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By Anthony J. Konya, Calvin J. Konya

Mine sites and construction projects have faced problems with blasting a smooth back wall. This lead to safety concerns with slope stability and rock falls from the walls. Decades ago Dr. Calvin Konya began a special type of blasting called “Precision Presplitting”. This form of presplitting used relatively light loads based on the rock type being blasted. The explosive loads were estimated for each rock type and adjusted as blasting progressed. This current research project also determined a new equation for prediction of the ground vibration from one type of presplitting and compared it to vibration from production blasting.

Jan 1, 2016

By K. Zeidler, T. Schwind

The Fort Canning Tunnel, Singapore, is an approximately 50 feet (15m) wide vehicular tunnel under shallow ground cover that has been constructed according to the principles of the NATM. Its shallow location in soft ground combined with a high groundwater elevation in close vicinity of historically important features called for special design considerations combined with a rigorous monitoring scheme. Surface, sub-surface and in-tunnel instrumentation was installed to monitor the performance of the ground and tunnel support during construction. Comparison of actual reading data with the results from the computer modeling carried out during the design phase is provided in this paper.

Jan 1, 2007

By G. C. Smith

Process control applications in the minerals processing industry have grown extensively over the years due to the many benefits derived, both financially and operation-wise. Although control theory is widely known, conventional control does not address many of the problems posed by minerals processing circuits. Some of these problems include interactions between process units, large dead times, few and sometimes unreliable measurements of process variables, non-linear systems, disturbances entering the process, processes with varying dynamics, and many more. For the past 26 years Mintek has been active in the field of providing specific, customized solutions for the minerals processing industry. This paper focuses specifically on applications in milling and flotation control. The underlying control principles have been applied to a wide range of other processes including submerged arc furnaces. Advanced control application is implemented on a common advanced control platform, called the PlantStar. Much innovation has been brought to the fore in terms of adapting theoretical techniques and developing new methods to resolve specific milling and flotation circuit issues by using process control. The general approach adopted by Mintek when implementing advanced control is to enforce stabilization of the process as a solid foundation for optimization strategies to be built upon. In doing this, a robust control solution is presented, and the end result is flow and level stability, better product quality regulation, increase in throughput and a stable feed to downstream processes. The MillStar advanced milling control system ensures that the milling circuit is at all times easy to operate while achieving optimum product quality and throughput. Stabilization should include product size regulation and sump level control. Another important aspect of stabilization control is the handling of milling circuit constraints without introducing cyclical behaviour and with minimal disturbance to the final product quality. Process constraints may include factors such as process water limitations, cyclone feed density, and cyclone underflow angle. An optimization strategy should be developed to increase the mill throughput without affecting product quality or introducing mill overloads. The relationship between solids feed and power draw is examined and manipulated for optimization. The interactive nature of flotation circuits and the presence of recirculating streams tend to make satisfactory control almost impossible with conventional techniques such as PI (Proportional plus Integral) or PID (Proportional, Integral and Derivative) control. The FloatStar Level Stabilizer simultaneously considers all the flotation levels in a circuit by use of a multivariable algorithm, and takes compensating action in anticipation of disturbances. The FloatStar Flow Optimizer is an optimization strategy that controls the concentrate flow rate between various sections of a flotation circuit (e.g. Rougher ?Cleaner; Cleaner ?Recleaner). By controlling the concentrate flow between the sections, the mass pull, circulating loads and residence times of the circuit can be stabilized, thereby enhancing the performance of the flotation process. Optimizing grade and recovery are coupled with the dynamic optimization of circulating flows. The FloatStar Grade-Recovery Optimizer will maximize the grade in a section, whilst ensuring that recovery or any other process specific limits remain within predefined limits. With successful applications on several milling and flotation plants worldwide processing amongst others PGMs, gold, copper and nickel, Mintek has shown that it is a leader in milling and flotation control innovation

Jan 1, 2004

By Paul J. Axtell

Self-hardening cement-bentontie (c-b) slurry walls were constructed as shear walls to stabilize the downstream slope of Tuttle Creek Dam near Manhattan, Kansas. The slope stabilization was required to protect the existing pressure relief well system located at the downstream toe of the dam. The wells require protection from slope deformation induced by liquefaction of the foundation sands during or immediately after the design seismic event. The shear walls are transverse to the axis of the dam, unreinforced, and relatively brittle members that may be exposed to relatively large shear strains, and possible cracking, during or immediately after shaking. An extensive laboratory investigation was conducted on recovered core samples to optimize the mix design and stabilization scheme. Furthermore, as is the topic of this paper, a portion of the laboratory investigation was to determine the large-strain, or post-peak, shear strength of the c-b material for use in limit-equilibrium slope stability analyses and numerical deformation modeling to assess the magnitude of permanent deformation caused by the design earthquake. These data may be beneficial to other projects that are considering the use of unreinforced c-b slurry walls for seismic retrofit purposes.

Jan 1, 2010

By Juan P. Camus

Mining is one of the oldest industrial activities. Its products are essential to modern civilization. Paradoxically, and despite a deep-rooted belief to the contrary, mining is not a lucrative industry— at least not in the aggregate. This assertion is true not only for recent years, one of the weakest periods in terms of metal prices, but also for a long time past. In 1776,Adam Smith said in The Wealth of Nations: “Of all those expensive and uncertain projects, how-ever, which bring bankruptcy upon the greater part of the people who engage in them, there is none perhaps more perfectly ruinous than the search after ... mines. It is perhaps the most disadvantageous lottery in the world... Projects of mining, instead of replacing the capital employed in them, ... commonly absorb both capital and profits.”

Jan 1, 2002

By Paul R. Smith

The Colorado School of Mines Research Institute (CSMRI) was founded in 1949 to fill mining industry and government needs for minerals research and development. The operations of scores of mines, mills, and plants around the world are based on the results of work done by the Research Institute. Among other things, the Research Institute conducts studies in geology, mine planning, mineralogy, size reduction, minerals processing, and hydrometallurgical techniques in extractive metallurgy. Many CSMRI projects also involve energy and environmental considerations. What follows is a summary of some of the studies in which the Research Institute has been and is currently involved, as well as some comments on trends and developments in the industry.

Jan 2, 1982

By Fábio Rogério do Carmo

O ar soprado é uma das principais utilidades responsáveis pelo processo de transformação do minério de ferro em gusa no Auto Forno. Para que ocorra o processo de redução o ar soprado é superaquecido nos regeneradores dos autos fornos a uma temperatura de 1.300°C. Este energético é fornecido na CSN-UPV pelos turbos sopradores da Central Termoelétrica nº 2 (CTE#2), área dos Motos Sopradores 1 e 2 e os turbos sopradores n°1 e 3 da CTE#1 que operam com a velocidade reduzida 24 horas soprando para atmosfera e consumindo vapor de 30Bar. Devido à obsolescência do sistema de ar soprado da CTE#1, alto custo de operação e risco para a segurança operacional, este trabalho apresenta o estudo do problema em questão, a metodologia utilizada para desativação do ar soprado da CTE-1 e a redução de custo.

Sep 25, 2017

By Earl C. Hutchison, Wade C. Hutchison

T 0 effectively evaluate property damage that is claimed to have been caused by blasting activities and in order to lay the proper foundation to build the best legal defense, identification of the actual causation for the damages are necessary. For the past twenty years, engineering personnel from VCE, Inc. (previously Vibration Control Engineering, Inc.) have been evaluating claimed blasting damages with pre- and postblast inspections, with analysis of seismic levels, blasting amounts at given distances, and with other engineering considerations. In addition to these evaluations, they have also documented other causes for damages which are of the types that are often claimed as blasting damage.

Jan 1, 1995

By Tsunenobu Nozaki

"AbstractThe PRESS-IN METHOD is widely recognised as “an environmentally friendly piling method”. However, this characteristic is only one of the fundamental advantages of the method and this paper presents the most up-to-date capabilities of the method. Due to the evolution in recent years, the Press-in Method is now applicable to 2.5m thick retaining walls, over 50m deep foundations, overcoming rock conditions and confined construction conditions.The Press-in PrinciplesThe basis of the Press-in Method is simple. The Silent Piler presses a pre-formed displacement pile into the ground by static jacking force. The reaction for the Press-in Force is generated by gripping previously installed piles. As a pile is pressed into the ground, “A Pressure Bulb” is formed around the pile toe. Accordingly, higher bearing capacity can be generated compared to driven piles without disturbing the ground and producing any vibration. (A comparison of jacked, driven and bored piles in sand (2005), Deeks et al.)Applicable Pile ProfileThe Press-in Method is applicable to most of the steel piles available on global market i.e. U sheet pile in single form and pair, Z sheet pile, also in single and pair and Tubular Pile as described in Figure 2. Wall thickness of those piles can be 0.3m to 2.5m and moment of inertia of the wall ranges up to about nine million biquadratic cm per meter, which can deliver similar elastic modulus EI (kNm2/m) to 2.0m thick diaphragm walls and can be utilised for extremely deep excavations required in today’s construction industry"

Jan 1, 2014

By A. G. Doll

"Many power-based grinding models exist, and most operators are familiar with Fred Bond's ""third theory"". Bond's model is most commonly used to describe primary and secondary grinding to product sizes above, for example, 100 µm. Operators sometimes use Bond's equation to describe grinding in situations where it is not appropriate, such as fine grinding below 50 µm. Using an alternative model would be a better choice in this situation.Bond's equation is one in a large family of models. Related equations better suited to fine grinding include the “signature plot”, Von Rittinger's model and Charles' equation. These models have a similar form to Bond's and can be fit to industrial regrind mills and laboratory tests using the simple regression tools in the charts of computer spreadsheets. Operators will find that fine grinding calculations are both easier and more accurate when using the alternative equations to fit their regrind milling surveys or when performing laboratory regrind mill scale-up for plant design.None of these models are new: Charles' equation was published in 1957 and Von Rittinger's model was proposed in 1867. A quick refresh how to apply these equations can turn these oddities from the undergraduate curriculum into useful tools for plant optimization. They can be fit to any type of mill including stirred and tumbling ball mills.IntroductionBuilding a case for fine grind modelling requires reviewing some theory before building a framework for doing fine grinding calculations. The actual calculation procedure recommended is easy and can be applied by plant metallurgists. Don’t be frightened by the theory; the end result is reasonably simple.The observation that mineral breakage is related to the absorption of energy is usually attributed to Von Rittinger (1867). Lynch and Rowland (2005) describe that the ability to empirical test and calibrate energy models of breakage didn’t exist until the widespread adoption of electric motors in the mining industry during the 1930’s and 1949’s. A series of technical papers published by the Allis Chalmers company during the 1940’s demonstrate that they were attempting to do such a calibration using Von Rittinger’s model which is usually stated as: “the energy consumed in the size reduction is proportional to the area of new surface produced.”"

Jan 1, 2017

Predicting Water Recovery from Flotation Cells

Sep 13, 2010

By Alain Bouchard, Germain Labonté, Jim Barrett

"Mill feed materials that are not run-of-mine ore are often a challenge for mineral processors and tend to accumulate in stockpiles, where they remain unprocessed for many years and become “slow moving inventories”. During a complete re-evaluation of the Clarabelle Mill operation (38,000 ton/day capacity) in 2000, it was concluded that there was an opportunity to assemble a 5,000 ton/day custom circuit to treat such stockpiles in the equipment that remained available during regularly scheduled maintenance shut-downs.This project was part of the larger Mill Redesign Project and involved testing the intended flowsheet under a number of operating scenarios for the first material to be treated: spent refractory bricks. The laboratory focus was on how to maximize returns using the available equipment and reagents.The circuit was successfully commissioned in the fall of 2000. As the brick stockpile was depleted, other potential feeds were evaluated at the laboratory, as well as in the new custom circuit itself. Processing of the spent refractory brick has yielded a significant contribution to the profitability of INCO. Significant opportunities lie ahead for generating more value from other slow moving inventories.INTRODUCTIONIntegrated mining operations tend to have slow moving inventories along the path from the mines to the finished products. Spent refractory bricks from furnaces and converters and furnace bottoms are materials that often end up in long-tern stockpiles. Such stockpiles are a challenge, although they represent small tonnages on an annual basis, because they are unique materials, which cannot be readily brought into the process at a rate anywhere near that at which they are produced, due to the high contents of deleterious components such as chromite or magnesia. Accumulation over years will eventually yield a metal inventory worthy of consideration given the right opportunity, such as availability of spare equipment or peak metal prices."

Jan 1, 2002

By J. Molgaard, J. Masounave, J. Prinsen, P. Beaulieu, G. Huard

"A study carried out on behalf of the National Research Council (NRC) indicates that economic losses due to wear in the Canadian mining industry are in excess of $700 million annually. Severe wear, mainly by abrasion, was identified as the most important wear mechanism in terms of possible savings. One way to reduce losses would be the proper use of databases. A joint project of The Canadian Institute of Mining and Metallurgy (CIM) and NRC (Tribology laboratories at IMRI) has been initiated to create a factual database containing all relevant experience in the area of wear in the Canadian mining industry. As a first step, a prototype covering slurry pumps is being built. This should help to answer many questions, such as the number of people involved, interest from industry, cost vs benefits, etc.IntroductionTribology is concerned with the understanding of the mechanisms of friction, wear, and lubrication.Tribology is concerned with the correct use of materials for interacting solid surfaces, with the interaction of those surfaces with lubricants, with the chemistry, physics and use of lubricants and their additives. It is concerned with the reduction of friction and wear (or, in the case of belts, brakes, clutch plates, and similar devices, in achieving optimum friction with minimum wear) and is concerned with the avoidance of associated failures in machinery.Lubrication is usually the solution to a problem of friction and wear. Yet far from all the problems of friction and wear are solved by lubrication. The wear of grinding rods or shovel track pads can hardly be solved by lubrication, to name just two examples with which mining engineers will be familiar. There are indeed many situations of wear and friction where the surfaces in contact are unlubricated.In part, tribology is a matter of design. A major aspect, however, has to do with the choice of materials, to satisfy external constraints upon the component design or choice. The operating conditions for much industrial equipment, particularly in mining are, often very severe. The development of wear resistant materials, including materials which are applied as coatings, is clearly an important technology from the point of view of tribology."

Jan 1, 1987

By Hwasoo Park

Keywords: FC mold, Argon, Magnetic, Solidification Fluid flow plays a significant role for steel surface quality in continuous casting. Although water models are able to model fluid flow, the flow pattern is not of practical interest since the moving solidifying shell cannot be accounted. Computer modeling has become a popular and dependable tool to analyze the complex phenomena occurring in continuous casting. In this numerical simulation we coupled momentum and energy equations considering the solidification of steel along with turbulence ?-e model. The vertical bending mold is equipped with bifurcated nozzle with 15 degrees of port angle. FC mold is supplied with DC induced magnetic fields. Influence of argon and magnetic fields on molten steel flow and heat transfer is investigated by solving momentum equations adding source terms due to multiphase ? magneto hydrodynamics. The results show that magnetic fields reduce the jet velocity from port by lower magnetic core induced field but the influence on meniscus velocity is complex to describe. Magnetic fields increase surface temperature and homogenize its distribution on surface and inside a mold.

Jan 1, 2005

By D. E. Pollock, T. W. Beck, J. A. Organiscak

This work presents the findings from a number of NIOSH studies evaluating the impacts of emerging technologies that may reduce dust exposures for continuous mining and roof bolting personnel. These technologies include use of a wet head cutting drum on a continuous mining machine that places water sprays on the cutting drum instead of placing them on a manifold outby the drum. Evaluations at two separate operations showed that the use of the wet head sprays reduced dust levels at the miner operator in the return air, although these reductions were quite variable. NIOSH also assessed the effectiveness of a canopy air curtain for protecting roof bolting personnel. The data showed that dust levels were lower beneath the air curtain than outside the air curtain. This study also suggested several future modifications to the air curtain to in-crease its effectiveness. Finally, NIOSH evaluated mist drilling technology for its effectiveness in controlling respirable dust exposures of bolting personnel. A recent study showed that higher dust levels existed around a machine using the mist system compared to a machine using a conventional vacuum system for dust control. Unfortunately, the true impact of mist drilling was confounded by this machine operating downwind of the continuous miner for much of the study.

By Yogesh Prashar

Three conventional uplift tests and 12 Rapid Pile Load Tests (RLT) were performed on total of fifteen 16-inch square pre-cast concrete driven piles at a test site in Emeryville California in December of 2000. The uplift tests were performed in accordance with ASTM standards, and the RLTs were performed using a FUNDEX RLT. The RLT is carried out by dropping a mass of 25-tons on top of the pile, thereby inducing a force that is measured by a load cell. An optical lens records the vertical deflection of LED's that are mounted on the pile. Ultimate uplift and compression capacities of each of the fifteen piles were determined using the Davisson method. Soil parameters were calibrated by back-calculation (cohesion and internal angle of friction) using both the results of conventional uplift load versus deflection curve, as well as the results of the triaxial compression tests. A two-dimensional finite difference model including soil elements, and structural elements representing the test pile was setup using the computer program Fast Lagrangian Analysis of Continua (FLAC). FLAC was used to simulate both the uplift as well as the RLT. Strength increase of cohesive material was also accounted for in the analysis. Numerically simulated and theoretically computed pile capacity curves and axial deformation variation with applied load curves are in close agreement to the observed curve during the field test. Conclusions are made from this test site regarding the factors influencing results of RLT.

Jan 1, 2002

By Ed D. Thimons, Douglas E. Pollock, Andrew B. Cecala, Gregory J. Chekan, Jay F. Colinet, John A. Organiscak

Researchers at the Pittsburgh Research Laboratory (PRL) of the National Institute for Occupational Safety and Health (NIOSH) work to reduce respirable dust exposures in mining operations. One focus of this research is silica dust control for surface and underground operations in the metal/nonmetal mining industry. PRL researchers analyze dust sampling results from the Mine Safety and Health Administration (MSHA) to identify high-risk occupations to guide research efforts. Research is then conducted in an effort to improve existing technologies and/or develop new controls for reducing worker exposure to airborne silica dust. During the last few years, PRL researchers have conducted research related to the following goals: improving protection provided by enclosed cabs on mobile surface mining equipment, reducing dust generation from surface drills, reducing dust levels in iron ore operations, and developing a new method to clean dust from workers’ soiled clothes. A description of each of these controls and subsequent dust reductions quantified through site surveys will be provided.

By G. E. Perry, R. D. Seba

The steam soak process is the most widely applied and most successful thermal supplemental recovery process in use today. This process, which consists of injection of steam in various quantities into a well that is subsequently used as a producer, can be repeatedly applied to the same well. The treatment, if successful, will increase the production rate of the well for a given period. For this reason, the steam soak process should be considered primarily as an acceleration method rather than as a method for producing oil that could not be recovered by primary means. However, application of this process to reservoirs containing viscous crude may produce oil that otherwise would have zero present value or would be produced at such low rates by primary methods that it would not be profitable. A major necessity for the successful application of the steam soak process is a source of natural energy. This source of energy may exist in one or more of the following forms: expansion of fluids, compaction, gravity drainage. This study was undertaken to determine the effect of gravity drainage on steam soak production and recovery and to develop a method for predicting production rates, ultimate recovery, and heat requirements when applying this process to a reservoir in which the primary driving mechanism is gravity drainage. (For additional discussion of some of the factors that affect recovery of viscous oils by the steam soak process, see Ref. 5.) Model The model developed for analyzing the performance of the steam soak process in gravity drainage reservoirs is a modified form of that developed by Matthews and Lefkovits.1,2 The model used in this study consists of two concentric cylindrical volumes of productive formation with cap and base rock of impermeable material. The inner cylinder, extending from the radius of the wellbore to some predetermined radius, is referred to as the hot zone; and the outer cylinder extending from the exterior boundary of the hot zone to the outer drainage boundary will be referred to as the partially heated zone. Fig. 1 is a schematic cross-section of the model, indicating its thermal properties. Horizontally the reservoir is divided into two regions, the upper region having a high gas saturation and residual liquid saturation, and the lower region containing a high liquid saturation. The boundary between these two regions is referred to as the free surface, which drops and changes shape as fluid is produced from the reservoir. The model was used to analyze the steam soak process by applying the following assumptions: 1. The horizontal formation is composed of one or more homogeneous noninterconnected layers containing incompressible fluids. Each layer is treated separately. 2. The hot zone is heated by the initial soak and is maintained at the steam temperature corresponding to atmospheric pressure by resoaking. 3. The height of the free surface at the producing well is at all times zero (producing well is pumped off). 4. The position of the free surface at the start of

Jan 1, 1970

By Lawrence J. Froisland

To aid in minimizing adverse environmental impacts of mining and mineral processing, the Bureau of Mines studied changes in soil characteristics in topsoil stockpiled during mining operations. Topsoil stockpiles in arid areas of New Mexico, Utah, and Wyoming were sampled over a 1- to 8-yr period to determine any changes in physical, chemical, or biological parameters in the top 15 ft of soil. Parameters examined in this study included soil moisture, pH, electrical conductivity, and cation exchange capacity; total nitrogen, organic carbon, carbon to nitrogen ratio, extractable potassium, and soluble phosphorus levels in the soil; general levels of bacteria activity in the soil; and productivity of the soil as measured by shoot yield in growth tests. Data were analyzed by multiple linear regression to determine possible effects of stockpile age and depth. Bacteria population counts, used as an indicator of goner l bacterial activity, was the only parameter found to be significantly correlated with stockpile age and depth at more than one site. Bacterial activity increased with depth at the two sites where it was measured. Activity increased with age at one site and decreased with age at the second. Significant changes in soil pH, electrical conductivity, and moisture were significantly correlated with stockpile age and depth at single sites. This study did not show significant, consistent deterioration in soil characteristics or growth yield of topsoil stored in stockpiles.

Jan 1, 1987

By Mark Fernald, Christian O’Keefe, John Viega

"In this presentation, the SONARtrac™ technology platform will be described. CiDRA's proprietary clamp-on, passive sonar array-based flow meter technology performs two independent measurements – flow rate and fluid characterization. Firstly, the meter provides the volumetric flow rate of the mixture by measuring the speed at which naturally occurring turbulent structures convect with the flow past an axial array of sensors. Secondly, the meter uses similar sonar-based processing techniques and naturally occurring sound in the process fluid to measure entrained air levels. The result is a unique ability to measure the flow rate and entrained air level of most fluids – clean liquids, high solids content slurries, and liquids and slurries with entrained air.Also to be presented is the application of the sonar-based technology platform in a variety of oil sands processes, hydrotransport, and minerals beneficiation applications. In particular, difficult slurry flow measurement and control in the areas of comminution and flotation such as mill discharge, hydrocyclone feed/overflow, final concentrate, thickener discharge, and tailings will be discussed. In addition new real time maintenance free process measurement capability will be presented in the areas of entrained air in slurry, collection zone gas holdup (?g), and slurry velocity profiling. The operational advantages and value of these measurements, even in the presence of scale buildup, will be discussed.INTRODUCTIONFlow measurements in the mineral processing and oil sands industry suffer from the limitations placed by previously available flowmeters including the commonly used instruments such as ultrasonic meters, magmeters, turbine meters, orifice plate meters, vortex flow meters, Coriolis flow meters, and venturi meters. The desire or requirement to make a non-contact measurement that is accurate and robust, and can be performed on practically any type of fluid within practically any type of pipe has driven the creation of a new class of flowmeters. This new class of flowmeter technology utilizes sonar-based processing algorithms and an array of passive sensors to measure not only flow, but also fluid composition."

Jan 1, 2007