these alternative fuels from a chemical perspective as well as the results of several studies focused on how the inclusion of various alternative diesels influences the production and performance of ammonium nitrate explosives. ANFO and emulsion were manufactured using representative fuel sources and studying in terms of the manufacturing parameters, shelf-life, interaction with other chemicals using in mining explosives. Detonation data was then collected for these products and compared to the behavior of products made with standard diesel fuels.

Jan 21, 2025

By Sam Taoum, Omar Riahi

Few tools allow for accurately tracking ore dilution after blasting. Existing methods often rely on data analysis or linear interpolation of velocity, which can be imprecise and less effective in varied geological settings. A promising alternative is the use of numerical simulations, which involve complex mathematical calculations incorporating real physical data about explosives and geological characteristics. These simulations can model blast-induced fragmentation and subsequent ore dilution with greater accuracy, providing detailed insights into blast dynamics by considering factors such as explosive type, blast pattern, and rock properties. Numerical simulations integrate data from sources like seismic sensors, blast monitoring equipment, and geological surveys, offering a holistic view that single-method approaches cannot match. By simulating different scenarios, mines can predict the outcomes of various blasting strategies, optimize blast designs to minimize ore dilution, and maximize recovery. Advanced numerical simulations enhance the prediction of fragmentation distribution and size post-blast, crucial for effective dilution control and maximizing ore recovery rates.

Jan 21, 2025

By Stephen Mansfield, Saran Sankar

The Sentinel open pit copper mine, operated by First Quantum Minerals Ltd, is located in the North West province of Zambia. The Sentinel orebody is a sediment-hosted, structurally modified deposit in which mineralisation is contained in the phyllite formation, which occurs as a series of layered, continuous sheets having a northerly 20 to 30⁰ dip. The persistent nature of the geological structure can lead to the generation of large slabs when joints are relatively close together or very large blocks when joints are more widely spaced. With standard blasting methodologies, the challenging fragmentation most commonly occurs in the stemming zone and blast interfaces, reducing excavation rates and increasing the risk of crusher bridging events and reduced throughput. A generalised approach to increase powder factor would increase in drill and blast costs and would not be sufficient to target the specific cause of the challenging fragmentation. Implementing differential blast energy based on post blast requirements for different material type, such as ore and waste, and rock mass characteristics is not new in the mining industry. High-energy blasts for ore aim to produce finer materials, enhancing downstream processes such as crushing and grinding, while reducing power consumption and increasing throughput. Conversely, waste rock often requires less energy in order to deliver optimised fragmentation for loading and hauling efficiency. Identifying and applying optimum blast energy to specific material type and geological domains will not only ensure smoother and efficient operations throughout downstream processes, but will have a direct impact on overall profitability of the entire operation. This paper will describe the methods used to model and implement differential blasting across a range of material types in order to deliver the required blast outcomes for ore and waste and the impact on downstream processes and drill and blast unit cost.

Jan 21, 2025

By Jorge Alvarez

In a large-scale open-pit mining operation, continuous efforts are made to control damage to the slope walls. An essential tool in this effort is determining the PPVc (critical peak particle velocity) in areas of interest. By knowing this value and generating criteria, drilling and blasting designs can be established to reduce vibrations that affect wall construction. It is crucial to understand that the PPVc changes as different mining phases develop, especially due to exploitation on the benches, which leads to vertical inherited damage. Therefore, it is imperative to regularly update the PPVc based on field tests that provide accurate data. With this information, vibration damage criteria can be established, and drilling and blasting techniques can be designed to minimize the impact on the remaining rock mass. This document presents a methodology for generating scaled criteria that best represent the reality of the rock mass.

Jan 21, 2025

By Visitor Makiyi, Chris Batten

Poor coal recovery due to coal damage or loss caused by blasting can have a significant impact on a mining operation. Increasing coal recovery by reducing blast damage can provide a significant opportunity for coal mines to maximise their revenue and reduce their operating costs. This paper provides details on advanced drilling and blasting techniques used throughout the coal industry globally to prevent coal damage and movement during blasting. Typical coal loss and damage mechanisms are explained, along with how each of the applied techniques works to minimise the impact of each mechanism. Key requirements for a coal loss reduction program are detailed with typical design parameters used for each of the methods discussed. The positives and negatives of each method are also provided to enable comparisons and help determine suitability for a particular coal mining operation.

Jan 21, 2025

By Park Yun-Seok, Jung Seung-Won, Hwang Nam-Sun, Song Jin-hyuk, Kim Young-ho

This study proposes a new blasting vibration estimation formula that reflects the vibration reduction characteristics of electronic detonators, which are not considered in the current MOLIT blasting vibration estimation formula. Test blasts were conducted across six types of Korean open-pit blasting designs. The results of the test blasts showed that the K value for electronic detonators decreased by approximately 30% compared to electric detonators. Predicted Peak Particle Velocity (PPV) analysis indicated a reduction effect ranging from 30% to 31% across various types. By incorporating this reduction in the K value into the MOLIT blasting vibration estimation formula (K=200), a new electronic detonator blasting vibration estimation formula (K=140) was proposed. Using this new formula, the blasting damage range (R) was calculated under various vibration limits to evaluate constructability improvement. On average, the R value for electronic detonators decreased by about 17%, with significant reductions of around 41% observed for TYPE I under certain vibration limits. In conclusion, the adoption of electronic detonators in open-pit blasting operations improves blasting efficiency, reduces economic costs, and significantly enhances constructability. Electronic detonators have demonstrated superior performance in minimizing damage to safety facilities compared to traditional electric detonators, thereby proving their practicality and effectiveness in blasting operations.

Jan 21, 2025

By Joe Atalla, Jesse Desrochers, Rodrigo Hayashida, Joseph Mukendi Kabuya

The Mont-Wright mine stands as a prominent open-pit operation in Canada, renowned for its vast iron-ore reserves. However, the efficacy of its blasting operations, crucial for efficient production, has encountered challenges due to the diverse lithological compositions across multiple pits. This study presents a comprehensive approach to optimize blasting practices at Mont-Wright mine, tailored to the specific lithological characteristics of each rock domain. Through systematic analysis and experimentation, blasting guidelines were meticulously developed, aiming to enhance grindability and equipment productivity. The implementation of these guidelines promises significant improvements in operational efficiency and resource utilization, positioning Mont-Wright mine at the forefront of sustainable iron-ore extraction.

Jan 21, 2025

By Maja Franjic, Ian Tolliday, Chris Collins, James Wiltshire

Ammonium Nitrate Emulsions (ANE) are a large segment of the explosives market for the mining industry. These emulsions are generally designed to be very stable but when breakdown does occur, removal of the resulting thick, crystallized material can be difficult, hazardous, time consuming and costly. A heavily crystallized emulsion cannot be pumped, so manual removal often becomes necessary. Buildup of semi-solid layers of crystallized emulsion can occur in bulk storage tanks or in truck compartments. In these situations, a manual cleanup involving hazardous confined-space entry and a significant amount of downtime is usually required. Once the crystallized emulsion is removed from the equipment, there is very expensive disposal of the resultant waste via a licensed trade-waste company. A much more desirable solution for dealing with waste emulsion is to completely break the emulsion, allowing the oxidizer and fuel phases to separate into two distinct layers. These layers would then be readily pumpable and could be disposed of much more economically. It may even be possible that the separated oxidizer phase could be repurposed as fertilizer and the fuel phase could be used to manufacture granular ANFO explosives. There are some existing products on the market for breaking emulsion explosives, but these generally need a high degree of mixing into the emulsion to achieve adequate breakdown. The aim of this study was to identify surfactants systems (demulsifiers) capable of effectively breaking a range of waste emulsions with minimized agitation. This paper describes the development and performance testing of novel demulsifier products. The test work involved a comprehensive series of laboratory screening tests, where the demulsifier formulations were optimized. A highly efficient formulation was identified, and field trials were conducted on real world, full-scale waste emulsions. Results will be presented that demonstrate a viable solution for the disposal, and potential re-use, of waste ANE in the explosives industry.

Jan 21, 2025