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By Harrison R. Cooper

Computer process analysis and control techniques are overcoming major hurdles to acceptance in the mineral industry. With the growing list of new advances characteristic of a rapidly maturing discipline, management of the companies on the leading edge are keenly aware of the advantages of using computer methods in process applications. Significant advancement is already evident in such technical areas as operations research, mathematical modeling, statistical methods, and computer-based procedural techniques. The early advances during the past decade are already documented in prior symposium proceedings of this series. Thus, the currently active areas of the advancing technology are emphasized here. This section deals with applications in pyrometallurgical and kiln processes. The two sections which follow deal with concentrating operations from two points of view: 1) mathematical modeling, and 2) on-line control. In the metallurgical field, emphasis on developing effective process computer applications for the steel industry began in the late 1950's. Simulation techniques also received substantial attention. The steel industry was soon joined by the cement industry in the development of computer methods for process applications. Computers were in use for feed-material blending and kiln control in the early 1960's. Computer development in other pyro processes, such as aluminum reduction and glass-making, also marked significant advances by the mid 1960's. Aluminum smelter potline control is a nearly universal application at this point, and the development of glass furnace computer process control represented a recent important technical advance in digital control techniques. Steel Hot strip rolling was the earliest significant process computer application in the metallurgical industry. Computer control of rolling mill operations is now a steel mill standard component, particularly in plants newly placed into production. 1, 2 Initial computer installations principally carried out procedural routines in setting mill clearances for production lot control. Recent developments are leading toward feedback control based on mathematical model techniques. 3

Jan 1, 1969

By Harrison R. Cooper

This section will outline procedural, statistical, and model applications developed for specific problem solving and for specific applications in beneficiation processes. Iron Ore Processing Introduction of taconite as a basic raw material in the iron ore industry took place with application of high order technical resources for process development and engineering. This investment of resources encouraged computer utilization to maximize efficient use of capital. From this recognition, process control computers have been installed for operations use in the major taconite plants of the iron range. One of these installations, the Minntac Division of U. S. Steel at Mountain Iron, Minnesota, is described in the paper by Chase in these proceedings. Other computer techniques used in taconite processing are outlined by Tuttle, Ahlquist and Carlson, representing Erie Mining. In this volume Tuttle, et al. describe statistical methods for development of information in taconite beneficiation. Statistical methods used in iron ore processing are described by Volin in treating flotation data as outlined in prior proceedings of the symposia and in other publications. 1,2,3 Industrial Minerals The use of linear programming for feed blending at the Carlsbad operation of International Minerals and Chemicals was outlined by Nunnekoven in 1963.4 Subsequent application of this procedure at the Kingston phosphate operation in Florida was described by Loper. Continued development led to installation of an on-line computer in the Kingston plant which reached operational status in 1967.6,7,8 Application of an on-line computer to industrial mineral production accomplished at Kingston is regarded as a milestone in computer use development. Following this achievement, the Cominco potash beneficiation plant near Saskastoon in Canada was automated by installation of an on- line computer programmed to carry out direct digital control functions to effectively operate the plant by process computer. The procedures used in the Cominco operation are described by Madge in this volume. Development of a mathematical model

Jan 1, 1969

By R. V. Ramani

It is common knowledge that there is an endless stream of possibilities, proposals, and projects - each representing a demand on available capital - for improving the mining company's performance measure. It is true that these proposals go through an increasingly stringent evaluation process as they move up the echelons of management for approval. Therefore, there is every reason to expect that a proposal or project accepted for deployment will make a substantial contribution to the organization's performance. The reality, too often, is otherwise. Castle (1985) reveals some significant insights into the difficulties in predicting the performances in the mining industry. A sample of eighteen mining ventures, which have been developed over the years, was selected by Castle to illustrate the problems. The actual performances were compared with the original projection. The sample encompasses both surface and underground mines, a large number of commodities, and a wide geographic distribution. The experiences in these mining projects were analyzed through answers to four specific questions.

Jan 1, 1989

By R. V. Ramani

"In a 1985 seminar, we were told that over-optimism abounds in Artificial Intelligence (AI), that AI is neither a science nor a technology yet, and that we will be both exhilarated and disappointed with AI. In fact, even today, there is no single accepted definition of AI; however, certain features have been identified by AI researchers as essential to consider an entity (e.g. machine or program) to be intelligent. According .to Shank (1987), these features include communication (to be able to communicate with), internal knowledge (knowledge about itself), world knowledge (awareness and knowledge about the world outside), intentionality (knowing what one wants and a plan to seek it, ie. goal seeking behavior), and creativity (being adaptable to changing conditions). None of these figures would individually define intelligence; however, each would be a part of intelligence in its own way.The prospects for the development of entities with AI have never been as good as they are now. The combination of advancements in computer hardware and .software along with new insights into the ways in· which we store knowledge and use it for problem solving has enhanced the potential for the creation ~f intelligent entities. After some unbounded optimism of a major breakthrough in the fifties and frustrating disappointments in the two following decades, it appears now that AI has emerged from research labs to industrial practice. This is confirmed by the growing number of repeat applications of AI in business and industry to the extent that AI can now be considered a technology.AI applications are categorized into several distinct areas such as Natural Language Processing, Speech Recognition and Synthesis, Expert Systems, Robotics, Machine Vision, etc. Of these practical realizations, Expert Systems (ES) has the greatest potential for meeting the decision-making needs of the manager in the ever-growing complex scoio-technical systems. Prof. Feigenbaum, an expert and leader on expert systems, has defined Expert System as"" ... an intelligent computer program that uses knowledge and inference procedures to solve problems that are difficult enough to require significant human expertise for their solution. Knowledge necessary to perform at such a level, plus the inference procedures used, can be thought of as a model of the expertise of the best practitioners of the field."""

Jan 1, 1989

By Daniel T. O’Brian

Mineral exploration activities are benefiting from new interpretive techniques which have become economically practical with computers. Government agencies, educational institutions, and industry have each contributed research and development efforts for improving the mathematical analysis and graphical display of exploration data, resulting in operational aids not foreseeable a decade ago. Progress has been worldwide and is expanding rapidly. Books 1-10 are supplementing the periodic literature, at least one abstracting service is now active, 11 and an association has recently been formed to encourage and publicize advances in this field. 12 With the diversity of applications, only partial coverage of the subject can be made at any single symposium. Four of the six papers in this section report on the current state-of-the-art in selected areas of interest: graphics, time-sharing, mathematics, and economic analysis. The remaining two papers are descriptions of advanced statistical techniques for gaining additional information during exploration, and illustrate methods which will become more commonly applied in the future. "Computer Graphics: A New Tool for Exploration and Mining" describes the use of a computer and accessory equipment as an information retrieval device, graphically merging and displaying pertinent information for visual inspection and interpretation. This is a rapid means of studying information which has been pre-stored in a form accessible to the computer. Time-sharing is a means of achieving a comparable rapid response when calculations are being performed. The paper, "Some Applications of Time-Sharing in Mining Geophysics," describes the experience of one company using a time-sharing facility for geophysical computations. Another paper on this subject, stressing mining applications, has recently been published. 13

Jan 1, 1969

By Wayne N. McKee, Scott A. Lewis

"Introduction to the Syncrude OperationSyncrude Canada Ltd., located 42 km north of the city of Fort McMurray, Alberta, (Fig. I) is an integrated operation that has produced synthetic crude oil from the Athabasca oil sand deposit since 1978.The operation, consisting of a surface mine, an extraction plant, a bitumen upgrader, and a utilities plant, is currently capable of producing over 60 million barrels of crude oil per year. Production is expected to increase to 70 million barrels of crude oil per year over the next five-year period with no major changes to equipment or process planned.The Syncrude surface mine, producing a total of 675 000 tonnes of ore and waste per day, rates as one of the largest mines in the world. A strip mining method is utilized, with two or three operating benches necessary to excavate a total depth varying between 60 m and 70 m. The 20 m to 30 m of overburden is removed by electric and hydraulic shovels and 200-ton haul trucks, and dumped in the mined-out pit for final storage. The overburden operation creates a flat bench near the top of the ore zone on which the four 60 m3 draglines operate. The draglines excavate interbanded ore and waste in the highwall, with ore placed on the operating bench in windrows, and waste returned to the mined-out pit. The windrowed ore is reclaimed by four bucketwheel reclaimers, and discharged onto a conveyor system for transfer to the extraction plant."

Jan 1, 1993

By C. A. Allen

FOR over three years we have been endeavoring to reduce the number of fatalities and minor accidents in Utah. The physical condition of the o? Represents the average of 4 States mentioned excluding the catastrophes indicated. FIG. 1.-NUMBER KILLED PER MILLION SHORT TONS OF COAL PRODUCED IN COLO¬RADO, NEW MEXICO, UTAH, WYOMING, AND BITUMINOUS MINES OF THE UNITED STATES, 1914 TO 1920. mines, concentrators, and smelters is good, yet the number of accidents,

Jan 5, 1922

By Miroslav Raudensky, Kallol Bera, Jaroslav Horsky, Jee G. Chang, Ampere A. Tseng

"A combined experimental and finite element approach to study the local heat transfer coefficient is presented in this paper. The heat transfer coefficients at different cooling regimes in a roll are quantified by an inverse heat conduction technique; the heat transfer phenomena involved are then discussed. A discussion of the application of the heat transfer information found in the present study for better design of a roll cooling system is also included. Finally, an identification of areas where further work is needed is presented.IntroductionIn metal rolling processes, the roll is used as a tool to deform the workpiece at very high speeds. As shown in Fig. 1, the heat transfer phenomena involved in the process are complicated by the interaction between the roll and the strip, mainly including 1) the heat transferred from the workpiece to rolls in the contact regions, 2) the heat created in the interface due to the deformation of the workpiece and the friction between the workpiece and roll, and 3) the heat removed by watercooling as well as the ambient air. All of these transport phenomena occur at extremely high pressure, high speed, and high heat flux; these make the control of the roll temperatures an extremely challenging problem.In hot rolling, proper cooling of rolls can lead not only to improve the roll shape quality by controlling the thermal crown of the roll, but also to extend the roll life by minimizing the thermally induced stresses [1,2]. Also, knowledge of roll temperatures can contribute to insights about the roll/workpiece interfacellubricant behavior, and lead to the desired surface condition of the workpiece. Therefore, adequate roll cooling or control of roll temperatures is of critical concern to mill designers and process engineers. In order to have proper operation of the process, a good understanding of the influence of cooling practices on the roll is essential [3]."

Jan 1, 1994

By A T. Spathis, M L. Lawlor-O’Neill

A methodology for the inversion of a scaled charge weight superposition model to predict peak particle velocity (PPV) has been examined. The inversion involves two steps: first simulated annealing is used to get an initial estimate of the model parameters; and second, these parameters are used as input to a quasi-Newton non-linear optimisation method, used to refine the value of the parameters. The methodology recovers the three required parameters (two charge weight scaling parameters and a time window width) and does this directly from a single production blast for a given point of interest. It has been tested on a synthetic example and recovered the input model parameters successfully in the presence of introduced noise with a coefficient of variation ranging up to ten per cent. Another test used the vibration measurements of three tunnel blasts monitored during the construction of the Citybanan tunnel in Stockholm. In this case, the three model parameters are found from one blast and for a given point of interest, and the PPV at the same point of interest is predicted for the second and third blast fired in the same vicinity as the first blast. The three blasts used different firing sequences. The predicted PPV limits use a confidence interval determined from the scatter in the peak levels obtained from the single calibration blast. The methodology was able to predict an upper bound for the PPV in 21 of the 26 tunnel blast vibrations studied. These predictions improve on a previous study involving the same model but which did not use the inversion process above. Given this reasonable success, further testing of the method on other data sets and alternative forward prediction models is recommended.CITATION:Lawlor-O’Neill, M L and Spathis, A T, 2015. An inversion method for the prediction of peak particle velocity in blasting, in Proceedings 11th International Symposium on Rock Fragmentation by Blasting, pp 97–108 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 24, 2015

By Matthew Violot

Introduction ?Located off highway 6, approximately 5 km, SW of Thompson, Manitoba ?Base metal mine: Nickel? Maximum Depth: 4100 ft ?Started Production in 1966 (INCO, 2006)?Halted in 1978?Re-opened in 1989 ?Two types of mining:?VBM (vertical block mining)?Cut and Fill 1.1 Problem ?Birchtree mine is experiencing failures and undesirable dilution in some of their stopes. ?Time can have a large effect on open stopestability. ?Birchtreeis interested in how time is affecting the stability of their stopes. ?The study focuses on the lower 84 complex, which extends from 2750 to 4100 foot level.

Nov 1, 2011

By Poole GR

An unusually high flow of water from an oxtr.iction panel in Wongawilli Colliery pr,;npted the investigation of the possible sources of the water. It is more probable that water is derived f r,m sources adjacent to or within the Woo ' iwi 1 I i Coal rat her than by direct t r.onnuni n i"n from any surface source.

Jan 1, 1986

By Frederic Benard

THIS paper constitutes a preliminary report on experimental work done to date on the anode-furnace treatment of blister copper containing relatively high percentages of nickel. The investigation has not been completed but results obtained to date are considered of sufficient interest to warrant publication. Blister copper treated by the Ontario Refining Co. originates from the Copper Cliff smelter of The International Nickel Company of Canada, of which the former is a wholly-owned subsidiary. The blister as received contains from 0.50 to 1.50 per cent Ni, and in this respect differs from that treated by other refineries on this continent. During the anode-furnace treatment, only a portion of the nickel content is removed, and of the amount remaining in the anodes a varying percentage is found in the anode slimes. This necessitates a more extensive treatment than ordi-nary, nickel-free material. Sometimes it is necessary to repeat roasting and leaching operations several times before the nickel content is low enough to permit the slimes to proceed to the doré furnace. This, besides increasing treatment charges, causes greater selenium stack losses and involves a longer tie-up of precious-metal values. Therefore this investi-gation was undertaken with the aim of determining the factors influencing the diversion of nickel into the anode sludge. From experience it was known that by keeping the nickel content of anodes at 0.55 to 0.60 per cent maximum a relatively satisfactory slime resulted. One avenue of attack therefore was developing improved elimination in the anode-furnace treatment so that the anode content mentioned above was not exceeded. Another angle was to improve the solubility, during electrolysis, of the nickel constituent in the anodes, thus decreasing the percentage diverted to slimes. It may he mentioned here that nickel dissolving electrochemically and entering the electolyte pre-sents no difficulty from a treatment standpoint. Both of these approaches were studied and are discussed sepa-rately below.

Jan 1, 1938

By S. E. Olsen, M. Tangstad, G. Tranell, K. Berg, S. Gaal

In this study, the reduction behaviours of MnO and SiO2containing slags by solid carbonaceous materials was investigated in both small and larger-scale laboratory experiments. Five types of carbonaceous material were investigated: 2 graphites, industrial coke, anthracite and eucalyptus charcoal. The effects of the reductant type/properties on the reduction kinetics, metal composition and metal yield, have been quantified. Results show that the reduction rate is highly dependant on the type of carbon used. It was found that the reductant type significantly influenced the SiO2reduction while it did not seem to have a large effect on the MnO reduction. This may be due to the different CO2and SiO reactivities of the materials.

Jan 1, 2004

By M. Unesi, S. Haj Mohammadi, M. R. Abdoli, M. R. Garmsiri

"Hydrocyclone-thickener circuit is a promising solution to enhance the dewatering efficiency in mineral industries. The challenges in the circuit is reducing particle size in the thickener feed and the good feature is a rise in the retention time of sediments in the thickener. In this work, the effect of particle size, bed depth and residence time on the thickener performance were investigated. In this order, pilot scale columns were employed at Sarcheshmeh and Shahrebabak copper complexes. Furthermore, the influence of residence time was differentiated due to the variations in the bed depth and settling flux. Moreover, a new approach was introduced to estimate solids residence time in the thickener. results indicated that with smaller particles that are introduced to the column, the bed density as well as thickener discharge solids concentration dropped significantly. It was found that thickener discharge solids concentration fell from 59.6 to 33.8 % with reducing particle size from 130 to 22 µm in the settling flux of 20 t/m2/day. Additionally, it was found that longer residence time and deeper bed resulted in an increase in the thickener performance while the bed depth has a stronger effect. It was proved that employing a hydrocyclone prior to the thickener resuted in an increase in the dewatering efficiency.INTRODUCTION Thickeners are widely employed in mineral industries to recycle tailings and concentrate water content. A limited fraction of suspension water content is recycled using a thickener. For instance, about 50 percent of tailings water content could be recycled using a shallow bed thickener during copper processing. Since the scarcity of global water resources became more serious, the demand for improving dewatering efficiency in mineral industries became more significant [1]. A number of solutions were recommended to enhance dewatering efficiency of thickeners including optimization of current thickeners, employing deep bed thickeners and utilizing thickener-filter or hydrocyclone-thickener circuits. Optimization of existing thickeners is essential, however, it does not meet the significant demand for recycled water. The application of deep bed thickeners (known as paste thickeners) has been rising in the mineral industries [2] due to a higher dewatering efficiency while its costs is remarkable."

Jan 1, 2018

By T. J. Kolokoto

This paper is based on a project conducted at Khomanani 2 shaft, Anglo American Platinum Limited. The main objective was to find an alternative support element in stopes to address the falls of ground (FOG) problem experienced at this shaft. Literature review was the major method used in the investigations. Resin bolts or any 1.5 m in-stope roofbolts were considered. The shaft was making use of 0.9 m long friction bolts, and these could not prevent the FOG experienced. Observations indicated that the FOG resulted in fall-out thicknesses averaging to 1.1 m, which is greater than the supported length of the friction bolts. The implementation of 1.5 m long bolts was recommended as a result of the project. These bolts will be able to address the fall-out thickness and provide sufficient support resistance to mitigate FOG. The chosen support element will result in a relatively small increase in support costs.

Jan 1, 2013

By J Zhou, L Crompton, K P. Galvin, J L. Sutherland, C P. Lowes, C Bezuidenhout, J Bijzet

Platinum Group Metal (PGM) bearing ores from the Upper Group 2 (UG2) reef often contain significant concentrations of chromite which can potentially be upgraded to produce a saleable product. A common approach is to implement gravity separation on the PGM flotation circuit tailings. However, where the particle size range of interest is broad and the lower size limit ultra-fine, the challenge is how to maximise the recovery at a saleable product grade without compromising throughput. This study was concerned with the performance of a REFLUX™ Classifier for beneficiation of a PGM bearing chromite ore and the benefits of size classification. The sample had a nominal top size of 0.5 mm and was processed over the complete size range and in two discrete size classes following classification at 106 µm. The primary goal was to produce a concentrate exceeding 40 wt. per cent Cr2O3, ideally approaching 42 wt. per cent Cr2O3, with minimal PGM losses above 106 µm. A major challenge was to process at the required solids throughput in a single stage with the feed pulp density constrained to a nominal upper limit of 30 wt. per cent solids. It was found that varying the controller density set point of the REFLUX™ Classifier produced strong control of the product grade. Products as high as 41.1 wt. per cent Cr2O3 were produced at 78.6 per cent recovery for the +106 µm material, while in the −106 µm portion the product grade was as high as 41.4 wt. per cent Cr2O3 at 83.2 per cent recovery. Processing the feed in discrete size classes enabled the volumetric feed and fluidisation rates to be optimised for a given application; hence, superior performance was achieved at the finer sizes. This work has demonstrated the value in considering feed preparation as well as technology selection in developing a robust process solution.

Aug 24, 2022

By W. W. de Graaf, M. J. Ntsekhe

Klipspruit Colliery is experiencing coal losses, which leads to a negative impact on coal production and subsequently loss in revenue. This study aimed to identify the possible causes of coal losses in the No. 4 upper and lower seams. The objectives were to identify potential sources of coal losses through a literature survey, to identify areas where the coal losses occurred, to determine factors affecting coal losses, and to identify the most cost-effective methods to reduce coal losses. Highwall losses, top-of-coal losses, and coal edge losses were identified as the major areas of coal loss at Klipspruit. These losses were mostly attributed to the drilling and blasting practises of the pre-split, interburden waste, and the coal seams. Recommendations include re-visiting the current pre-split design and the tolerances adopted for the interburden and coal seam drilling and blasting design. It is furthermore recommended that Klipspruit implement a continuous improvement plan for the drilling and blasting and refresher training for the blasting crew and operators.

Jun 10, 2024

By B. S. Agbenuvor, R. Morrison, V. Jokovic, C. Antonio

Body breakage usually involves breakage of particles by compression between two surfaces or impacted against a rigid surface, with the latter of interest in this current study. This mode of breakage has been identified to be the most elementary size reduction process and the most effective breakage process in comminution devices. It has been found in the literature that the progenies produced from this form of breakage possess a residual velocity at which they move, after the breakage event. In the pursuit of efficiently utilising applied comminution energy, a laboratory-scale breakage device has been developed to deliver precise specific impact breakage using the concept of a fast-moving hammer and a slow-moving particle to effect breakage. The residual velocities of the progenies from the breakage event may be used to generate secondary breakage without further addition of energy if the particle encounters a stiff obstacle such as a steel plate at right angles to its path. To measure the extent of secondary breakage, the steel wall of the device was lined with a rubber material to suppress the second set of breakage events. The performance of the new device is analysed, based on calculated t10 values and measured residual velocities of the moving daughter particles. Testing involving anvils showed a much finer PSD and higher t10 compared to the test involving rubber lining. This finding is corroborated by the measured residual velocities of the progenies. The resulting energies calculated from the measured residual velocities of the progeny were found to be approximately 42-88% of the primary specific impact energy. This retained energy was found to be sufficient for secondary breakage. Keywords: Impact breakage, residual velocity, secondary breakage, energy utilisation

Jan 1, 2020

By Dunbavan M, Mallett C. W

The sequence of development and back analysis of the failure of a spoil pile in the 1B pit of the Moura Mine are given. The mode of failure was a two-wedge mechanism with a basal slip plane passing through a clay band about 2 m below the pit floor. Remedial actions for improving spoil pile stability are discussed.

Jan 1, 1981

By Nawal Kishore, Nilesh Pratap Singh, Amit Kumar Verma, Vikram Seervi

In India, despite its natural abundance, demand for coal exceeds its countrywide supply due to failure to achieve high production targets, especially in opencast mines, which are responsible for 94.98 percent of total raw coal production in the country. Employment of technological solutions, such as surface miners, is key to achieving higher coal production and productivity in an environmentally friendly manner, especially in populated areas adjacent to the mining zone. This technology eliminates blast hole drilling, blasting and primary crushing units, thus reducing related environmental hazards like ground vibration and fly rocks.

May 1, 2023