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By W F. E Ouedraogo

This study data has been collected on a three-month period from November 2020 to January 2021 and based on three different pits: Vindaloo Main, Vindaloo Central and Bouere. Both pits having specific geotechnical and geological properties. Vindaloo Main, VIM, and Central, VIC, have the same mineral composition as volcanic tuff with felsic intrusion or monzodiorite, both rock mass is fractured with small joint. Geotechnically the uniaxial compressive strength UCS between 200 to 300 Mpa, Young’s Modulus 110 Gpa and Poisson’s ratio between 0.1 to 0.2. Bouere pit is basically made of volcanic tuff stock works as intrusive, UCS between 200 to 300 Mpa, Young’s Modulus 103 Gpa and Poisson’s ratio between 0.2 to 0.3. The first step of this study was to collect various data from mining operations around the drilling and blasting inputs. This was based around the different scenario of drilling parameters and the outcomes on the blasting, and how they impact load and haul operations and productivities of excavators from the heave to the last flitch. In most cases surface photos of the blast do not represent the overall fragmentation in the blast volume. Photos of the different flitches will not show only the effect of blast, as the loading operation generating more fragmentation by applying weight on the muck pile. Then the record of the different material uses for feeding. The last part of the analysis is the physical data from process plant such as particle size, throughput rate, both for the crusher and the mill, per pit and material and the specific Bond Work index (BWI). Fine particle quantity production is also a key point as is one direct indicator of milling performance. In overall, making link to BWI can influence at each stage of the mining to the processing operation. Drill and blast constitute a high cost in hard rock mining and trying to reduce these costs without an overview of all the integrated processes and context could end up by cost relocating to other activities in the process. However, the cost associated to size reduction builds exponentially as the particle size becomes smaller.

Jun 22, 2022

By J Loeb, J Dampney, P Cameron

Optimisation of Blast Design and Execution must be done right the first time. It is too late after the ore is broken. Consequences of poor design and execution negatively affect productivity from load and haul through the primary crusher to processing and hence reduce mine site profits. Harnessing and utilising ‘big data’ from geology, geometallurgy, drill hole location, powder loading, blast timing, blast movement and fragmentation to close the loop in blast design and optimise the blast increases productivity across the entire value chain from Mine to Mill. As the internet of things and artificial intelligence increases the quantity of data available, being able to capture and utilise this data to advantage is a challenge. Recent advances in software and hardware together with the increased power of cloud computing allows engineers to close the blasting loop to increase mine site productivity. Numerous case studies over the years detail significant gains from implementing the innovative technologies available to Mine to Mill projects. The opportunity is available for all members of the multi-discipline teams at each mine site to actively ensure productivity improvements are realised and maintained not only in their area, or silo of responsibility but across the entire mine site. This paper refers to recent case studies which outline how significant improvements in productivity are available to all mining operations to increase mine site profitability and dividends to shareholders.

Jun 22, 2022

By M Jacobs

This abstract discusses a heap leach copper mine that was failing to perform and as a result was not meeting targeted production. The mine had numerous technical challenges including: high water inflows, low levels of geotechnical monitoring, performance issues with mining, resource model and grade control reconciliation issues, and unexplained low levels of performance from the heap leaching operations. A team from various organisations with specialist skill sets including: a forensic accountant, the owner’s representative and a mining engineer, was arranged to visit the site. The task was to investigate the situation and determine what could be done to turn the performance of the mine around. After an initial assessment in late 2018, efforts were directed to better understanding the operations and improving the performance of the site through preventative management. A key part included the creation of production forecasts that could be achieved that would help restore confidence in the operations. Uncertainty in the mine achieving production forecasts and the performance of the heap leaching operations were contributing to the decline of the operations. Investigations uncovered the fact that while the resource model could reliably predict total copper, a lack of sequential leach data meant the accurate prediction of soluble and insoluble copper species, both important for heap leaching, was difficult to do with any degree of certainty. The crushing and mining contractors also appeared to have suffered somewhat from a lack of management by the owner’s team and performance had affected the production of copper. Collaboration and management were used by the team to understand and stabilise the operations. Ongoing collaborative efforts by the management team, site personnel and contractors resulted in a positive outcome for the owners and their mine – and could at yours.

Jun 22, 2022

By J Nortier, J Dray

There is no single factor that determines the appropriate capacity for a mining project. It is driven by the size of the resource, the capacity of the market, the availability of capital, the availability of power, the availability of water, and a myriad of other considerations. There is also no single solution to the question of how big the project should be. However, to develop a project, the study team needs to select the configuration options that it regards as the best for the project. To be able to make this selection, the study team should consider the range of available options and do so at a level of detail that gives it confidence in the conclusion but does not lead to multiple detailed design exercises. Having considered the range of options, and with a clear definition of the project owner’s objectives and constraints, the work to be carried into feasibility studies can be focused appropriately. This paper discusses the process of completing strategic mine planning to identify project configuration options to assist in the selection of the processing plant throughput rate (Capacity Study) for a large greenfield open pit mine. The processes described in this paper allow for the basis of design to be set for subsequent studies that meets the objectives at a risk profile acceptable to the owner.

Jun 22, 2022

By D Prior

The Australian mining industry is a significant contributor to the nation’s greenhouse gas (GHG) emissions, and like any industry, it must make efforts to reduce these. Medium- and long-term strategies will include the replacement of diesel engines with alternative energy sources, but what can be done in the short-term to reduce diesel consumption and hence CO2 emissions? Haul trucks are identified as the major contributors of CO2 emissions in the mining fleet and this paper focuses on firstly identifying what drives haul truck emissions and secondly, discussing what is the role of the Fleet Management System (FMS) in reducing these. A key enabler of this is having a robust fuel consumption model within the FMS, and I describe how this may be done. Besides novel approaches to incorporating fuel consumption (CO2) management into truck assignment algorithms, this paper also describes how the FMS can be used to implement and manage procedures and policies to reduce haul truck emissions.

Jun 22, 2022

By Y G. Anoman

This paper discusses the operating model within Endeavour Mining Corporation regarding the options of owner mining against contract mining. It’s based on the concept of ‘are we carrying out the most efficient mining’ regarding cost and performance. This question can only be answered through an extensive contract mining tender process and conducting a comprehensive comparison to evaluate the transition viability. Karma mine, located in Burkina Faso, is the subject of this paper. The Tender model included sales of equipment, parts and tooling associated with the traditional Load and Haul Schedule of Rates (SOR). The methodology focused on the structure of the tender process, which consists in the development of a SOR based on haulage profiles and mining schedule. This is a new Endeavour framework that allowed the bidders to compete on an even level. This was performed using a systemic analysis which encompassed all the elements involved in a transition such as the Human Resources (HR), taxes and customs implications, directs and non-direct costs (Finance and interest on assets, depreciation, insurance), contractor risk profiling. It was assessed against the normalised internal pricing tender-based. This paper gives an insight into how a West African mining operation addressed the sensitivities of the HR functions against the commercial aspects. This was one of the most successful transitions in West Africa and was carried out during the COVID crisis. The outcome of this project has created value by detailing a lesson learned model for both commercial and HR aspects. This discusses the commercial comparisons along with the internal model with the underlying HR functions as a risk factor that could have jeopardised the continuation of the operation. This resulted in a smooth transition with the additional cash flow generated by the sale of the parts and equipment turned Karma into a viable operation.

Jun 22, 2022

By X Hu, Z Pokrajcic, R Embry, P C. Stewart, J Carpenter, E Jones

Whilst the value of Pit to Plant and Mine to Mill optimisation has been proven since the 1990s, sustaining the productivity and efficiency gains typically requires ongoing test work, blast trials, plant surveys, and model calibration services. In contrast, the input to digital twin Pit to Plant or Mine to Mill optimisation is tens to hundreds of millions of tonnes of standard mine operating data. This paper presents a series of digital twin case studies from across the mine value chain, including machine learning testing methodology, model accuracy statistics and the application of Shapley Additive Explanations (SHAP) for model interpretation. These case studies demonstrate how machine learning and data fusion ore tracking connects hundreds of millions of tonnes of downstream performance data to produce digital twin models (operating models that are continuously updated and integrated into the wider Mine to Mill/Pit to Plant ore tracking system). Digital twin modelling software has been used to add block model variables for dig-rate, crusher and mill throughput, recovery (tailings grade), lump yield, product grade and product quality, fines yield and fines in lump. Block-by-block predictions are added to the geological resource and grade control block models as new block model variables. These new block model variables are used across all mine planning time horizons from life-of-mine planning to daily schedules. In addition to the materials handling and geometallurgical prediction case studies, the paper also presents digital twin case studies for drill and blast simulation and plant set point optimisation. The case studies show how digital twin simulation enables drill and blast engineers to simulate the effect of different blast designs in different blast domains using the mines operating data. Plant set point optimisation applies mathematical optimisation algorithms to the machine learning model to provide live operational decision support to metallurgists and plant operators. The digital twin machine learning case studies demonstrate a digital and sustainable paradigm for Mine to Mill and Pit to Plant optimisation.

Jun 22, 2022

By L Schürmann, R Kendall

Social licence to operate is becoming part of a mining company’s DNA in the same way as health and safety. Consequently, mining companies are receiving increasing pressure from their shareholders to ensure that they add enduring value to the local communities in which they operate. Apart from the shareholders, a company has responsibility to suppliers, customers, employees, the government and the community, which means under the social responsibility model they must be accountable to the other stakeholders. External and internal challenges in mining are increasing the difficulty and complexity of mines to operate. The external mining environment has a big impact on mining operations and is driving matters such as the focus on safety, responsible mining and resource management, sustainability issues, profitability and productivity. Considering this, it is expected that the widespread implementation of Environmental, Social and Governance (ESG) related practices across the mining industry in the next ten years will increase, not just for the big players but for juniors as well. Companies, investors, governments and insurers who fail to act on ESG matters are to likely face greater risks. Demonstrating leadership in ESG will ultimately become a differentiating factor and market participants have much to gain from embracing ESG stewardship as part of their competitive advantage. Stock Exchanges have an important role to play in advancing sustainability in the capital markets. It is for this reason that the Sustainable Stock Exchanges (SSE) initiative was founded to serve as a global platform for exploring how exchanges can enhance performance on ESG issues and encourage sustainable investment. The SSE initiative provides an effective platform for dialogue between the United Nations, stock exchanges, investors, companies and regulators in the mining industry. The paper will explain why ESG reporting is crucial for the survival of a mining company and how the lack of transparency could be detrimental to its public image and shareholder relations. The paper will also identify bodies that regulate ESG reporting, as well as the available tools that provide guidelines on reporting ESG matters. Key ESG reporting parameters (at a global scale) will also be highlighted.

Jun 22, 2022

By DEVY DYSON, Brian Hart, JOHN LANGHANS, Stamen Dimov, STEVE YOPPS

A recent Nevada Gold Mines research program focused on pressure oxidation pre-treatment of a Carlin-type double refractory ore from the Turquoise Ridge Mine. The research team found that both arsenian pyrite and carbonaceous matter were highly oxidized within an hour at 300 °C using a bench-top autoclave reactor and that the gold recovery from the residues after cyanide/carbon-in-leach approached the technical limit set by the amount of gold encapsulated by silicate minerals. Although the 60-min pre-treatment at 300 °C yields robust performance when treating a whole ore, copper additives can catalyze the oxidation rate of carbonaceous matter and reduce the residence time needed at elevated temperature. Certain gangue minerals are susceptible to dissolution in acidic solutions at 300 °C, and this may cause poor gold recovery. This recovery challenge is mitigated by keeping free acid in the discharge solution below a key threshold.

Jun 21, 2022

By Steven J. Schatzel, Kayode M. Ajayi, Bo H. Kim, Zoheir Khademian, Gabriel S. Esterhuizen

The stability of shale gas wells drilled through current and future coal reserves can be compromised by ground deformations due to nearby longwall mining. Depending on the longwall-induced rockmass permeability, the high-pressure explosive gas from the damaged well may reach mine workings and overwhelm the mine ventilation systems. This study uses geomechanical models to estimate the rockmass permeability induced by mining. A two-panel longwall model of a deep, 341-m-cover mining site in southwestern Pennsylvania is constructed in 3DEC to explicitly model the rockmass by a discrete fracture network (DFN) technique. Stress-induced fracture apertures and permeabilities are calculated across the model and are validated against permeability measurements. A fracture flow code (FFC) is developed to use these results to predict potential inflow to the mine should a gas well breach occur. One hundred DFN realizations are simulated, and the results show that for a gas pressure of 2.4 MPa, the average of the predicted inflow rates to this deep-cover mine is 0.006 m3/ s, significantly lower than the average inflow of 0.22 m3/ s for a shallow-cover mine (145-m deep) studied in the previous work (Khademian, et al. 2021). The result can help assess the potential hazards of a shale gas well breach for mine safety and evaluate the ventilation requirements to mitigate the risk.

Jun 19, 2022

By JOHN HOMER, Jacob L. Carr, Jonathan K. Hrica, Kathleen M. Stabryla, Iman Benbourenane, Jennica L. Bellanca

Given the recent focus on powered haulage incidents within the US mining sector, an appraisal of collision avoidance/warning systems (CXSs) through the lens of the available research literature is timely. This paper describes a rapid review that identifies, characterizes, and classifies the research literature to evaluate the maturity of CXS technology through the application of a Technology Readiness Assessment. Systematic search methods were applied to three electronic databases, and relevant articles were identified through the application of inclusion and exclusion criteria. Sixty-four articles from 2000 to 2020 met these criteria and were categorized into seven CXS technology categories. Review and assessment of the articles indicates that much of the literature-based evidence for CXS technology lies within lower levels of maturity (i.e., components and prototypes tested under laboratory conditions and in relevant environments). However, less evidence exists for CXS technology at higher levels of maturity (i.e., complete systems evaluated within operational environments) despite the existence of commercial products in the marketplace. This lack of evidence at higher maturity levels within the scientific literature highlights the need for systematic peer-reviewed research to evaluate the performance of CXS technologies and demonstrate the efficacy of prototypes or commercial products, which could be fostered by more collaboration between academia, research institutions, manufacturers, and mining companies. Additionally, results of the review reveal that most of the literature relevant to CXS technologies is focused on vehicle-to-vehicle interactions. However, this contrasts with haul truck fatal accident statistics that indicate that most haul truck fatal accidents are due to vehicle-to-environment interactions (e.g., traveling through a berm). Lastly, the relatively small amount of literature and segmented nature of the included studies suggests that there is a need for incremental progress or more stepwise research that would facilitate the improvement of CXS technologies over time. This progression over time could be achieved through continued long-term interest and support for CXS technology research.

Jun 17, 2022

By Bülent Erdem, Zekeriya Duran, Tuğba Doğan

The objective of this study was to evaluate the potential health risk associated with exposure of dozer operators to whole-body vibration. Measurements were made on 31 dozers used in different surface mines in Turkey. Predictions of adverse health effects of vibration were based on the standards BS 6841:1987, ISO 2631–1:1997, ISO 2631–5:2004, and the EU Vibration Directive:2002. Operators experienced high and comparable levels of vibration acceleration and dose during all dozer tasks: pushing the material (DOZE), moving forward (FORWARD), moving backward (REVERSE), and ripping (RIP). Specifically, DOZE, FORWARD, REVERSE, and RIP showed high potential of adverse health effects in terms of vibration dose according to the worst-case axis and vector sum criteria and a moderate adverse health effect for acceleration according to the worst-case axis criterion. Operators of large dozers were exposed to lower levels of vibration. However, no statistically significant relationship between vibration exposure levels and the propelling mechanism and the service time of dozers, operator experience, operator age, and ground type was found.

Jun 16, 2022

By Peter Zhang, Todd Minoski, Gabriel Esterhuizen, Jack Trackemas, Berk Tulu, Morgan Sears

Longwall mining is a highly productive and efficient coal mining method used in the USA. During longwall retreating, the belt entry must be maintained stable, and any roof fall in the belt entry would jeopardize mine safety and substantially interrupt the continuous production of coal in the longwall face. Past experience of longwall mining has shown that belt entry stability was the greatest challenge in longwall ground control, and the occurrence of roof falls in belt entries was largely associated with high horizontal stress. To properly support the roof in the belt entry, it is important to understand how longwall-induced horizontal stress changes affect roof stability in belt entries and to strategically install supplementary support to prevent any potential roof falls. Researchers from the National Institute for Occupational Safety and Health (NIOSH) performed horizontal stress measurements in the immediate roof of the belt entries for two Pittsburgh seam longwall panels oriented unfavorably to high horizontal stress. Hollow inclusion cells (HICells) were installed in the immediate roof at the intersection in each of the belt entries, and stress changes were monitored as the longwall face was approaching and passing the intersection. Numerical models were set up to calculate the longwall-induced horizontal stress changes in the roof at the monitoring sites. With the verified model, investigations were made of how horizontal stress is concentrated and relieved in the belt entry roof near the face under different panel orientations. Both measurements and modeling results showed that high horizontal stress is concentrated in the roof in the belt entry within about 15 m outby the face when a longwall panel is unfavorably oriented to the major horizontal stress. The study demonstrated that longwall-induced differential horizontal stress can be used as an indication of the degree of horizontal stress concentration. Roof support strategies are discussed on how to maintain the stability of belt entry under high horizontal stress concentration.

Jun 14, 2022

By Ali Jaberi Zamharir, Abolfazl Shoghian‐Alanaghi, Hossein Aghajani, Arvin Taghizadeh Tabrizi

In this study, the leaching rate of molybdenite concentrate was evaluated in sulfuric medium, and the influence of the diverse oxidants including hydrogen peroxide, manganese oxide, copper sulfate on the leaching rate was studied. Also, the effect of the addition of the ethylene glycol to the hydrogen peroxide was studied and results showed that with the addition of ethylene glycol, the leaching rate is increased 55% from 41% up to 80.3%. The optimum condition is achieved as 0.7 M of H2SO4, 4.4 M of H2O2, and 3.5 M of EG at 30 °C within 4 h of leaching time and 500 rpm. Also, inserting the oxygen with the pressure of 6 bar to the leaching autoclave, the leaching rate is increased more up to 86.4%. Finally, the leaching process was studied kinetically and the determined mode of controlling factor was specified based on the activation energy which equals 46.252 kJ/mole indicating the chemical reaction mode.

Jun 5, 2022

By Galymzhan Karamyrzayev, Rashid Nadirov

Zinc ferrite ( ZnFe2O4) is a by-product of non-ferrous metal production and is considered a promising source of raw zinc. The most efficient way to extract zinc from its ferrite is via acidic extraction, specifically leaching by hydrochloric acid. A comparative study of synthetic zinc ferrite hydrochloric acid leaching in isopropanol, aqueous, and the mixed solvent was performed. Zinc ferrite was obtained by sintering a zinc and iron (III) oxide mixture. Crushed samples were subjected to leaching in 1 M HCl at 323, 333, and 353 K and pulp density of 1 g/100 mL. The dissolution of zinc and iron into solution in organic media reached 77% at 353 K, while in an aqueous environment this value was 65%. The activation energy of 70.0 kJ/ mol was found for the leaching process in an isopropanol environment, which is lower than that in an aqueous solution by 15%. The more efficient leaching effect of isopropanol is attributed to the lower dielectric constant of the alcohol which increases the affinity of chloride anions for zinc and iron cations at leaching.

Jun 5, 2022

By S. D. Dladla, S. Ramsamy

The majority of the tailings dam operations in South Africa will be required to comply with the new Global Industry Standard on Tailings Management (GISTM) within the next one to three years, depending on the dam classification and the requirements of the respective investors and insurers. With up to 72 auditable requirements, the implementation of the Standard needs careful planning and prioritization. This paper focuses on the practical steps to GISTM compliance for tailings facilities in operation in South Africa. The discussions are based on current practices, South African regulations, and industry standards requirements. The possible changes in dam classifications and the associated requirements are presented.

Jun 2, 2022

By F. Hörtkorn, Y. Narainsamy

Rather quietly, a new generation of European norms dealing with earthworks has been developed over the past few years, in particular a part of EN 16907 pertaining to extractive waste. Whereas the majority of the parts deal with routine geotechnical aspects, one part deals specifically with tailings dams. The standard is currently in draft form but if this becomes a European Standard, members of the European Union are bound to comply with the regulations. As such, the standard has the capacity to influence mining in Europe and potentially in South Africa. In this paper we review the standard and compare it to the South African standard on mine residues and the recently published Global Industry Standard on Tailings Management (GISTM). We conclude found that although the European norm makes great strides towards increasing tailings dam safety, there is room for improvement. The current South African standard has served well since its inception, but can be improved by using concepts from the European and global tailings standards.

Jun 2, 2022

By V. Miguel-Silva, B. C. Afonseca

Drill-hole spacing analysis (DHSA) and optimization are becoming commonplace for uncertainty assessment and management in the mining industry. However, there is no standardized DHSA workflow, and the outputs of certain methodologies are not interchangeable. We group available simulation-based DHSA methods according to their accounted uncertainty into (i) raw uncertainty, assessed by drawing realizations from synthetic data-sets with the drilling spacings to be tested; and (ii) model uncertainty, in which these synthetic data-sets are used to assess the variation between the estimated model and the (unknown) actual value. DHSA workflows available in the literature ignore the differences between both types of uncertainty. Commonly, the DHSA algorithm is chosen without a detailed analysis of its uncertainty output, which may lead to misleading results and suboptimal decisions. While available solutions are based only on assessing raw or model uncertainty, the proposed approach simultaneously analyses both and their relationship for models at different stages of the mine. The integrated analysis results deliver more information to support decision-making than available methods. Principles, practical considerations, and discussions of the advantages of the proposed integrated analysis are presented. The approach is applied to a real gold deposit to illustrate its use.

Jun 2, 2022

By H. Karabulut, S. Gündüz, K. Karacif, M. A. Erden

The corrosion properties of iron-based composite materials containing graphite and silicon carbide (SiC) reinforcement were investigated. The effects of silicon carbide reinforcement were investigated by adding 0.5% graphite and 1%, 2%, and 4% SiC. A powder metallurgy method was used to produce the composite samples. Iron, graphite, and silicon carbide powders were blended for one hour with a threeaxis mixer and then unidirectionally pressed under a pressure of 750 MPa. After pressing, the composite materials were sintered at 1100°C for one hour. The corrosion properties and microstructure, density, and hardness properties of the composite materials that can affect the corrosion properties were also investigated. It was determined that the pore ratio and hardness of the composite material increased, and corrosion resistance decreased, with increasing silicon carbide content.

Jun 2, 2022

By T. Bezuidenhout, J. D. Visagie

In recent years the requirements for a barrier system between the waste body of tailings storage facilities (TSFs) and the natural ground (NG) has necessitated the use of HDPE-lined TSFs in South Africa and other countries. The addition of an HDPE liner creates an interface between, inter alia, the tailings and surrounding soils on the footprint of the TSF. It is known that low-strength materials beneath slopes can cause slope instability. One method which can theoretically mitigate this instability of a lined TSF is the addition of stability bunds along the footprint of the TSF. Altering the profile of the footprint to include slope changes which oppose the direction of the failure creates passive slices in a limit equilibrium analysis. The passive slices actively oppose the movement of active slices, resisting the mobilization of tailings, thus greater active slice forces are required to develop a failure surface running along the liner interface. Two scenarios are presented and compared. The first scenario retains the ground profile unaltered and the second scenario includes stability bunds along the ground profile. An in-depth assessment is made of the interslice forces and the interface shear stresses for each scenario. The theoretical background is discussed in greater detail to determine the mechanisms of reinforcement provided by the bunds.

Jun 2, 2022