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By Morandini AF, Occella E, Clerici C, Mancini R

This contribution presents the first results of an experimental research aimed at finding an unified description of the first stages of a rock comminution process. With reference to the case of the jaw crushers and to the specific subject of the comminution law, the tests reviewed and analysed in this contribution have been carried out, at a laboratory scale, on five different materials (limestones, quartzite, serpentinite) at different reduction ratios and feed rates, and accurately recording both total power and idle running power. The analysis of the results has shown that: ò the grain size distribution of the products complies with a modified form of the Rosin-Rammler equation, already found to be well suited to representing the grain size distribution of blasted rock in previous works by the authors; ò observed trends of the consumed power at increasing reduction ratios is steeper than predicted by the classical Rittinger, Kick and Bond laws, Rittinger law representing however a closer approximation of the experimental results; and ò a more accurate description of the experimental results is provided by a modified form of the Rittinger law. Accuracy of the semi-empirical expression has been found to be usually better than ten per cent by comparing actual results with expected Results.

Jan 1, 1993

By Zamora C

The performance of a system for detecting the onset of overloads on rod mills is described. The system has bee,, tested at CODELCO E1 Salvador Concentrator where, due t,, variations on size distribution of the copper ore feed, th' rod mill is frequently subject to overloads. The main inpur signal to the system is the rod mill sound, after being measured and analog conditioned. This signal and othe signals measuring the fresh ore feed and the mill watt addition are fed to a computer containing a simpl mathematical model. The model parameters are empiricall estimated and an analog output signal is generated, whic gives an early prediction of the overload condition. The experimental results described in this paper show that the overload condition may be predicted with an anticipation of about three minutes.

Jan 1, 1985

By Nightingale RJ

A column (50 cm 4) provided with a bell charging mechanism and a rectangular perspex insert was used to investigate the inter-relationship between charging pattern, size analysis and velocity profile for a number of charging methods. It is shown that a strong correspondence exists between size distribution and velocity profile for bell charged ore and coke and that decreased coke volumes cause higher pressure drops and increased central flow in beds with "V" shaped layers. It is also shown that a bell charged mixed burden exhibits greater segregation than when it is bell charged as layers and that when uniformly charged the mixed burden shows least segregation and a virtually flat velocity profile. A relationship is derived for "V" profile charges showing the extent of central segregation with furnace size.

Jan 1, 1975

By Warner R. E

Present capacity for molten iron production at Port Kembla is an average of 13 000 t/day from five blast furnaces. The most recently installed blast furnace, No.5, was commissioned in March 1972 with a design capacity of 4 500 t/day. For the first reline currently scheduled for 1977, plans are being finalized.for significant modifications and uprating of capacity. Achievement of the initial design capacity from No.5 blast furnace on a sustained basis was not realised until the third year of operation. Although the furnace is only 42% larger than No.4 blast furnace on an inner volume basis, the more stringent raw materials, operation and maintenance requirements of the larger furnace and more complex equipment have been found to be much more critical than anticipated in the planning stages. These problems have also been experienced by many other companies who have recently installed large new blast furnaces. Some of the principal problem areas are described together with measures taken to over- come the difficulties. The problem areas include the failure of'the shower cooled bosh, failure of the upper shaft brickwork, sludge

Jan 1, 1976

By Estoque J, Abaigar J, Domingo B, Acenas M

The Siana gold-silver deposit of Surigao del Norte, Mindanao, Philippines is perhaps one of the most complex in the world, being related to an ancient suture zone known as the Philippine Fault. Early accounts described the deposit as epithermal, consisting of an upper limestone replacement orebody and a lower vein type deposit hosted in andesite. Recent field and laboratory studies, in correlation with the latest findings on the archipelago's tectonic evolution, however, led to the present interpretation of the Siana ore deposit's origin as involving both syngenetic and epigenetic processes, with limestone breccia, similar to the Cow Head Breccia of Newfoundland, as the principal host to mineralization.

Jan 1, 1987

By Khosrowshahi S

The objectives of grade control remain unchanged but new methods are being developed to attain them. Since the early-1990s, an improvement in the power of mine site computers has made the geostatistical tools of conditional simulation more accessible. Optimisation of the grade control process on mine sites now involves two stages: optimisation of the sampling regime and optimisation of the interpretation of ore and waste boundaries. Optimisation of the sampling regime first requires an understanding of the nature of the mineralisation and in particular the impact of particle size on the sampling precision. This relationship, termed the Fundamental Error of sampling, enables an optimum subsampling protocol to be defined for the sample preparation and assaying. However, the actual sample collection method, whether drilling or trenching, must be correctly selected and the sampling grid should be optimised. The relative costs and benefits of various alternative sampling methods and grids can be determined using the method discussed. The use of the grade control data can also be optimised. In the past ore and waste boundaries were often defined using a linear interpolation algorithm that smoothed the data (such as polygonal, sectional, inverse distance squared or even kriging methods). Frequently the relative impact of ore loss and dilution could not be estimated. Conditional simulation to generate equiprobable alternative maps (realisations) can now be adopted to address these issues. A transfer function is then used to evaluate the similarities and differences between the maps. The Ore Block Optimisation (OBO¬) process is a transfer function that produces a three-dimensional model of the optimal ore block outlines. This provides a clear guide for the mining geologist to refine and mine. The nature of the transfer function and the inputs and outputs are discussed. In the past, reconciliation has been the `acid test' for any grade control system. Any ore blocking method based on conditional simulation can make use of the exhaustive data set to ensure that reconciliation between prediction and production will improve significantly. The OBO¬ method provides a guide to the mining geologist to ensure that the best ore blocks are mined. Misclassification between ore and waste is reduced, ore loss and dilution are minimised (and are measurable) and ore is optimally assigned to stockpiles of various cut-off grades. These advantages significantly enhance mine profitability and control of the mined grade.

Jan 1, 1997

By Wagland D. G, Guo H

The Mt Whaleback orebody is in a complex geological regime. A good understanding of geological structure is essential during the design and implementation stages. The amount of information on the rock-mass condition available at the design stage is considerably limited. It is essential to validate the rock-mass properties used in the design during implementation. It is important to achieve integrity of the final pit wall during development and to maintain the integrity until the end of its designed life for safe and economical extraction of ore. The original geological model is updated by way of on-going detailed geological face mapping. Original design is reassessed and is modified based on any significant variations to the previously evaluated geotechnical conditions. Information gathered during design implementation provide tools for effective management of the pit walls. Controlled blasting techniques are employed in the final limits blasting. Presplit blasting is used in most limits blasts. Presplit helps to maintain the integrity of the wall by venting excessive gases from the limits blast. This helps to reduce bedding dilation by gas penetration. Also, it helps to define the design batter for the operators for final batter trimming. Pyritic shale needs special attention during blasting due to its reacting nature. Cablebolting is applied in selective areas to secure small-scale potential instabilities. During the development phase, pit wall monitoring instruments are installed. These instruments are used to monitor the performance of the wall during and after excavation of the slope.

Jan 1, 1995

By Nolan D. P, Balales M

Over the last two years work has been undertaken within the Pasminco Metals - BHAS Zinc Plant to improve the efficiency and maintain the production capacity of the operation. The work has centred upon the installation of suitable process instrumentation to improve process control and the development of new unit operations to maintain control of the circuit water and sulphate balance. A key aspect of the new process instrumentation has been the development of an on-line analyser to monitor the total antimony concentration during zinc dust purification. As a result of changes made to the Zinc Plant in order to contain all effluent within the circuit, a problem developed with control of both the water and sulphate balance of the circuit. A new neutralisation plant to treat all cell house waste water so that it can be contained within the circuit has been developed and installed. In addition changes have been made to the existing circuit to control deliberately the circuit sulphate concentration by precipitation of sodium and potassium jarosite.

Jan 1, 1993

The transportable moisture limit of a mineral concentrate (TML) is of great importance in the shipping of that material from Australian ports. Each year Australian mining companies incur substantial costs as a consequence of delaying shipments and/or multi-handling concentrates so as to comply with transportable moisture limits. Despite this there is a general lack of in-depth knowledge concerning factors that influence the parameter. Eight major Australian mining companies supplied sizing, specific gravity and TML data for their concentrates. Zinc, lead, copper and bulk concentrates were represented in their data. Estimated surface areas of the concentrates, as calculated from their normalised sizing data, correlated strongly with the reported transportable moisture limits. This high correlation prevailed in spite of the acknowledged limitations associated with the use of multi-sourced data and the adoption of simplistic approaches in the normalisation of sizing data and the estimation of surface area. Based on the broad range of concentrates studied, concentrate sizing data were concluded to offer potential as an alternative means of reliably estimating transportable moisture limits.

Jan 1, 1993

The issue of flyrock is critical to the operation of all mineral extraction sites that use blasting. This paper takes a risk-based approach to identifying, analysing and managing the flyrock hazard. The basic cause of flyrock generation is a mismatch between the energy available and the work to be done. It should be noted that the energy available depends on the charge confinement. This mismatch can be caused by an abrupt decrease in rock resistance (geological weaknesses), overcharging, inadequate delays between holes and rows, inappropriate blast design and inaccurate drilling. The mismatch can come about from two sides; either too much energy (charge) for a fixed burden (work to be done), or insufficient burden (work to be done) for a fixed charge. The main mechanisms of flyrock generation are rifling, cratering, face bursting and secondary blasting. Each source mechanism has different characteristics in terms of vulnerable locations and each requires different control measures. However, all controls require a high level of quality control and assurance. A range of different approaches for managing flyrock risk and determining blast clearance zone dimensions are presented. A prescriptive consequence-based approach is discussed. A conventional risk matrix based approach is outlined with some innovation regarding controls rating and uncertainty ratings. A published semi-empirical approach is discussed. Two examples of quantitative flyrock risk analysis are presented; one involves bench blasting based on a published paper and the second is a cratering example developed by the author based on consulting projects. Finally, a stochastic approach based on published work is presented which simulates cratering superimposed on face bursting mechanisms. Also, a stochastic analysis undertaken by the author of the cratering example is presented. Effective blast emission management is required for two reasons; firstly to reduce and/or eliminate safety risks and secondly to manage public perception of blasting risks such as flyrock. The conclusion of the current research is that the wild flyrock risk can be estimated using existing techniques. Furthermore, both qualitative and quantitative risk management methods as discussed in this paper can be used for flyrock management for a given blasting situation. A combination of both is considered to be best practice.

Jan 1, 2007

Commencing early in 1975, Saraji Mine in Central Queensland will product 3.56 million tonnes in the first year and then 4.57 million tonnes annually for the Japanese and European markets. The coal will be mined from a series of pits separated by corridors which will be mined at a later date. Through the corridors flow regional drainage structures and power lines. Relatively easy areas will be mined initially to assist the cash flow and to minimise start-up difficulties. For ease of scheduling it is desirable that pit lengths exceed 3 000m but this will not always be possible. Ramps were designed using 1 200m spacing and 5 per cent gradient as optimum but modified to suit specific conditions. One ramp will be in the end of each pit nearest the ROM hopper and stripping will commence from this end. The advantages so gained are shorter haul distances, immediate access to the coal after stripping and simplification of the excavation of the first ramp. Haul road location was defined by the minimum present value of construction plus operating costs. Road design utilised airfield construction charts because wheel loads were outside the range of available road design manuals. Low load resistance characteristics of

Jan 1, 1974

By Visnovsky

The computing needs of a mine planning office vary greatly depending on the staff available and the nature of the work undertaken. Some offices work acceptably with few aids apart from hand held calculators while others use mainframe computers with associated data bases and sophisticated mine planning software. Not every mine planning office requires the big system approach but all can benefit from the intelligent use of small computers. There is virtually no limit to the design problems which can be solved using modern desktop computers. The simple language required encourages engineers to work interactively to facilitate both large and small computations. However a limit does exist in the speed and ease with which solutions can be obtained. The important ingredients for the successful application of such machines are a little computing knowledge, a flexible machine, and an engineer who really understands the mining problems confronting him. If these are available it is possible for the engineer to tailor the program to the task at hand and efficiently achieve the required result.

Jan 1, 1983

By Perring CS, Barnes SJ

The nickel exploration boom of the late-1960s and early-1970s led to the discovery of numerous komatiite-hosted nickel sulphide deposits, associated with variably serpentinised bodies of olivine-rich cumulates. Subsequent research has shown the importance of volcanological processes to understanding the genesis of these deposits. Crucial developments have come through consideration of the fluid dynamics of magmas and magma-crystal mixtures, through observation of the dynamics and geometry of modern day basaltic lava flows, through application of theory and experimentation on the kinetics of crystal growth from magmas, and most importantly from extensive detailed field mapping of komatiitic sequences in the Yilgarn Block and elsewhere. From these studies has emerged a new integrated view of the volcanological setting of komatiite-hosted deposits, and a recognition that a complete continuum of deposit types exists. Nevertheless, komatiite associated magmatic nickel deposits generally fall into two overall types based on the nature of the sulphide ore. In the first type the bulk of the ore is either massive Fe-Ni-Cu sulphide or a variable mixture of massive sulphide and an ore characterised by olivine crystals in a continuous matrix of sulphide occupying between 30 and 75 per cent by volume of the rock (called Matrix Ore). Nickel grades of massive sulphide ore range from 2 - 20 wt% and those of the matrix ore generally fall in the range 1 - 5 wt% (average 2.5 wt%) Ni/Cu ratios of the sulphide fraction are generally >10.

Jan 1, 1996

By Davey KJ

Complex sulphide ores are characterised by complex texture of the valuable minerals. Any assessment of the performance of differential flotation circuits treating such ore should include analysis of the effects of poor liberation of the valuable minerals. Selected samples were taken from balanced size by size surveys of the flotation section of a concentrator treating an ore body containing fine grained galena and sphalerite in a matrix of iron sulphides which is mostly pyrite. liberation measurements were made using the QEM*SEM system on four or seven size fractions. The measurements indicated that less than 40 per cent of the galena and less than 60 per cent of the sphalerite in the flotation feed was liberated. The final concentrates were largely composed of composites of valuable minerals and iron sulphide however there was a small but significant fraction of liberated iron sulphide. Using the sized mineral flows obtained from the original balances and the liberation measurements, a satisfactory liberation balance was obtained. This enabled the effect of liberation on the flotation performance to be examined; not only for the entire circuit but also in the rougher, scavenger and cleaning sections. In the zinc circuit the effect of a regrind mill could be assessed. Recovery of galena in the lead circuit was limited by the recovery of composite lead particles. Recovery of liberated galena exceeded 95 per cent in all size fractions while the recovery of composite galena exceeded 85 per cent below 38 ¦m but fell sharply above 38 ¦m. Examination of the behaviour of the liberated and composite galena in the various sections of the lead flotation circuit revealed high recoveries of both liberated and composite galena particles in the roughing and scavenging sections but very low recoveries in the final two cleaning stages. Similar trends to those observed in the lead circuit applied in the zinc circuit although the performance of the liberated sphalerite also fell off at sizes greater than 38 pm in this case. Thus the zinc recovery was limited by the flotation of both the liberated and the composite sphalerite. The effect of regrinding was to increase the recovery of sphalerite mainly by reducing the amounts of sphalerite in less liberated sizes rather than by increasing the liberation of the sphalerite within a given size Fraction.

Jan 1, 1993

By P Church

What is the best method of splitting a sample from a reverse circulation drill rig? How important is it to obtain a correctly split sample? What is the impact of an incorrectly split sample? These are just a few of many questions asked daily in the mining industry with regard to sampling. Modern sampling theory is well described in the literature in texts and is taught in short courses throughout the world, however little has been published on the relative performance of sample splitting devices used in the field. This paper compares the performance of the Jones tiered riffle splitter with a cone splitter manufactured by SGS Metal Craft in Western Australia. The testwork was carried out at AnglogoldÆs Sunrise Dam Gold Mine, 55 km south of Laverton in Western Australia. Mineralisation at Sunrise Dam is hosted in a structurally complex framework of shear zones with dips that range from steep (70¦) to shallow (25¦). The deposit is characterised by significant amounts of coarse gold, which presents a challenge in sampling, analysis and grade estimation. The three major areas where sampling errors can occur are in drilling, sampling, sample preparation and analysis. Sampling errors attributable to drilling and sample preparation often far outweigh the errors made at other stages in the process, however historically most effort to identify sampling errors has concentrated on the laboratory and analytical procedures. Splitter design and cleanliness can have a large impact on sample collection and preparation. Splitter performance was tested with respect to sample weights, particle size distribution, and gold grade consistency. The aim was to determine if each particle has an equal probability of being sampled, the resulting sample has integrity, and if any segregation problems occurred. The cone splitter was found to provide the best split in terms of particle size distribution, with no apparent size bias. Duplicate samples had more comparable masses than those provided by the riffle splitter. Most importantly, the cone splitter gave less grade variability between duplicate samples than the riffle splitter. Testwork also confirmed that, like the riffle splitter, the cone splitter must be oriented vertically and the design of the rig or cone splitter trailer should accommodate this requirement.

Jan 1, 2003

By Thomas W

Due to record low tin prices and an uncompetitive position in world markets, the Renison tin mine has undergone three major phases of restructuring in the last three years. This has involved substantial job losses, almost all of which have been through voluntary retrenchments. Retrenchments took place in 1988, 1990 and 1991.The last phase of restructuring was the most dramatic, as many aspects of the operation of the mine were changed. New pay structures were introduced, and the miners' contract system was scrapped. Drastic pay cuts occurred in many areas, although the opportunity was also taken to increase pay at some of the lower levels where inequities existed. Work practices were changed, as was the management structure.

Jan 1, 1992

Sampling criteria and practical implementation of these criteria are discussed with a view of achieving and maintaining a high level of quality for minerals at their various stages of production through to their utilisation. From this it will be shown the advantages that can be gained by producers who undertake stringent quality control programmes for their ores, thus ensuring they have a competitive edge over other producers.

Jan 1, 1985

Paddington processing plant is located approximately 30 km north of Kalgoorlie on the Menzies Highway and is owned by Placer Dome Asia Pacific. First mining was from the Paddington Pit, but in subsequent years the plant has had a history of treating ores from a large number of sources, and has used several different methods to reconcile mining and mill production. Reconciliations are necessary to keep a check on the quality control of mining and grade control processÆs. There is a need to be able to identify and resolve issues that will affect the profitability of the organisation quickly. They are also used to check the quality of the resource/reserve statements, and allow the accurate and timely payment of royalties to stakeholders. During the formation of the Kalgoorlie West operations when Delta Gold Limited and Goldfields Limited merged in 2001, the complexity of reconciliations increased dramatically. The expansion of the scope of reconciliations to include two mills, four underground mines and seven open pits, and ore from one deposit to both mills meant that a revised strategy was essential. A variety of issues have arisen over the years with discrepancies occurring when reconciling both tonnes and grade. There are many ways to approach reconciliations, and in recent times these philosophies have been widely debated on site. A consistent and logical approach that takes into account many different sources of ore, as well as different methods of delivery to the Run of Mine stockpiles is therefore necessary. This would standardise the different approaches taken by the various operations that combined to form Kalgoorlie west. The new method reconciles mill production back to the individual ore sources, and produces reconciled-mined tonnes and grade based on the mill throughput and the change in stockpiles. There will generally be a small discrepancy between the claimed mined tonnes produced (and grades) and the mill production. This needs to be highlighted to the operations concerned if it considered unacceptably large. Paddington mill over the last few years has had up to ten sources of ore each year, and up to 15 different stockpiles being processed during each month from those various pits. This combined with the need for a blended oxide/fresh feed, whilst striving to deliver a consistent (grade and hardness) product to the mill, has meant that reconciliations have been very difficult.

Jan 1, 2003

By A S. M A Haseeb

Zircon is the second in abundance among the heavy minerals occurring in the beach sand along the coastal belt of Bangladesh. In this study a detailed characterisation of Bangladesh zircon extracted at the pilot plant of the Bangladesh Atomic Energy Commission at CoxÆs Bazar has been attempted using chemical analysis, X-ray diffraction and optical microscopy. From the chemical analysis it is found that Bangladesh zircon has a purity of 95.88 per cent. The main impurity in Bangladesh zircon is titanium oxide (3.01 per cent). This is followed by iron oxide (0.42 per cent). A number of other oxides are also found. Microscopic study revealed that Bangladesh zircon has an elongated, prismatic shape with pyramidal termination in about half of the grains while the rest are more or less rounded. Some fractured and irregular grains are also found. Bulk sample of Bangladesh zircon in the as-received condition shows a yellowish brown color. However, individual zircon grains are seen to be almost colourless and transparent under polarised light. XRD study confirmed good crystallinity in the sample. Under the microscope it is found that zircon grains constitute 94 per cent while total impurities amount to six per cent in Bangladesh zircon. This result agrees fairly well with the chemical analysis results. Microscopic study identifies oxides of titanium (both rutile and ilmenite) to be the main impurity, in conformity with the findings of chemical analysis. Further, monazite was also identified as an impurity under the microscope. An iron bearing coating is also found on a few zircon grains. Most of the impurities found in Bangladesh zircon exist as discrete minerals.

Jan 1, 2000

Recent developments in engine, transmission and control technology, likely to give rise to improved performance and efficiency of underground mobile equipment, are reviewed. Turbocharging and the electronic control of fuel pumps and injectors can improve diesel engine performance whilst minimizing exhaust emissions. Ceramic materials promise further improvements in engine efficiency. Nevertheless, electrically powered machines, equipped with trailing cables or 'travelling plugs' are expected to find increasing application where there is less need for flexibility and where the cost of ventilation and heating or cooling makes diesel engines unattractive. Voltage to frequency converters and induction motors appear to have a future in mains powered machines. Vehicles employing energy storage in the form of batteries or flywheels will find increasing application, but it is expected that they will remain a minority until there is a significant break-through in battery technology. Hydrostatic transmissions having high power density and efficiency are likely to be used more widely. Electronic control systems are likely to be used to simplify jobs and to improve performance and productivity. Enhancement of remote control systems is to be expected for work in unsafe areas, but true robot operation is considered unlikely for the moment. Attention to ergonomic factors should produce significant productivity gains.

Jan 1, 1985