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By Qian Liu

Mining in highly stressed ground conditions has been an increasing challenge at the Brunswick Mine. Two large regional pillars were established on the 1000 m Level to support the ground for safe extraction of the surrounding ore. The South Regional Pillar contains about 5 million tonnes of ore and the North Regional Pillar has about 3 million tonnes of ore. In the fall of 2000, mining activities were suspended following a series of ground movements around the South Regional Pillar along weak geological structures. After extensive geotechnical investigations, a decision was made to carry out a mass destress blast in the West Ore Zone (WOZ) to cut the principal stress across an area of 135 m along strike and 86 m high. At the end of July 2001, the WOZ mass blast was successfully initiated. Following this success the mine decided to take a similar approach to destressing the North Regional Pillar (NRP). The final mass blast was taken in early February 2003. Advanced blasting technologies, including state of the art electronic detonators and blast simulation, played an important role in achieving the successful blasts. The high precision of delay timing and long delay duration of the electronic detonators ensured accurate and reliable initiations of over 800 blastholes in the WOZ mass blast. Orica?s DMC_Blast (Distinct Motion Code) simulation code was used to study different blasting blocks for the desired timing in the initiation sequence. This paper describes the process of applying electronic detonators in complex blasts, and discusses how blast simulation results were interpreted to guide engineering design of the mass blasts.

May 1, 2003

By D. H. H. Quon, A. Ahamd, G. Pouskouleli, T. A. Wheat

An outline of the contributions of hydro- metallurgical techniques such as sol-gel processing, direct precipitation and hydro- thermal decamposition for the development of high-quality ceramics is given and examples drawn from recent work on both structural (engineering) and functional (electrical) ceramics are discussed.

Jan 1, 1990

By T. A. Wheat

"The presently increasing world-wide interest in advanced ceramic materials is generally focussed on their exploitation in both structural and functional applications. With the opportunity to engineer microstructures and thereby closely control and tailor the final properties, there are many new applications being made for these materials in both areas.The scope and some of the applications for functional ceramics are reviewed and examples of the present Canadian activity in this field are discussed.BackgroundThere has been progressively increasing international interest in the development and exploitation of ceramic materials in the last five years. The stimulus for this interest arises from several quarters, each of which are independent of the other.• There is a growing awareness of the strategic nature and vulnerability of supply of the raw materials used to produce high performance metal alloys.• The metal alloys are reaching the upper temperature limit for their performance as structural components in engines.• The dramatic increase in oil prices during the late 1970s focussed attention on the need for reduced consumption in many sectors, i.e., there is a need for more efficient engines that operate at higher temperatures - above those tolerated by the present superalloys.• A number of ceramics, especially the structural materials such as SiC, A120 3, AI20rSi02, Si3N4 and the Sialons are produced using non-strategic raw materials and they can exhibit startling performance-auto turbo-rotors are in production mad e of Si3N4 that operate up to 190000 rpm at 600°C, 150000 rpm at 900°C.• Ceramic s are generally of lower density - significant in the weight-reduction of automobiles such as the replacement of a 20-kg five-segment steel leaf spring with a single segment carbon-fibre reinforced unit of 3 kg. • Ceramics also offer major ad vantages in generating, monitoring or controlling the electromagnetic spectrum whether in bulk or thin-film devices that exploit optical, magnetic, pyroelectric, piezoelectric, electronic and I or ionic conductivity characteristics.The opportunity to combine several of these char acteristics in a single material by composition, processing and microstructural design has resulted in an advanced ceramics industry that had world-wide sales in 1980of $4.2 billion (U.S.)(I) and is predicted to grow to sales in the range $7 to $10 billion by 1990 and $16 to $24 billion by the year 2000(2). However, at present, advanced ceramics account for less than 20010 of the total ceramic market."

Jan 1, 1987

By T. Grammatikopoulos, A. Jordens, C. Gunning

"Exploration activity for rare earth element (REE) deposits (i.e., alkaline complexes, carbonatites) has increased significantly in the last decade. A number of deposits have been evaluated around the globe. However, new mines have not been commenced in the last few years with the exception of Mount Weld (Lynas) and Mountain Pass (Molycorp).Resource estimation of REE can follow similar guidelines to other metal projects. However, the inherent mineralogical characteristics of the REE deposits, despite their complex nature, have been generally overlooked by many exploration companies. These include variability of the ore, liberation and association of the REE minerals, and grain size, all of which can affect the processing of the ore. Each deposit appears to be different in terms of matrix and REM (rare earth minerals). Light REE bearing minerals such as allanite, monazite, bastnaesite, synchysite, and HREE bearing minerals such as fergusonite and xenotime can vary widely in composition, grain size and association (e.g., carbonates or hard silicates). On the other hand, although not really REM, zircon, Zr-silicates, titanite, fluorite, apatite, and in some cases many other common silicate minerals can carry trace to significant concentrations of REE.The evaluation of REE deposits should include an appropriate mineralogical characterization in order to quantify the REM, distribution, liberation and association by quantitative mineralogical techniques (i.e., QEMSCAN, MLA, TIMA and others); chemistry of the REM by electron probe micro analysis (EPMA), Laser Ablation ICP-MS or ToF SIMS.These techniques provide valuable data for geological purposes such as: defining quantitatively, the variability and distribution of the REM; differentiating between LREE and HREE zones to delineate ore; and metallurgical purposes to predict minerals/REE behaviour during processing. The lack of a comprehensive mineralogical characterization often leads to the wrong processing path and ultimately affects the elemental/mineral recovery."

Jan 1, 2016

By David Wilshaw

Continuous Surface Wave (CSW) testing has been the “next big thing” in ground characterization for the last 25 years. The technique uses surface geophones to measure the speed at which Rayleigh waves (generated by a vibratory source) travel through the ground over a range of frequencies. The velocity at which surface waves travel through the ground is directly related to ground stiffness; the velocity of shorter wavelengths is influenced by the stiffness of shallower soil layers, while the velocity of longer wavelengths is influenced by the stiffness of deeper layers. Measuring the surface wave velocity over a range of frequencies, therefore, allows a stiffness / depth profile to be produced. Using the small-strain stiffness data measured by the CSW technique greatly improves the accuracy of simple limit state analyses; the data are also of sufficient quality for use in Finite Element modelling. Nonetheless, the technique has suffered from a perception of high cost, low productivity, and poor repeatability. An improved Advanced Continuous Surface Wave (ACSW) testing system has been developed by Ground Stiffness Surveys in the United Kingdom, has been deployed there commercially for several years, and is now available in the United States. ACSW uses an automated electronic control system that generates vibrations (from a purpose designed and manufactured portable seismic “shaker”) at different frequencies, measured across a 3m (10-foot) array of geophones, linked to a robust data acquisition and analysis software package. The range of applications in geologic and geotechnical site characterization includes rapid preliminary non-intrusive site assessments (utilizing published soil correlations); stiffness profiling to detect discrete layers (such as a variation in rockhead); average stiffness profiling for earthwork or ground improvement control testing, Working Platform stability assessments, foundation settlement analysis, rock quality and rippability assessments, and void detection.

Oct 1, 2022

By J. C. Hawkins

Determining moisture content and rate of flow of a solid product make measurement and control of dryers unusually difficult. This paper de-scribes a method of accomplishing this with readily made air-temperature measurements. The system can cope with changes in feed moisture and feed rate. It does not measure solids temperature. The system's application to several typical rotary dryers is described, and control schemes using feedforward techniques are explained.

Jan 1, 1971

By Michel Ruel

"This paper describes how to make advanced control choices when difficult processes need improvement. The decision-making process involves choosing between a rules-based approach and a model-based approach as well as weighing benefits and drawbacks, complexity and simplicity, investment and results. This paper will present briefly each solution: basic control, advanced regulatory control, model predictive control, and expert systems such as fuzzy logic controllers and neural networks. The article then proposes a decision tree for selecting the most appropriate approach. A table will compare usage, development, commissioning, maintenance and lifecycle costs for each approach. Finally, conclusions and suggestions will summarize the methodology.INTRODUCTION Advanced process control (APC) is a popular topic. How can one decide whether advanced control should be added to an existing system? Advanced control is used to improve performance, stabilize production, handle constraints, protect equipment and manage grade changes. Most plants use feedback controllers, usually PID (proportional, integral, derivative) controllers. It is common to develop special control schemes to handle more complex processes. In classic PID process control, a controller brings a single value close to a set point using a single manipulated variable. On the other hand, APC brings several values close to optimal targets simultaneously using several manipulated variables. APC's four main strategies are advanced regulatory control, model predictive control (MPC), fuzzy logic and neural networks. Simple solutions are always preferred. Complexity will be increased if performances (production, quality, etc.) are below par. Profitability analyses should be conducted to validate project viability. Needs—not trends—should dictate choices! Before increasing complexity, it is important to define needs, goals, technical support, budget, etc. All these approaches entail strengths and weaknesses. Building a project based on technology rather than needs spells trouble."

Jan 1, 2014

By G. A. Kosick, G. S. Dobby

"This paper presents the principles and application of a recently developed control system for flotation columns and column circuits. The control system uses triple pressure sensors to directly sense zone densities and level, and to help in characterizing the operating behaviour of individual columns. A complete expert system development tool is incorporated within the system to provide the facility for full operator training, an on-line help facility, and a means for incorporating the column behavioural patterns into decision making rules. The system is configurable to any number of columns and can be run in either supervisory mode or direct control through Minnovex PIO software. Additional process signals can be interfaced with the system if desired. Operating experience with the control system on the Minnovex column flotation pilot plant is described.I: INTRODUCTIONColumn flotation cells have been more difficult to control and are more sensitive to circuit changes than conventional mechanical flotation cells. This susceptibility encouraged investigation into various types of control strategies ranging from inexpensive single pressure measurements for level control, to highly instrumented and expensive systems using a variety of control methods.Flotation operators, in many cases, do not understand the column control philosophy or have not been trained to deal with this new type of cell. Some operators have subsequently absolved themselves of the column operating responsibility. Some column cells, for example, have run for hours with slurry pouring over the top or no froth coming off at all.ColumnEX is a column flotation control system which was developed from the viewpoint of an operating shift foreman who wishes to:1. control the column or column circuit through a genuine understanding of what is happening inside the columns, and2. to share this knowledge with his flotation operators and be available to guide them through times of circuit upsets."

Jan 1, 1990

By Robert K. Jonas

"Minerals processors can improve production by using the best available control technology to control their operations. Many mines use expert systems that can provide improved results over manual or basic control, but better results can be achieved using multivariable predictive control. Over the past few years, the application of multivariable predictive control has gained acceptance in many mining processes and has recently proven to be suitable for some of the most challenging processes. This advanced control technology has been successfully applied to a wide variety of processes; alumina digestion, ball mills, CCD/thickeners, kilns/calciners/roasters, heat exchangers/evaporators, and more demanding processes like SAG mills and flash smelters.This paper discusses the needs of advance control technologies in the mining industry, including the impact of these technologies on best practices for implementation and long term sustainability. Results of the multivariable predictive control applications in mineral processing are discussed, and in particular the application to the SAG mill. In addition, an example of the benefits improvement that can be achieved with this technology is presented.INTRODUCTIONThere has been a long term perception in the mainstream mineral processing industry that best advanced control solution is an expert system. There a numerous instances of expert systems used for control of SAG mills, as well as kilns or roasters, thickeners and more recently flotation circuits. Many of theses expert systems have been installed by small, independent companies or by OEMs of processing equipment. Undoubtedly these expert systems have provided millions in benefits to the owners of mineral processing plants.It is this author’s proposition that it is a misconception to believe that expert systems are the best solution for mineral processors, and that in many cases the best solution is Multivariable Predictive Control (MPC). Better control and optimal operations can be achieved through the use of MPC. Another important consideration when considering advanced control technologies is the implementation and support effort. These types of applications have been known to deteriorate, even to disuse, when they are not kept up to date with changes to the process or equipment. The audience is invited to listen to discussion and draw their own opinion. The author has been involved in installing control systems for over 20 years, advanced solutions for over 15 years, and has had privilege to consult with many miners concerning the selection and application of advanced controls over the past 6 years."

Jan 1, 2008

By R. K. Jonas

"Pressure leaching and pressure oxidation in autoclaves are important alternatives in the extractive processing of gold, copper and nickel ores. The application of advanced control to pressure leach and pressure oxidation autoclaves could achieve significant benefits as has been shown in alumina pressure leaching. This paper compares and contrasts alumina digestion autoclaves to other mining autoclaves with respect to advanced controls. The application of advanced control in alumina with over 30 units controlled worldwide, and its benefits will be reviewed. The design and potential benefits from advanced control for pressure oxidation and leaching will be presented.INTRODUCTIONIt is this author's position and the purpose of this paper to propose that advanced control could be effectively applied to autoclaves in the nickel, gold, and copper mining processes. This is based on the proven effectiveness of advanced control on autoclaves used in the alumina industry for pressure leaching of bauxite ores. Incremental, but significant increases in production could be realized by applying advanced control to autoclaves, as evidenced by the alumina industry, and this not being implemented in other autoclaves in the mining industry.In addition, today the mining industry is being challenged to improve their production methods. In some markets like nickel, there is pressure to improve productivity and reduce the cash cost per ton. While in other markets like copper and gold, demand is vigorous with favourable pricing, and there are advantages to increase production and productivity given limited plant capacity. Advanced control has proven its capability to improve mineral processing operations through increases in throughput, recovery, as well as reducing variability. In today's mines, autoclaves are being used to a much larger scale and with much larger importance, thus it would be beneficial to improve operational performance through the use of advanced control.Accordingly, it is the author supposition that an opportunity exists in the mining industry to use a proven advanced control technology to improve the operations and financial performance of mines using autoclaves."

Jan 1, 2012

By J Pearce, M Barteaux, S Pearce

The prediction of how waste materials will evolve geochemically within waste storage facilities has been the subject of hundreds of thousands of hours researched by geoscientists globally. Despite the quantity of research there are a number of significant areas of uncertainty that remain as partially resolved issues. One of the most significant issues is the applicability of scaling laboratory test results to field conditions, and the use of laboratory data for predictive calculations to determine geochemical evolution of waste materials in the field. This issue has arisen predominantly as a result of the relative paucity of field monitoring data from waste rock storage facilities (WRSFs) and the fact that laboratory test methods are not typically linked to specific field conditions; rather they are based on generic standardised methods and designed primarily to simulate accelerated weathering conditions that do not relate to field conditions in a linear manner.To address these specific issues the authors have in the last two years made significant progress in the development and deployment of advanced field monitoring equipment within numerous WRSFs. O’Kane Consultants (OKC) has previously reported the findings from data collected from these monitoring installations in a number of papers presented throughout 2013–2014. This valuable site data has subsequently been used by OKC as the basis to design and engineer advanced customisable site-specific kinetic leach columns at OKC’s geochemistry research laboratory. These columns represent an important advancement in kinetic column assessment methodology as they have been designed to replicate the field internal conditions within waste facilities.Key features of the columns include their capacity, size and technical specifications; including fully programmable solenoid-controlled air supply with variable flow and pressure control and in-line heating option, automated temperature control and monitoring, automated oxygen consumption and carbon dioxide production monitoring, and soil moisture/matric suction monitoring.This flexibility of the design not only allows for more accurate field-based assessment of pyrite oxidation rates (POR) but also assessment of the potential effectiveness of waste management options such as deposition within a reduced oxygen environment, for example, as simulations of reduced net percolation rates or oxygen ingress rates can be accommodated.CITATION:Pearce, S, Pearce, J and Barteaux, M, 2015. Advanced customisable leach columns – a new kinetic testing method to simulate site-specific conditions, in Proceedings Tailings and Mine Waste Management for the 21st Century , pp 137–144 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 27, 2015

By Kato Y

As a direct result of the Mining Industries need to improve efficiency and production in Open Pit type operations, the size of haulage units have increased dramatically. This trend has continued such, that the majority of dump trucks operating in Open Pit operations are in the 170 ton class. Continued mining in existing locations has meant that the increase in vertical lift and resultant grades, and increases in hauling distances are making electric drive systems unsuitable. This is largely due to the electric drive systems heat limitations on major propulsion components. With these mining requirements in view and the present limitations on electric drive systems in mind, Komatsu have been developing the Komatsu HD1600M. A diesel powered mechanical drive dump truck capable of operating in deep pit operations. This presentation introduces: Komatsu HD1600M Dump Truck

Jan 1, 1982

By Gerald Stolarczyk

The Radio Imaging Method (RIM) is based upon electromagnetic (EM) wave propagation in the coal seam waveguide. The radio geophysics theory underlying RIM was developed by Hill of the national Institute for Science and Technology (Hill, 1984). Recent advances in radio geophysics instrumentation have increased operating range in the coal seam waveguide to almost 3,000 feet. This paper describes RIM longwall panel reconnaissance scans and tomography results.

Jan 1, 2006

By G. Luttrell, S. Keles, M. Eraydin, R. Yoon

The dewatering of fine particles is energy intensive and often requires costly capital expenditures. To address these issues, a series of advanced dewatering technologies have been developed at Virginia Tech. These include novel dewatering aids that enhance the performance of existing filtration equipment and an innovative hyperbaric centrifuge that utilizes both air pressure and centrifugal force for dewatering. The moistures obtained using these processes are 30-50% lower than those obtained using conventional methods. Another dewatering technology, known as the hydrophobic displacement process, can reduce product moistures to a level previously attainable only through the use of thermal dryers. This article presents test results obtained with these various advanced dewatering technologies along with estimates of the power consumption for each process.

Jan 1, 2007

By R. A. L. Drew, G. Mendoza-Suarez, J. Filipi, R. Vintila, J. A. Kozinski

Economics and environmental considerations along with the increasing demand of hydrogen encourage development of novel technologies such as plasma processing of hydrocarbons and thermal cracking of natural gas. Plasma discharges, either in thermal or non-thermal regimes are expected to allow low temperature and fuel flexible on-site hydrogen generation. The main drawback of thermal plasma reformers is the high-energy consumption resulting from high-temperature operation. On the other hand, non-thermal plasma, generated by dielectric barrier discharge (DBD), is able to simulate the chemical reactions employing much lower energies than those required by thermal treatment processes. The non-thermal plasma process allows for instance, a direct conversion of methane into hydrogen and carbon black with no CO2 release. The focus of this research was on the GHG-free method of H2 generation in compact non-thermal plasma reactors using low, medium and high permittivity dielectric ceramics. A stable, non-thermal plasma was generated by placing a dielectric ceramic between two electrodes with a 25 thou gap and applying an alternating current of 1-5kHz and voltages of 4-8kV. In order to ensure energetic efficient plasmas, experiments were conducted to analyze the behaviour of different permittivity ceramics. It was found that the dielectric properties of a ceramic, when used in a DBD reactor, have a strong influence on the discharge characteristics, which in turn influence the power consumption. Higher dielectric constant resulted in higher conversion rates of methane (higher yield of hydrogen and carbon). At the same time, the mechanical properties of the dielectric material, which are closely associated with its processability, influenced its resistance to electron bombardment, as well as thermal and mechanical damage. Therefore a reliable ceramic should have good dielectric properties, in addition to good thermo-mechanical stability.

Jan 1, 2004

By M. Lindgren

"Hydrometallurgical processing involves process stages, like leaching, that create harsh environment for stainless steels. High acidity, the presence of chlorides and oxidizing ions combined with relatively high temperature create risk for both uniform and localized corrosion. Advanced electrochemical techniques were employed to study uniform and pitting corrosion of two stainless steel grades 316L and 2205. Results obtained with the linear polarization resistance technique combined with the harmonics distortion analysis, electrochemical noise and coupled multielectrode array systems are compared to the results of conventional electrochemical techniques and immersion tests.INTRODUCTIONHydrometallurgical processing has become favoured in metals production in recent years due to energy costs, leaner ore bodies and environmental factors. Because the hydrometallurgical processing route is flexible, various types of secondary raw materials, like flotation tailings, dusts, sludges and slimes can also be treated in addition to conventional mineral concentrates (Sarveswara Rao & Acharya, 2008).Hydrometallurgical processing relies on aqueous chemistry, usually acids, at temperatures around 100°C for the recovery of metals from ores, concentrates, recycled or residual materials. The processing route can typically be divided into three stages: leaching, solution concentration/purification and metal recovery. The processing environment is aggressive, especially in leaching. High acidity, relatively high temperature together with impurities, like chloride ions, place high demands on the corrosion resistance of construction materials. The dominant corrosion mechanism may be uniform corrosion or localized corrosion depending on the process conditions (Ekman & Torsner, 2010). This complicates the prediction of corrosion rates and, consequently, cost effective material selection.Traditional means to evaluate uniform corrosion resistance of stainless steels are immersion tests and the results are published in the form of iso-corrosion diagrams (Outokumpu Stainless, 2010). For the localized corrosion, namely pitting and crevice corrosion, immersion tests can be used but the duration of the test is rather long because an incubation period takes place prior to the occurrence of the actual localized corrosion damage. Electrochemical techniques, traditionally in the form of cyclic polarization scans, have been employed to assess the susceptibility of a material to pitting corrosion (Papavinasam, 2008). They cannot, however, give any indication of the pitting corrosion rate and lack potential for on-line measurements."

Jan 1, 2012

By Jian Li, P. Liu, R. Zhang and J. Lo

In the past decades, focused ion beam (FIB) has evolved into a powerful microscope that provides capabilities that no other microscopes can offer. The combination of high-resolution imaging and stress-free ion beam cross sectioning provides valuable microstructure information both at the specimen surface and beneath. FIB techniques are also the preferred method to prepare site-specific transmission electron microscope (TEM) specimens. CanmetMATERIALS owns a world-class microscopy facility, where advanced microscopy work provides strong supports to research programs that cover a wide range of subject areas. This paper is aimed to provide a few practical examples of FIB applications in microstructure characterizations that include cross-sectioning and imaging, serial sectioning, and advanced TEM specimen preparation in materials research at CanmetMATERIALS.

Jan 1, 2015

By K. E. Harrison

Acid rain legislation as proposed by President Bush [1], if enacted, will immediately refocus current thinking on the economic decision-making as related to coal preparation facilities. Unit operations currently ignored because of their costs, will become mandatory to coal plant designers and operators to ensure maximum energy recovery and sulfur reduction in the entire coal stream. In anticipation of this need, the U.S. Department of Energy, The Ohio Coal Development Office, EPRI and others are sponsoring research in several areas of coal preparation, and coal plant designers are beginning to consider more innovative techniques as they configure their flowsheets for plants of the future. Preparation plants then will have recleaning

Jan 1, 1990

By K. E. Harrison

The acid rain legislation has passed into law. This new law has caused the power generation community to investigate alternative methods to obtain compliance with the new legislation. One thing all of the power companies have concluded is the answer is not easy. Do we switch fuels to burn all low sulfur compliance coal? Maybe possibly only partial desulfurization by means of a dry sorbent system? Or, finally, maybe a wet scrubber system? Whatever the choice, the power community needs to investigate all of the alternatives. In 1988, ICF Kaiser Engineers, Inc. (ICF KE) responded to a request by the U.S. Department of Energy for the engineering development of advanced physical fine coal cleaning. ICF KE responded and was awarded a contract to conduct a multi-task program to develop an advanced flotation system to eliminate pyritic sulfur and retain as much energy as possible. ICF KE assembled a team that included members of industry, academia, and industry research organizations to conduct this multi-task program. The program includes sixteen (16) tasks. This team had personnel to help solve some of the anticipated problems and to provide industry prospective on the viability and commercial potential for any concepts proposed. The primary team consists of a major coal producer, Babcock and Wilcox, Eimco Process Equipment Company, and Virginia Polytechnic Institute and State University.

Jan 1, 1992

By Marcus Vinicius Laudares Mendonça

SMS calculates and improves tooth and flank profiles individually to realise a homogeneous pressure distribution over the complete load flank. With a tooth profile and flank profile according to AGMA, ISO or DIN standard the contact pressure varies along the load flank. To realize a homogeneous distribution of the contact pressure and to avoid a premature mesh, SMS improves the tooth profile and flank profile in three steps. First SMS is doing a preliminary calculation and design according ISO, DIN or AGMA standard, with safety factors based on more than 125 years of experience. Second SMS calculates and checks the local contact pressure at the load flank under consideration of shaft, gearing and housing deformation, as well as the bearing behaviour. Finally SMS calculates and designs an improved tooth profile and flank profile to receive a homogeneous contact pressure at the load flank. The result is an increase of the torque transmitting capacity of up to 30% of the SMS advanced gears with the same outer dimensions than traditional gears.

Aug 17, 2017