Search Documents

By Laura Steeves, Inoka Eranda Perera, Jhon Silva, Arend Spaeth

"This paper reviews the main concepts ruling the design, implementation and performance of active explosion barrier systems for underground coal mines in the USA. The document examines the parameters needed for the design of this type of system, such as overpressure and flame speed, suppressant deployment speed and duration time of the active barrier. The document also discusses the available solutions for gassy mines and the concepts behind the selection of machined mounted and roadway active explosion barrier systems. The paper includes a review of active explosion barrier systems developed in the USA and South Africa. The paper provides an overview of the current status of this technology in the underground coal mining industry in the USA, and the possible implementation of such systems. The paper concludes with the identification of the future work needed for the successful implementation of the systems in several conditions to enhance the safety of underground coal mine operations and to provide more tools to the miners for their safety.INTRODUCTIONUnderground coal mine explosions can be addressed in two ways, through prevention or mitigation. The United States mining industry practices have emphasized the prevention of explosions in underground coal mines, with little being done to mitigate the explosion once it occurs. Despite successful practices for the prevention of underground coal mine explosions in the US, the threat of an explosion does still exist. Other mining countries around the world have developed and implemented mitigation systems such as active explosion barriers in their underground mines. In the 1970s, the United States Bureau of Mines (USBM) carried out extensive research on the use of active or triggered explosion barrier systems in the US; however, they are not currently used.Explosion barrier systems do not prevent explosions but mitigate the propagation of the shockwave and flame to other areas of the mine. The use of active explosion barrier systems enhance the safety of underground coal mines. Active or triggered explosion barriers will detect the arrival of the shockwave or flame front of the explosion and release inert material to suppress or extinguish the flame. The technology required for active barrier systems is readily available based on their presence in other mining countries and must be adapted for their use in US coal mines. The adaption must consider the coal dust and methane concentrations in US coal mines, the mine geometry, and the mining equipment used."

Jan 1, 2019

By Jaana Romppanen, Satu Jyrkönen, Tiina Ranki, Peter Björklund, Markku Lahtinen, Kaj Eklund, Päivi Suikkanen

Outotec is continuously developing our existing process equipment and new equipment solutions to enhance the Flash Smelting process. Thanks to the long operating history of the Outotec Flash Smelting process feedback from the numerous operating references are available and is utilized. The general goals for development work are to improve equipment performance, thus realizing savings in Smelter plant operation costs by increasing the process efficiency and online availability. Digitalization also opens new possibilities for the feeding equipment and furnace operation monitoring. These solutions will improve the safety and performance of the smelter, and provide process and equipment related information which has not been available earlier. INTRODUCTION The year 2019 marks the 70th anniversary of Flash Smelting. The technology was operated on industrial scale for the first time at the Outokumpu Harjavalta copper smelter in Finland in 1949. The Flash Smelting technology, is now owned and developed by Outotec Oyj and the first plant, is now owned by Boliden Harjavalta Oy. The two companies have been evolving throughout history by optimizing the process for various feeds and raw-materials, as well as through developing the equipment and operating practices. Even though sustainability was not a hot theme/topic during the first days of Flash Smelting, it has nevertheless been the key principle in guiding the development. This is well proven by the wide adoption of Flash Smelting for the processing of copper and nickel concentrates, mostly due to its ability to fulfil the economic and resource efficiency criteria demanded by its operators. Along with the process technology development, also development of the equipment has taken place over time. Outotec is continuously working on developing our equipment to better suit the changing need of our customers in the continuously changing operational environment. Orebodies are getting more challenging with lower ore grades and more impurities. Achieving high recoveries for all valuable elements becomes more difficult with high slag quantities and with the need to tackle the high impurity concentrations. There is a need for higher capacities in greenfield and brownfield smelters. The role of the Loss-in-Weight Feeder, the Air Slide and Concentrate Burner is to ensure even feed into the reaction shaft of the Flash Smelting Furnace, and to enable controlling the process well, thereby enabling the best performance for the customers smelter. The design of the Flash Smelting Furnace aims for high availability, long campaign and safe operation.

Jan 1, 2019

By E. Watkins, V. Gangrade, P. Zhang, J. Addis, D. W. H. Su, T. Minoski, C. Hollerich, M. Van Dyke, S. Schatzel, H. Dougherty

"This paper presents the results of a comprehensive study conducted by the Centers for Disease Control (CDC), National Institute for Occupational Safety and Health (NIOSH), Pittsburgh Mining Research Division (PMRD) to evaluate the effects of longwall-induced subsurface deformations and permeability changes on shale gas well integrity and safety under shallow cover. NIOSH researchers selected a study site over a southwestern Pennsylvania coal mine, which extracts 1,500-ft-wide longwall faces under 482 feet of cover. One in-place inclinometer well and three permeability monitoring wells were drilled and installed over a 125-ft by 275-ft centers abutment pillar. In addition to the inclinometer well and monitoring wells, surface subsidence measurements and underground coal pillar pressure measurements were conducted as the first 1,500-ft-wide longwall panel on the south side of the abutment pillar mined by the site.A number of FLAC3D finite difference simulations (Itasca Consulting, 2017) were conducted to estimate surface subsidence, coal pillar pressure increases, and horizontal displacements in the in-place inclinometer (IPI) monitoring well. Comparisons of the FLAC3D finite difference simulation results and the surface, subsurface, and underground instrumentation results show that the measured IPI casing deformations are in reasonable agreement with those predicted by the FLAC3D models, and that the measured surface subsidence and underground pillar pressure are in excellent agreement with those predicted by the 3D models. Measured permeability changes were incorporated into a preliminary calculation to evaluate the effect of a hypothetical shale gas well leak on longwall ventilation. Results from this 2018 research clearly indicate that under shallow cover, the measured horizontal displacements within the abutment pillar are at least one order of magnitude higher than those measured in a 2017 study under deep cover and slightly higher than those measured in a 2014 study under medium cover. This research represents a very important step and initiative in utilizing the knowledge and science obtained from mining research to improve miner and public safety as well as the safety and health of the workers in the oil and gas industries"

Jan 1, 2019

By Damian Connelly

The metallurgical heart of the majority of copper oxide processes is the heap leaching operation. Fresh low grade sulfide ores is a far greater challenge.The success of this unit operation is so important that operators need to understand the ramifications of their decisions or non-decisions and how they could affect the downstream processing. Heap leaching is an operation that can be described as a scientific art whereby principles of science can be used to guide experienced personnel in attaining their goals. Recent advances have been made based on better understanding the ore characteristics. The success of a heap leach operation, or otherwise, is dependent upon a number of factors, notably: The type of ore to be treated The extent of testwork completed to define the process The interpretation of the testwork results Ore preparation prior to stacking Agglomeration and curing requirements Other issues are: Compliance with the ’smaller’ requirements of environmental authorities Adequate and timely drainage of solution from the base of a leaching lift The degree of saturation in the pads Heap porosity – coarser or finer ore, which is better? Higher or lower irrigation rates – which would produce a better result? Laying out irrigation pipework for ease of operation and maintenance The addition of water, raffinate during agglomeration where needed The heap leaching of sulfide ores, including chalcopyrite, via enhanced bacterial leaching is discussed. INTRODUCTION Over the last twenty years, production of extremely pure copper from solvent extraction and electrowinning (SX/EW) has become more common in a market of real declining prices for copper metal. This paper touches on a number of heap leach operations and experiences. These projects were subjected to extensive engineering design and resulted in low capital cost, efficient operations with a number of lessons learned. The key to these operations was the performance of the heaps and associated fluid collection systems rather than the plants themselves.

Jan 1, 2019

By B. R. Maas

Processing material at a consistent rate through the continuous countercurrent decantation (CCD) thickeners presented a major bottle neck to unlocking additional value from one of the post-flotation streams at the Kansanshi processing plant. The manual operation of the thickeners making up the CCD train resulted in frequent imbalances and process upsets across units. The automation of CCD trains is notoriously tricky as the available manipulated variables are outnumbered by the parameters requiring regulation. The implementation of an advanced, auction-based, control philosophy to manage the movement of both slurry and solution inventory through the train addressed this parameter imbalance and lead to the stabilisation of the circuit. Since the commissioning of this control strategy: an additional 7 200 dmt/day (+36% throughput) of material can reliably be processed through the train, the number of monthly downtime events has reduced, and a saving of $354 000/month in reagent cost has been achieved. INTRODUCTION CCD operation Agitated leaching is a common method used in hydrometallurgy to extract a metal from its host ore. The host ore is initially finely ground to liberate the surfaces of the valued minerals and improve the kinetics of the leaching process. The ore is then contacted in an agitated tank with a lixiviant to dissolve the desired metal into the aqueous phase. The resultant slurry from the leaching process comprises of a solution pregnant in the metal salt and a barren ore. The first purification step taken after leaching is to wash the pregnant liquor solution (PLS) from the depleted ore. On the industrial scale, a set of between two to ten thickeners arranged in a countercurrent configuration is often used to carry out this separation (Perry & Chilton, 1973). The slurry is introduced at the head of the train and a wash solution at the tail. The two streams are pumped through each thickener countercurrent to one other. At each stage the residual PLS in the slurry is mixed and diluted down with the countercurrent overflow solution from the downstream thickener. The diluted slurry is fed into the thickener where the solids separate out through gravity sedimentation. The settled solids are channelled towards the underflow of the thickener by a rake mechanism and pumped downstream to the next thickener in the train. The outcome is the recovery of a PLS from the overflow of the lead thickener and a slurry of washed solids from the underflow of the tails thickener.

Jan 1, 2019

By M. G. Beukes

"In South Africa most of the large gold mines operate between 1500m and 4500m below surface where reef is accessed initially through a vertical shaft system then via a network of tunnels and mined in either a longwall, sequential grid or scattered mining configuration. Due to the complexity of the ventilation networks used to ventilate these mines and the potential disastrous consequences associated with underground fires, it is of utmost importance that these mines are managed in such a way that underground fires are prevented. However, if they do occur the fires are managed to firstly prevent the loss of life and secondly protect the infrastructure and viability of the mine. The aim of this paper will be to: • Discuss current SA mining legislation regarding underground fire prevention and control. • Examine these fires from a risk management perspective by means of a bowtie assessment. • List and discuss the major Threats and Consequences as determined by the bowtie assessment. • Discuss the various prevention and consequence controls for deep level underground fires. • Examine how to effectively run an emergency control room. From this, a practical way of designing, implementing and managing an underground fire management system is explored. Lastly, the paper identifies new technology and ways of thinking and how these can be used to combat underground fires. INTRODUCTION The orebodies of South African gold mines are generally narrow tabular structures that vary in thickness between 0.8m and 1.2m with an inclination of between 200 and 700. This, coupled with depths of between 1500m and 4500m, as well as the unpredictable geology, creates unique challenges and significantly impacts on mine designs and mining methods. In general, gold bearing reefs are accessed initially through a vertical shaft system then via a network of tunnels and mined in either a longwall, sequential grid or scattered mining configuration (Figure 1). Mining is very labour intensive with very limited mechanisation opportunities and this increases the risk to human life if an underground fire occurs. On 16 September 1986, one of the worst mining disasters in SA mining history took place when 177 mineworkers were killed at Kinross Mine. An acetylene tank sparked flames that swept through the mining tunnel igniting plastic covering on the wiring and the flames also set fire to polyurethane foam. The burning plastic combined with polyurethane and the toxic fumes that filled the shafts caused the miners death. This incident was a stark reminder of the serious consequence that underground fires can have on human life as well as the crippling financial and asset impact for the mining companies. Over the past thirty years, the SA mining industry reduced the number of mine fires significantly by replacing normal timber support with fire retardant treated timber, alternative support systems such as backfill and elongate support and many other fire prevention initiatives. Although the number of fire incidents and number of fatalities due to fires does not show a direct correlation because of various factors, the controls put in place against fires has had an impact on the number of fire and explosion fatalities (Figure 2)."

Jan 1, 2019

By R. Bishop, J. Baggett, J. Monsalve, J. Hole, N. Ripepi, A. Abassi

This work focuses on the operational and safety issues associated with karst voids in large opening underground mines. Issues include water inrush, structural instability, and engineering uncertainty in these environments. Coupled with the fracturing prevalent in folded sedimentary rocks, karsts are complex and challenging ground control risks. Traditional methods of predicting karst locations, such as probe drilling, are impeded by the inconsistent spatial distribution and variable sizes of the features. Ground penetrating radar (GPR) is a geophysical technique that transmits radio waves into a medium and subsequently detects reflected waves via a receiver. The travel time and energy of received signals are then processed and interpreted. The difference in material properties between limestone and open karsts causes strong reflections. GPR is frequently used as a geophysical surveying technique in several industries, however there is a lack of published research on underground mining GPR applications. The purpose of this work is to prove the viability of GPR in underground stone mines for karst detection, and to discuss the importance of karst detection ahead of mining. INTRODUCTION The Mine Safety and Health Administration (MSHA) currently lists 116 active underground stone mines in the United States, the vast majority of which extract limestone for crushed stone products. These limestone mines have the potential to encounter karst voids at some point in their operation, as most karstic regions of the United States develop in limestone rock masses (Kuniansky, Weary, & Kaufmann, 2016). Karsts, the cavities formed by the dissolution of carbonate rock, have long plagued the mining and tunneling industries, as well as been a hindrance on the Earth’s surface, producing sinkholes and ruining otherwise valuable land for construction and public use. The impact of karsts on the Gavarres tunnel in Spain is well documented by Alija et al; constant instability conditions, material spills into the tunnel, and unexpected cavities seriously delayed the project deadlines and “were not foreseen in the design” (Alija, Torrijo, & Qunita-Ferreira, 2013). At the water supply project in Sohngua River, China, Bin et al detail the presence of both water and sediment filled karsts which are sources of disastrous conditions at this tunnel (Bin, et al., 2017). A hydrological tunnel in Lebanon encountered numerous massive karsts in the tunneling path which required remediation via friction anchors, rockbolts, welded wire fabric, channel steel arch segments, invert steel beams, and shotcrete (Leech, Jaoude, & Ghanem, 2008). From a design standpoint, rock mass classification schemes, such as the RMR from Bieniawski and the Q-system from Barton, are not able to represent the true nature of a karstified carbonate rock mass, and therefore complex case-by-case analyses of underground conditions are necessary (Andriani & Parise, 2017).

Jan 1, 2019

By Beatrice Pierre, Juan Carrasco

Altonorte began as a concentrate roasting operation in 1988 under the name of Refimet. In 1993, a copper smelter was built with a design capacity of 203,000 tonnes per annum of concentrate. Since 2001, many technological advances have been made in Altonorte, where the biggest Noranda Reactor in the world is installed being the first Noranda Reactor reaching above one million tonnes of copper concentrates processed per annum. In 2013, Altonorte was acquired by Glencore. Recently due to various new environmental regulations in Chile, Altonorte has evolved to new standards of operation in order to reach the vision of becoming a World Class Smelter. This paper describes the path followed to improve safety, environmental performance, process capacity, reliability, and productivity. The foundation for the growth and success in Altonorte is our People. Employee engagement and branding of our cultural journey is what allows Altonorte to face the future with the certainty of becoming a World Class Smelter. INTRODUCTION Altonorte is located in Antofagasta, the mining capital in the north of Chile and is the last smelter built in Chile practically completed with second hand equipment. The biggest technological change in Altonorte occurred during the phase 3 expansion in 2003, where the old Reverberatory furnace was shut down and replaced by the biggest Noranda Reactor installed in the world. The vessel measures 5.3 m × 26m. ºAdditionally, this project contemplated a new rotary dryer, three (3) new Peirce Smith converters, new anode furnaces and a new Acid plant. The nominal capacity was to treat 816.000 tons of new concentrate per year. In 2008, a new expansion phase was implemented where a new double absorption acid plant replaced the oldest acid plant. Bottlenecks such as blowing capacity and oxygen availability were solved installing a new air blower and a new contract was negotiated with our oxygen supplier to increase oxygen availability up to 683 tpd. This improvement defined the current nominal capacity of 1.100.000 ton of new concentrate per year. Current process description All concentrates are received by trucks directly from domestic mines or from the Antofagasta international port in cases of imported concentrates; the concentrate warehouse has a capacity of 25 kt where the blend is prepared to feed the smelter.

Jan 1, 2019

By C. Opoku-Ware, M. Kukay, P. Conrad, F. Inkoom, R. Pal

Researchers at Montana Tech are investigating the potential for developing trees tolerable to degraded un-reclaimed mine site tailings and soils as a solution to re-establishing long-term tree growth on those sites. This project involves growing tree seedlings from seeds planted in the degraded mine tailings and soils in which they will eventually be planted. The outcome of the project is expected to lead to a successful solution for re-establishing tree growth in degraded tailings and soils in Butte, Montana with minimal post-planting human intervention. Work conducted on the project to date has shown successful growth of seedlings in degraded tailings and soils. INTRODUCTION In an effort to improve Butte Area One natural resources, this research project is working to help restore tree growth in the Butte Priority Soils Operable Unit Boundary (BPSOU) (Opoku-Ware, et al 2018). Research by Blicker, et al (2003) found that, the BPSOU, which is part of the Silver Bow Creek/Butte Area National Priorities List (Superfund) Site within and near Butte, Montana has multiple historic mining sites situated entirely within the urban setting of Butte. Mine wastes and mill tailings, accumulated from over 100 years of gold, silver, and especially copper mining are dispersed throughout Butte, posing health risks to human and environmental receptors. Stabilization of tailings sites is needed to control fugitive dust, prevent run-off of toxic material resulting in subsequent sediment deposition in streams, reducing the volume of water seepage through acidic and heavy metal contaminated material, and improving land productivity and aesthetic values (Watkin and Watkin, 1982). If successful, the project will help restore water quality and maintain stream flow in Silver Bow Creek where it flows through Butte Area One. Trees native to Butte are being grown to seedlings in a greenhouse located on Montana Tech’s campus which will be planted in degraded soils located within the BPSOU. Growing trees is expected to help restore vegetative ground cover within the watershed contributing to stream flow in Silver Bow Creek. The trees will prevent soil and tailings from eroding and being deposited in Silver Bow Creek where they could degrade water quality and choke stream flow. The project combines research with tree seedling growth to provide a resource for Butte that could produce thousands of tree seedlings each year adapted to the harsh climate, soil, and tailings conditions that exist in the BPSOU where they will grow. It is anticipated that the trees developed by the project will have the capability for long-term survival and growth because they will be germinated and grown into seedlings in the degraded soils and tailings collected from the BPSOU where they will be planted. Soils and tailings collected for the project have been evaluated to determine if they lack nutrients or contain substances potentially toxic to the long-term growth and survival of the trees. Toxic levels of metals, high concentrations of soluble salts, extremes in pH, nutrient deficiencies and imbalances, surface crusting, high bulk density, low infiltration rates, high surface temperatures, low cation exchange capacity, restricted microbial activity, low water retention, harsh climatic conditions and surface particle movement are some of the traits of mine tailings sites that restrict revegetation efforts (Barth, 1986).

Jan 1, 2019

By C. Hudson, D. Tremblay, A. Frey

"A discussion of the design, challenges and successes associated with the commissioning of the gravity recovery circuit at Canada’s newest open pit gold mine - Atlantic Gold’s Moose River Consolidated Project in Nova Scotia, Canada is presented. An overview of the project, its historical significance and overall flowsheet is provided with special focus given to the design and selection of the gravity circuit equipment including the scalping screen, gravity concentrators and the novel intensive leaching technology selected for the project. The performance of the gravity circuit is benchmarked against the feasibility study process design specifications and the outcomes are discussed. Challenges encountered during commissioning are also presented, including the use of third-party automation and the effects of screen sizing on overall gravity circuit performance. Mechanical modifications made to the Sepro Leach Reactor for the Moose River project are also discussed. A detailed technical review of the mechanical and operational aspects of the Sepro Leach Reactor is provided with key operational data on leach times, recoveries, reagent usage, solid-liquid separation, pregnant solution quality and its influence on bullion purity.INTRODUCTION Atlantic Gold Corporation’s Moose River Touquoy Mill in Nova Scotia, Canada was commissioned in the fourth quarter of 2017 with commercial production declared in March of 2018. The 2 Mtpa process plant uses a conventional, gravity-CIL process. This site was previously mined in the 1870s. Interest waned in the early 1900s but resumed in the 1930s and the mine was brought back into production in 1935 until an underground mine collapse in 1936. This mining district became famous after CRBC radio commenced a ground breaking, around the clock, broadcast of the rescue operations. Over 100 million people listened to the broadcast from Canada, the United States and the United Kingdom. These broadcasts changed radio, transforming it from a medium for music to on the spot, breaking news reporting. The mill was constructed by Ausenco on a fixed price EPC contract in the historic Moose River gold mining district, 95 km north-east of Halifax by road. The mill will process ore from the adjacent Touquoy pit for the first 5+ years of operation; after the Touquoy reserves are exhausted, the mill will process ore trucked 37 km from the Beaver Dam deposit for an additional 5 years."

Jan 1, 2019

By A. A. Wessels, D. P. Allison

"Mine hoists are built to handle a certain nameplate capacity; they are specified and designed according to the required duty. However, as production capacity increases in other parts of an operation, the hoist capacity can become the critical constraint. Such a situation occurred at Lundin Mining’s Neves-Corvo operation. This paper examines how each component of the existing hoisting system was examined and optimized. Through a combination of engineering study and hoist simulations, the annual hoisting capacity was improved by 24% through increases in payload capacity and available hoisting time combined with a reduction in cycle time, while no changes were made to the hoist motor, drum or headframe. The additional payload capacity was achieved by reducing the mass of the hoist ropes and skips, and improving load monitoring systems. The cycle time was reduced through the shortening of the creep distances and increased availability through the installation of a shaft collar safety platform, alternative guide rope bushes, and superior liners for both the skips and underground measuring flasks. Enhanced cooling of the hoist electrical system was also incorporated to increase hoist availability by reducing downtime during hot summer months. The changes will increase the capacity from the current 4.5 mega tonnes per annum (Mtpa) to a planned 5.6 Mtpa and are being implemented over a 2-year period whilst maintaining the mine production during the upgrade work. INTRODUCTION Neves-Corvo Mine Neves-Corvo is primarily a copper and zinc mine producing copper, zinc and lead concentrates. The operation is owned and operated by Somincor, the Portuguese subsidiary of Lundin Mining. Located in the Alentejo district of southern Portugal, the operation is situated approximately 15 km southeast of the town of Castro Verde, where summer temperatures can reach as high as 45ºC, and approximately 220 km southeast of Lisbon. The principal means of mine access is via a ramp from surface, with the vertical shaft used to hoist ore and waste from the 700 m level, while conveyors descend from the 700 m level to transport ore and waste up from the deeper levels of the mine. The mine is highly mechanized and several different stoping methods are employed, with the most significant being bench-and-fill and drift-and-fill. The Neves-Corvo mine currently exploits five orebodies: Neves, Corvo, Graça, Zambujal and Lombador for copper and zinc-lead ores which are processed in one of two plants. All the orebodies are currently exploited over their full elevation with the exception of Lombador which is only mined down to the 220 m level, approximately the top 50% of the orebody, known as Lombador Phase 1."

Jan 1, 2019

By A. Esterhuizen, S. Essack, H. Joubert, N. Fowler

Tenova Pyromet has developed innovative technologies for copper smelting and electric slag cleaning furnaces. Based on client feedback and requirements, innovative designs have been developed to address key design areas and improve furnace reliability, operability and hygiene. These developments include the NovaLance™ lance system to prevent lance bending on top submerged lance furnaces, the SlagFlo™ slag tapping flow control device to better control bath levels and tapping rate for granulation, and an electrode seal for improved sealing directly onto the electrode casing to allow water-cooled electrode components to be located above the furnace roof. The potential application and benefits of these innovative designs are discussed. INTRODUCTION Tenova Pyromet has a long history in the engineering and supply of innovative electric furnace and related equipment for the base metals and platinum industries. Recently Tenova Pyromet has used its furnace equipment design experience to engineer innovative solutions for top submerged lance (TSL) furnaces, and potentially other furnace technologies. These equipment design solutions are developed to address specific operating challenges and operator requirements. Three of these innovative equipment developments are discussed in this paper. First the NovaLance™ lance technology to prevent lance bending during operation in TSL furnaces, such as used for primary copper smelting, is described. Lance bending has been identified as a significant problem for TSL furnace operators as it causes down time and affects furnace availability. The SlagFlo™ device to control the slag flow rate during tapping has been developed based on specific requirements in the mineral wool industry. The SlagFlo™ device can be used to control slag bath levels in primary smelting, converting and slag cleaning furnaces for base metals including copper. In addition, it can be remotely activated for the safe closing of slag tapholes located upstream from a water granulation system. Finally, Tenova Pyromet developed an electrode seal that seals directly onto an electrode surface. This is a special requirement related to base metals and platinum electric smelting and slag cleaning furnaces where furnace operators prefer to keep the water-cooled electrode equipment above the furnace roof. The seal can be used to seal directly onto the potentially hot and uneven surface of Söderberg, pre-baked and graphite electrodes.

Jan 1, 2019

By A. Ghahreman, M. Oliazadeh

"Heap leaching is an attractive process for low grade deposits where the metal content of ore does not justify the high cost of milling and agitated leaching. In general, the heap leaching capital cost is low, construction is rapid, and production costs are low. The primary disadvantage of heap leaching is low recoveries (typically 65% of agitated leach recovery); thus, recovery improvements could convert more lower-grade deposits into minable reserves. This will also allow to process primary sulfide ores and result in a dramatic expansion of the technology, as ~80% of total ore types are sulfidic in nature. The old gold operations tailings are another massive source of low-grade gold material that can be retreated by the heap leach process. The major parameters affecting the recovery rates are ore characteristics (mineralogy, particles size of metal and host minerals, ore permeability), and operational conditions (segregation of ore, compaction, leach cycle time, lift height, and solution application rates). The design of a percolation leach process is based on a limited number of coarse ore bottle roll and/or column tests under ideal conditions. The economics of the projects and engineering design of the process facilities are developed based on the bench scale test work results and the application of the conventional engineering scale up factors. This paper will deal with the parameters affecting the HL efficiencies and focus on the potential improvement of gold heap leach recoveries. This would include design of heap leach operation and evaluation of processes such as fine crushing and bioleaching.INTRODUCTION Gold heap leaching is a hydrometallurgical process designed to treat amenable low-grade gold ores that contain typically 0.5 to 1.5 g/t gold (Marsden and House, 2006; Wong Wai Leong and Mujumdar, 2010). Ore is stacked by various types of equipment on an impermeable barrier, and a sodium cyanide solution is applied to the surface of the stacked ore. Gold, silver, and other metals contained in the ore are dissolved to various degrees by the cyanide application, as it percolates downward through the stack of the ore. The pregnant leach solution (PLS) is then collected at the bottom of the heap. The PLS is then sent to the gold recovery plant where the metals are extracted. The barren leach solution (BLS) is then reapplied to the top of the pad. Ore is placed on a pad or previously leached lift by various means, including ramp conveyor belts, radial-arm and self-leveling stackers, and trucks. Once trucks are used to construct the pads, the pad can be compacted and hence the pad should be graded and ripped or scarified (roughened up) with wheeled or tracked equipment to produce shallow cuts to increase surface area exposure to the leachate."

Jan 1, 2019

By E. Vesely, A. Saxena

"SAG mill liners are designed for protecting the mill shell and providing lifting power for ore charge and grinding media. Due to the impacts from the charge and the grinding media, the liner experiences dimple, plastic deformation, strain hardening, fatigue, peening and final failure. Because of the collisional environment directly measuring such dynamical loads is extremely difficult if not impossible. In this study we tried to evaluate the liner failure risk by simulating the collisions of solid particles with mill liner using Discrete Element Method (DEM). DEM simulation has been proved to be a very useful tool in evaluation of granular flow and its impacts on the solid structure. But there are certain limits in DEM coherently, such as the number of solid elements, the computer runtime, etc. Here we first present the general feature of the particle-liner collision in terms of impact force and collision energy. Then the effects of parameter selection is discussed. Our simulations show the fatal collisional event of huge impact force is very rare and the collisional events of low impact is much more frequent. The fatal event may contribute most to the liner failure. The rarity of the fatal events may be missed in a short runtime simulation. This technical challenge combined with lacking of criterion to evaluate varying impact loads in fatigue problems may further complicate the evaluation. Should we use the largest impact force alone or we should use the more frequent events is an open question and requires more effort. In order to evaluate the quality of liner design, we proposed a relative comparison method. In the end we show the implication and application of this method in liner optimization by a work example. In particular, the effects of the charge level of grinding balls and their size on the operation performance is presented.INTRODUCTION Grinding is one of the most important and expensive steps of mineral processing. A variety of grinding mills such as rod mills, ball mills, semi-autogenous (SAG) mills and autogenous (AG) mills are being utilized for comminution of mineral ores (Gupta & Yan, 2016). Up to today, SAG mills and AG mills have been widely used to reduce operation costs and increase throughput. In an AG mill, a rotating drum throws larger rocks of ore in a cascading motion which causes impact breakage of larger rocks and compressive grinding of finer particles. Unlike AG mills, SAG mills use steel grinding balls to break ores of size quite small such that they cannot be easily broken in AG mill. SAG mill liners are designed for protecting the mill shell and providing lifting power for ore charge and grinding media. Due to the impacts from the charge and the grinding media, the liner experiences dimple, plastic deformation, strain hardening, fatigue, peening and final failure. Quality and performance of SAG mill liners play a fundamental role to enhance efficiency of grinding mills, because failure of liners is the major cause for unexpected breakdown (Banisi, Hadizadeh, Mahmoudabadi, & Eilkhany, 2006)."

Jan 1, 2019

By Arsenio Enriquez, Adrian Deneys, Ryan Walton, Jenny Esker

NOx emissions at the Rio-Tinto Kennecott Copper (RTKC) smelter, near Salt Lake City, Utah, are regulated to a compliance emission limit at the Main Stack of 15.9 kg/hr on an annual rolling average. The paper discusses RTKC efforts and improvements, particularly related to the anode furnace operations, since the Smelter modernization in 1995 to comply with the air quality approval limit. This includes replacement of gaseous ammonia to Steam-Gas Refining (SGR) system during the copper reduction stage, upgrade anode furnace oxygen-fuel burner from Praxair’s Stabilized Jet (S-J) to Jet Lance (J-L) technology, development and implementation of operational best practices and continuing to investigate and evaluate NOx control technology and strategy in the industry. In early 2016, changes to Praxair J-L Burner technology on both anode furnaces, utilizing wider lance spacing, was adopted and further improved NOx emission levels well below the compliance limit. INTRODUCTION Since the establishment of the Clear Air Act in 1970, the Environmental Protection Agency (EPA) has been regulating emissions of nitrogen oxides (NOx) to reduce impact on public health and the environment (USEPA, CAA, USEPA, NAAQS). As a requirement of the Clean Air Act, the EPA evaluates the standards for NOx and criteria pollutants on a periodic basis and as a result, standards have been revised and ultimately reduced over time (USEPA, CAA, USEPA, NAAQS, UDAQ, SIP). To remain competitive with changing regulations and in conjunction with Rio Tinto environmental standards for continuous improvement, the RTKC smelter has been motivated to research and implement NOx control strategies. NOx health and environment impacts NOx refers to a group of seven compounds including the most common, nitrogen dioxide (NO2). (USEPA, NO2). The EPA enforces both short-term (1-hr average) and long-term (annual average) standards for NO2 to protect against associated respiratory system impacts. Short-term exposure of elevated NO2 concentrations can aggravate respiratory diseases and lead to symptoms such as coughing, wheezing or difficulty breathing while longer exposures may contribute to the development of asthma and potentially increase susceptibility to respiratory infections. (USEPA, NO2) Additionally, NOx is necessary in the formation of ozone and particulate matter less than 2.5 microns (PM2.5). Ozone concentrations can negatively impact lung function and in some cases, contribute to chronic obstructive pulmonary disease. (USEPA, Ozone) The particles associated with PM2.5 can reduce lung capacity and aggravate heart conditions. (USEPA, PM2.5) For all NOx related pollutants, children and the elderly are generally at greater risk for the health effects. (USEPA, NO2, USEPA, Ozone, USEPA, PM2.5)

Jan 1, 2019

By Paulo Couciero

Since explosives are the source of all energy used for rock blast fragmentation and heave, multidimensional effects in the detonation driving zone become essential to better describe the detonation process. In order to use the explosive as an energy source-information for more realist blasting performance simulations, a simple and effective modelling strategy is desirable. Facing this challenge, an engineering approach to two-dimensional unconfined non-ideal detonation is proposed. Based on the elliptical construction of the shock locus, the model combines the axial cylindrical stick Q1D solution with some additional limiting conditions to determine the sonic edge of the charge. For a given set of rate law parameters and velocity of detonation, a complete axial solution is firstly computed through the Q1D model. From this solution, a vital relationship between the axial shock curvature with the shock shape parameters can be stablished. Once this relationship is found, the problem simply reduces in finding the shock shape parameters subject to the sonic edge condition. As a result of this calculation, the corresponding charge diameter can be found. Consequently, the proposed model can map the diametereffect curve by relating the unconfined velocity of detonation with its corresponding diameter. Finally, because of its low computation cost, the proposed engineering approach can be also used for characterizing the rate law parameters by fitting to data from unconfined detonation experiments

Jan 1, 2019

By K. Trapani

"The study undertaken aims to investigate an ice stope heating and cooling system for its potential to be implemented in sub-arctic mines, as a low carbon alternative to conventional natural gas and refrigeration chiller systems. Its performance was simulated for a years’ worth of data, taking into consideration hourly temperature data. Results showed that to supply the required heating and cooling loads, the ice stope system had to supplement its heating with natural heating. The techno-economic performance of this system was compared to that of a conventional heating and cooling system in a mine, with the ice stope thermal storage system hawing the lowest annuitized cost and significantly lower carbon emissions.INTRODUCTIONConventional heating and cooling, in a mine is implemented using natural gas heaters and chiller refrigeration systems respectively. This results in a significant portion of energy consumption in underground mines attributable to ventilation (De Souza, 2015), including the conditioning of the air to ensure that temperatures do not exceed work comfort standards (ACGIH, 2011). Especially at depth where heat could become a significant issue. An ice stope thermal storage, using ice as the storage medium is being proposed as an alternative to provide the heating and cooling—with the ice creation resulting in heating and the ice melting providing the cooling required. A techno-economic investigation of the two systems is undertaken to identify the capital and operating costs for the two systems, and to assess the ice stope’s potential to be considered a low cost and carbon solution for heating and cooling of mines in sub-arctic climates.NATURAL STORAGE SYSTEM – CONCEPT DEVELOPMENTThe concept for the natural storage system is developed from the ice stope at Frood-Stobie Mine, ON, Canada (Stachulak, 1991). The ice stope was developed for mine air heating, with the heating occurring by spraying warm return service water onto the cold intake air—resulting in the air temperature increasing and ice being created in the stope. In summer this ice was melted by passing warm air on top of it, resulting in slight cooling of the air but no significant temperature difference which could allow effective cooling. A schematic of the Frood-Stobie Mine ice stope is provided in Figure 1."

Jan 1, 2019

By C. P. Newman, T. Gray, G. Beale, T. Cluff

Predictive geochemical and limnologic modeling of pit lakes is an important aspect of modern permitting. One of the key assumptions of many predictive pit-lake models is that highwalls and pit backfill become unreactive once submerged by the filling pit lake. Existing pit lakes provide useful data to test this assumption. The Sleeper pit lake (northwestern Nevada) is near hydrologic equilibrium and contains good-quality water that generally meets regulatory requirements for pit lakes. Despite the overall stable geochemical composition, seasonal trends in the hypolimnion indicate the generation of solutes and fluctuations in pH. This work applies mass balance, analysis of subaqueous pyrite oxidation, and trends in solute concentrations to evaluate the potential causes of long-term solute generation in the hypolimnion of the Sleeper pit lake. Results will aid in refining the effect that inundation of highwalls and waste rock has on ultimate pit lake chemistry and long-term closure planning. In the case of the Sleeper pit lake, ongoing solute loading does not substantially change the closure plan at this time as influent groundwater contains abundant alkalinity. INTRODUCTION As mine pit lakes become more widespread, regulatory agencies are increasingly requiring advanced predictive modeling of pit-lake geochemistry during permitting. The end goal of all those involved in these permitting actions (i.e., the mining company, the regulatory agencies, and the public) is to have pit lakes become geochemically and hydrologically stable for the long term, which may then allow mining permits to be relinquished. The modeling endeavors therefore are important to inform long-term closure of pit lakes. The conceptual models and numerical methods used to predict pit-lake water quality are complex and require substantial amounts of data and a variety of assumptions (Castendyk et al., 2015). One of the common modeling assumptions is that solute generation via acid mine drainage is eliminated (or at least decreased) by the filling of the pit lake and inundation of highwalls and any in-pit waste rock. However, few studies have reported on observations that support or refute this assumption. The water-quality record of the Sleeper pit lake is an ideal dataset with which to test these assumptions. The former Sleeper mine is located in northwestern Nevada (Fig. 1), and has been inactive (in terms of ore extraction) since 1996. The mine extracted Au and Ag from the famous high-grade Sleeper vein and associated widespread stockwork mineralization (Nash et al., 1995). Water quality in the pit lake has been monitored since the cessation of dewatering in 1996. The current pit lake actually occupies three separate sub-pits, the Sleeper, Wood, and Office pits (Fig. 1). The Sleeper and Wood pits undergo regular water-column monitoring using a conductivity-temperature-depth (CTD) probe, and sampling for dissolved inorganic constituents at several depths (~10, ~130, and ~330 ft. below lake surface). Groundwater quality is also monitored using a series of wells (Fig. 1).

Jan 1, 2019

By P. Rosario

"Industry practice for high-pressure grinding roll (HPGR) assessment and sizing relies on tests using pilot-scale machines with 0.7–1.0 m roll diameters. Typically 1–10 t of sample are required, depending on the level of study and resource complexity. This is challenging during early-stage development, which hinders incorporating HPGR into designs. With support from the Canadian Mining Industry Research Organization, researchers at the Norman B. Keevil Institute of Mining Engineering at The University of British Columbia developed bench-scale piston–die press tests (PPTs) that correlate to pilot- and full-scale HPGRs. This paper describes a new regression model to estimate the HPGR-specific throughput rate using both PPT results and an HPGR database. A case study is presented to show how the current PPT method is used for engineering studies. ¦ KEYWORDS Empirical modelling, High-pressure grinding roll (HPGR), Piston–die press test (PPT), Sizing and scale upRÉSUMÉ La pratique en vigueur dans l’industrie concernant l’évaluation et le calibrage d’un cylindre de broyage à haute pression (HPGR, de l’anglais high-pressure grinding roll) dépend d’essais menés à l’aide de machines à l’échelle pilote dont les diamètres de bobine sont de 0,7 à 0,10 mètre. On a généralement besoin de 1 à 10 tonnes d’échantillons en fonction du niveau de complexité de l’étude et des ressources. C’est une pratique difficile durant les premières phases de développement, qui empêche l’intégration du HPGR dans les plans. Bénéficiant du soutien de la Canadian Mining Industry Research Organization (CAMIRO, l’organisation de recherche de l’industrie minière canadienne), des chercheurs du Norman B. Keevil Institute of Mining Engineering (l’institut Norman B. Keevil de génie minier) de l’université de la Colombie-Britannique (UBC) ont mis au point des essais en laboratoire sur des presses à matricer à pis¬ton (PPT, de l’anglais piston–die press tests), qui mettent en corrélation les HPGR aux échelles pilote et réelle. Cet article décrit un nouveau modèle de régression qui évalue le taux de production spécifique aux HPGR à l’aide des résultats tirés des PPT et d’une base de données dédiée aux HPGR. Une étude de cas est présentée afin de décrire l’utilisation de la méthode actuelle des PPT dans les études techniques. ¦ MOTS CLÉS calibrage et mise à l’échelle, cylindre de broyage à haute pression (HPGR), essai sur presses à matricer à piston (PPT), modélisation empiriqueINTRODUCTION It is widely accepted that high-pressure grinding rolls (HPGRs) are a viable, energy-efficient solution for modern comminution flowsheet design. Table 1 summarizes select examples of HPGR applications in the mining industry. The main benefits of HPGRs are energy savings, which leads to lower operating costs, and stable operating characteristics that can better cope with variations in ore hardness compared to the conventional autogenous (AG) or semi-autogenous (SAG) mill-based comminution circuits."

Jan 1, 2019

By G. E. Sreedhar, R. Kumar

The pockets of high silica blue dust across the entire high grade hematite deposits in the Bailadila sector bothers the excavation activity due their iron content, which is higher than the threshold value specified by the Indian Bureau of Mines and the agony of stacking them separately due to their fragile & powdery nature. The physical nature of blue dust and its negligible alumina content makes these a potential source of hematite, which is a blessing in disguise. As most of the particles are in the form of an independent grain making it appropriately suitable feed for dry magnetic separation and thus the dry beneficiation has turned a bane into boon by enabling to produce concentrate either suitable for using as DSO or amenable for blending. The emphasis on carrying out dry beneficiation studies in the present context serves the purpose of mineral conservation, mitigates the issues of excavation and stacking as well as conservation of water resource. This paper describes the laboratory and pilot scale dry beneficiation studies carried out on blue dust of 48 – 60%Fe and Silica up to 30% at 25 Kg/hour to 400 Kg/hour, resulting in production of concentrate assaying 60 – 65%Fe. INTRODUCTION High silica blue dust (HSBD) is associated with Banded Hematite Quartzite (BHQ) and is available in abundance in various pockets across the Iron ore body in the Bailadila region of Chhattisgarh state. High Silica Blue dust occurs in the form of free granular particles and also as friable lumps. The chemical quality of this falls under sub-grade category (45 – 55%Fe) and as per the guidelines of Indian Bureau of Mines, these are to be stacked and conserved as future resources of Iron if it can’t be utilized in the present circumstances. Due to its friable nature, stacking of HSBD is a challenge and it is also compounding the problem by polluting the air under high velocity wind conditions. Because of its physical nature and occurrence in pockets pose challenge to systematic mining. The existing processing set up of the operating mines is designed to treat either Direct Shipping ore (DSO) or Run-of-Mine (ROM) have grade >60% Fe. The present practice of beneficiating iron ore fines (<1 mm) comprise combination of two or more processes such as desliming, hydraulic classification, magnetic separation and flotation apart from requirement of grinding depending on liberation characteristics. The HSBD which is predominantly occur as free granular particles, is significantly low in its alumina content. This gives us an opportunity to utilize them by exploring a suitable beneficiation process so that the concentrate produced can be used as a sweetener for alumina rich iron ore/concentrate. Thus, in the present study, an attempt has been made to adopt dry high intensity magnetic separation technique to explore the amenability of the high silica blue dust for beneficiation.

Jan 1, 2019