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By Barun Gorain, Andy Stradling

"The traditional metallurgical scale-up techniques for flotation plants are based on lumped flotation rate constants, dimensionless hydrodynamic numbers and the use of safety factors. Once the plant has been designed, the flotation principles that govern scale-up play almost no role in the optimisation of the circuit to meet its metallurgical targets. This deficiency can potentially lead to a plant design incapable of meeting its targets, especially when circuits incorporate large flotation cells. This paper demonstrates the application of the k = PSbRf model in providing a suitable framework for flotation modelling, scale-up and circuit optimisation, thus presenting an integrated approach to the problem. Studies were conducted at Teck Cominco’s Red Dog concentrator to characterise cell hydrodynamics, gas dispersion properties, fioth flow behaviour, entrainment and ore floatability to obtain the key data necessary to develop a model for the flotation circuit. The findings of these studies are presented in this paper, which provide valuable insights into the modelling and optimisation of the Red Dog flotation circuit.INTRODUCTIONThe traditional methodology for flotation scale-up and plant design is based on the rule-of-thumb with safety factors, dimensionless hydrodynamic group similitude considerations, etc. With the recent trend towards larger flotation cells with volumes of 150 m3 and greater in concentrators, the problem of scale-up has become even more acute. The scale-up factors that may have been tolerated on smaller cells are not applicable to larger cells. The transportation of froth in these large cells adds further complexity to the problem. Arbiter et al. (1980) foresaw this problem and pointed out that if scale-up were attempted by rule-of-thumb and trial-and-error, then the probability of failure would increase with scale. This problem is confounded by the fact that the design and scale-up considerations used for a new flotation circuit play almost no role in optimisation of the circuit to meet its metallurgical target. This results in a plant design incapable of meeting its metallurgical targets. There have been several instances where new concentrators have required significant circuit modifications and additional capacity to achieve design targets."

Jan 1, 2002

By N. J. Themelis, R. V. Flint

In a four-year period between 1973-76, the Metal Mining Division of Kennecott Copper Corp. conducted a company-wide program of operations improvement which involved line and staff personnel from all company functions. Specialist teams performed detailed studies of all operational aspects at Kennecott's four copper mines and concentrators, four smelters, and two electrore-fineries. The specific recommendations that resulted may transform the Metal Mining Division into the country's lowest cost producer of copper by the mid-1980s. In this article, N. J. Themelis and R. V. Flint describe the mechanics of MMD's integrated approach to operations improvement.

Jan 6, 1979

By A Riles

"Three issues of relevance in a modern tailings storage facility (TSF) are:geotechnical stabilitymanaging acid rock drainage (ARD) from pyritic tailingsmanaging the tailings from cyanidation of gold ores. Drawing on examples from both copper porphyry flotation and sulfide-hosted gold ores, this paper demonstrates that giving some weight and importance to the process tails properties upfront can influence the flow sheet and not only improve tailings management effectiveness but also impact positively on economics. In the case of a typical copper porphyry ore with moderate pyrite content, the rougher tail in a conventional high pH selective flotation step is usually classified as potentially acid generating (PAG). To avoid the generation of ARD within the tailings and the requirement for a costly plastic lining, subaqueous deposition is recommended, which in turn has negative implications for tailings stability, consolidation and closure. Adopting a neutral pH rougher stage rejects silicate gangue but recovers pyritic material to the cleaners for a subsequent selective flotation stage, often after regrinding. This effectively quarantines the PAG pyritic material in a much lower volume cleaner tail, which can then be appropriately encapsulated within a larger non-lined flotation tails facility. It also facilitates cyanide leaching of the cleaner tail for gold recovery, with the encapsulated tailings facility being suitable for cyanidation tails storage. A case study from Europe is examined. For gold ores where the gold is sulfide-hosted, but not refractory, a flotation route with cyanidation of the concentrate can similarly produce the majority of tailings as a benign flotation tail and again quarantine the low volume concentrate leach tail in a small encapsulated cell with appropriate residual cyanide management measures applied. Overall economics for intensive leaching of a low volume concentrate stream can also be surprisingly positive. A feasibility study design example of the process and TSF is presented. CITATION: Riles, A, 2016. An Integrated Approach to Optimising All Concentrator Products, Including Tailings, in Proceedings The Third AusIMM International Geometallurgy Conference (GeoMet) 2016, pp 341–346 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Jun 15, 2016

By E. Córdova, A. Anani, W. Nyaaba

Optimization of panels, haulage fleet, and waiting area involves deterministic and low-fidelity methods and experiential knowledge. The process is challenging because coal recovery and operational capabilities must be considered in the solution. The approach in this manuscript comprises the development of an integrated stochastic simulation model of a coal room-and-pillar system that addresses these challenges. The decision variables evaluated are panel width, number of shuttle cars, and change-out time (COT). The results show that the mine should implement the shortest possible COT, decreasing the cycle time and thereby increasing productivity and continuous miner (CM) utilization. The highest productivity and CM utilization for a fleet size of three shuttle cars is found in the 15-entry panel width. For the evaluated fleet sizes, the 19-entry panel width is optimal for the four and five shuttle cars. Among the three variables studied, panel width and fleet size had the most significant effects (5% increase) on the CM productivity, cycle time, and utilization.

Apr 2, 2022

By T Huynh, K Tungpalan, E Wightman, M Edraki, S Palaniandy

Most preventive environmental management practices promote proactive integrated approaches to waste management. For example, life cycle assessment is often used to find the ‘hot spots’ of environmental burdens. This kind of approach is often based on generic data and has rarely been used for tailings. Besides, life cycle assessments are less useful for designing operations or simulating changes in the process and consequent environmental outcomes. It is evident that an integrated approach for tailings research linked to better processing options is needed.The aim of this Nextmine™ project is to develop new tailings management models by streamlining orebody characterisation, process optimisation and rehabilitation. We present an integrated tailings management approach and preliminary results from a case study. Combined grinding and flotation models were developed using geometallurgical data from the orebody, to predict the properties of tailings produced under various processing conditions. The modelling scenarios based on the case study data provide the capacity to predict the composition of tailings and the resulting environmental management implications. For example, the type and content of clay minerals in tailings will affect the geotechnical stability and water recovery. Clay content will also influence decisions made for paste or thickened tailings and underground backfilling.CITATION:Edraki, M, Huynh, T, Wightman, E, Tungpalan, K and Palaniandy, S, 2015. An integrated approach to proactive tailings management, in Proceedings Tailings and Mine Waste Management for the 21st Century , pp 323–332 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 27, 2015

By R. L. Grayson

An integrated approach to mine management is presented. A model for achieving the level of control of operations critical to surviving in the current market is outlined. The integrated Production and Cost Management System (PRaCaST) is designed to provide mine managers with a reliable, quantitative, decision-assisting system that can be used in formulating timely responses to complex fluctuations in operations. PRacaST consists of a productivity forecast model, sectional bills of materials containing current resources consumption factors, a linear programming scheduling model, and operations analyses that focus on production and cost performances. The system is applied to an underground coal mine.

Jan 1, 1988

By Ian Misich

A research programme has been undertaken to evaluate and predict the effect of total extraction of coal by underground methods on the superimposed strata, aquifer systems and ground surface in the Collie Basin. Western Australia. The research work has integrated comprehensive field monitoring of surface and subsurface subsidence with empirical, analytical and physical modelling in an effort to develop an effective predictive tool which can be used in all mining scenarios. Early results indicate that although each method has certain limitations, this approach has enabled the researchers to develop a very good understanding of the subsidence mechanisms from the mine panel through to the surface in the weak, water saturated sediments in the Collie Basin. Given that both subsurface and surface subsidence characteristics have tied in well, greater confidence can be held for predictions made by representative models.

Jan 1, 1993

By Murali M. Gadde, John A. Rusnak

Rock mass classification systems are extremely useful for site characterization and have been employed by the rock mechanics community for several decades. While empirical in nature, the classification systems provide a viable means to quantify the nature of rock mass, which is necessary for stability analyses. In U.S. coal mines, the Coal Mine Roof Rating (CMRR) is the most widely used classification system for several purposes, including sup-port selection, chain pillar design, assessing the stability of extended face cuts, etc. The Analysis of Roof Bolt Systems (ARBS) is an empirical method developed from the CMRR to guide selection of roof bolts as the primary support system in U.S. coal mines. In this paper, the experience of Peabody Energy in applying ARBS to sup-port design is discussed. In general, data from the Peabody mines show that ARBS predictions match well with field conditions. Peabody, however, does not use ARBS as the stand-alone methodology for support selection. Peabody uses a two-pronged approach in which the support requirement is initially estimated from the classification method, and then numerical modeling is used to select the proper reinforcement system. Such an integrated approach is necessary, as ARBS suggests only the “amount of steel” that may be used to support the roof and does not specify which type of roof bolt to use. A case study is used to demonstrate the usefulness of ARBS and Peabody’s integrated approach to support design. Also, the application of ARBS at several Peabody mines showed a very good correlation with support cost. The correlation indicated a direct relation between bolting cost and the ARBS value.

Jan 5, 2007

By D. S. Limpenny

Marine benthic habitats are vulnerable to the influence of a wide range of anthropogenic activities (e.g. sand and gravel extraction, dredged material disposal and trawling). Traditionally, benthic ecologists have relied on point sampling techniques such as grabs, corers and dredges to provide information on the physical nature of the substrates and their associated benthic fauna. However, information of this nature only relates to the specific point on the seabed from which the sample was collected and the interpolation of such data to predict the wider distribution of substrata and associated fauna may be unreliable. Our approach uses a range of acoustic, photographic and physical sampling methodologies to produce continuous acoustic coverage maps which can be used to assist with the interpretation of faunal distributions. This approach has been used to assess the impacts of marine sand and gravel extraction at the seabed at two sites off the east coast of England in the southern North Sea. The first study site (designated ?Area 222?) is located 20km off the southeast coast of England and was surveyed in 2001 using sidescan sonar, single beam bathymetry, seabed photography and also a 0.1m2 Hamon grab for the collection of benthos and sediment samples. The main objectives of this investigation were to provide an indication of the spatial distribution of the sediments and macrofauna in the wider area encompassing the dredged site, to evaluate the scope for the effects of marine sand and gravel extraction to extend beyond the boundaries of the site and to provide a wider geographical context for time series investigations. At this site, an acoustic basemap was utilised in conjunction with faunal sampling and photographic groundtruthing, to determine the nature and distribution of the seabed sediments and their associated features. Disturbances at the seabed arising from historic sand and gravel extraction activities were mapped, and this information was helpful in establishing biological cause and effect relationships. The acoustic basemap was also used to target biological reference sites against which the effects of adjacent man-made disturbances could be evaluated.

Jan 1, 2004

By A. Chrzanowski

The integrated approach to monitoring surveys is based on a simultaneous utilization of geodetic, photogrammetric and geotechnical measurements of displacements, tilts, strains and any other geometrical parameters of deformation. New techniques for the integrated surveys are being developed at the University of New Brunswick in cooperation with the Canada Centre for Mineral and Energy Technology. A telemetry system for continuous monitoring of geotechnical measurements under difficult climatic and topographic conditions has been constructed and successfully tested in a coal mining area in western Canada. A generalized method for analysing the integrated deformation measurements has been developed and applied in the test area to yield three dimensional empirical modelling of surface movements from geodetic, photogrammetric and tilt surveys. The most appropriate model can be chosen from a statistical assessment of several modelling possibilities. The empirical model of the deformation can be employed in a "calibration" of the prediction (deterministic) model of the ground movements. A computer programme for two- and three-dimensional finite element modelling of elasto-plastic deformations has been developed at UNB as a part of the integrated approach. The :EM has been tested in predicting deformation in the test area in difficult geological conditions which were associated with an extraction of a steeply inclined coal seam. The results gave good agreement with the actual displacements obtained from geodetic measurements and confirmed the existence of a suspected fault.

Jan 1, 1984

This paper contends that optimisation of energy resources through active control and predictive simulation modelling is possible, and that such monitoring leads to large savings in the electricity costs of hot mines (where refrigeration has to be employed). In addition, active monitoring and control can positively affect the establishment of a safe, healthy and productive working environment. In the entire optimisation process certain guidelines were set to ensure that the requirements of the Mine Health and Safety Act were met (South Africa). Varying the quantity of air supplied underground by means of variable speed drive (VSD) fans is one of the crucial factors in the interactive approach towards the optimisation of ventilation, as is refrigeration and the pumping requirements associated with refrigeration. This article highlights the interaction between the amount of air supplied and the effect it has on refrigeration requirements underground. This article also considers the effect that this would have on contaminant control. Various tools are available for ventilation and cooling design for mining. A lot of these tools are based on the assumption of steady state conditions and do not take into account instantaneous changes in conditions, day-to-day, or hour-to-hour (such as for temperature and contaminants). They also do not take into account the optimisation of energy resources related to the creation of the acceptable underground conditions. With these tools worst-case and best-case scenarios are identified, and strategic decisions are made accordingly. Currently, the amount of the fresh air, the velocity of the air, and its general temperature in the mine are only changed when one production phase changes into another (or when unacceptable conditions occur as a result of poor design or neglect). This means that during a specific production phase (which can last for several months), there can be an oversupply, or undersupply, of energy resources, which will obviously affect the concentration levels of the various contaminants (through under or oversupply of air).

Jan 1, 2005

By M. Canty

An innovative biological treatment system designed to detoxify cyanide and nitrate and immobilize metals from cyanide leach operations is described. A pilot-plant demonstration was conducted to detoxify cyanide and immobilize several metals from a process stream at the McCoy/Cove Mine. Testing was performed under the EPA's Mine Waste Technology and Superfund Innovative Technology Evaluation Demonstration Programs. This technology was successful in detoxifying cyanide and effective in removing metals. The pH was consistently neutralized and nitrates were successfully removed. Results show that biological treatment can offer an innovative, cost-effective alternative for the treatment of mining wastewaters.

Jan 1, 1999

By H. Eccles

BNFL, an internationally acclaimed company noted for its nuclear fuel cycle services and waste management technologies, collaborated with Viridian BioProcessing Ltd, a small company acknowledged for developing environmental biological processes, and an internationally recognised professor of biological sciences, to develop an unique bioremediation process for treating toxic, heavy metal contaminated land. This paper describes the process, with particular reference to the problem and scope of land contamination with toxic, heavy metals and the current available technologies. The process technologies are based on using indigenous, soil micro-organisms which can be stimulated to produce acid or sulphide ions to mobilise or precipitate the heavy metals respectively. Laboratory studies have indicated metal removal efficiencies of greater than 90 % can be achieved, whilst recovery efficiencies from the metal loaded leachate are even higher at approximately 95%.

Jan 1, 1996

By Jennifer Drake, Edward T. Moriuchi, Jennifer A. Hill

SEAMSYS and CSD/SMP are sets of computer programs that assist geologists and mine engineers in modeling and evaluating coal properties. The systems are tailored for treatment of waste and coal quality data, including metallurgical coal product capabilities. The gridded SEAMSYS model honors all drillhole data and incorporates user- defined mining parameters, losses and dilutions, and operational constraints. A variety of reserve reports and graphic displays are available from the model. Preliminary mine planning is accomplished through automatic cut generation and production targeting. CSD/SMP refines the preliminary plans to help anticipate the consequences of various mine schedules and evaluate equipment capacity requirements.

Jan 1, 1983

By C Tapia Cortez, A G. Dempster, R Fradet, S Saydam, T de Roche, R Shishko, J Coulton

Human ventures into space are entering a new phase in which missions formerly driven by government agencies are now being replaced by those led by commercial enterprises – in launch, satellite deployment, resupply of the International Space Station and space tourism. In the not-too-distant future, commercial opportunities will also include the mining of asteroids, comets, the Moon and Mars. This research examines the role of off-Earth mining in a growing space economy. In this investigation, the term ‘mining’ is taken to embrace minerals, ice/water and other in situ resources. As the off-Earth mining initiative could be the engine that drives the space economy, it would be useful to understand what off-Earth mining market conditions and technology requirements are needed for that economy to prosper. These specific elements are studied in the wider context of creating an economy that could ultimately support a sustainable Mars colony. The methodology for developing the model focuses on the extraction of ice from the surface of Mars to produce propellant and water for life support for a possible colony.CITATION:Saydam, S, Shishko, R, Tapia Cortez, C, de Roche, T, Fradet, R, Coulton, J and Dempster, A G, 2015. An integrated economics model for in situ resource utilisation in support of a Mars colony, in Proceedings Third International Future Mining Conference, pp 305–312 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 4, 2015

By MANZOOR ALI BROHI, IZHAR MITHAL JISKANI, Atta Ur Rehman, SHUAI HAN, MUHAMMAD TARIQ, NIAZ MUHAMMAD SHAHANI

A thorough improvement in mine safety is contingent on many factors that require scientific decision-making for selection and prioritizing of important factors for safety improvement. Their analysis using an established scientific method can improve mines’ safety conditions and assist the administration for informed decision-making. This research establishes a mine safety evaluation index and proposes an integrative model based on the entropy weight and grey clustering methods. In the evaluation index, 27 significant factors of safety are identified and categorized into 7 criteria. The proposed evaluation system analyzes all indicators according to Pakistan’s current mine safety situation and their significance for potential safety improvement in the future. Results reveal that current safety practices are outdated due to a lack of mechanization in the mining industry and minimal capability of the management to achieve the desired safety targets. Appropriate safety policies and safety education are missing in the daily working environment. The lack of overseeing the execution of safety operations and the lack of ambition and strong work ethic workers contribute to the paucity of mines’ safety conditions. The prevention and control systems to manage risks and hazard are not in place, and the working environment in mines remain difficult. Therefore, to have enhanced mine safety, important factors can be addressed in chronological order, as presented in this paper. The proposed methodological approach can be applied to other prioritization applications to analyze the indicators and determine the appropriate management strategies.

Jun 14, 2021

By MANZOOR ALI BROHI, IZHAR MITHAL JISKANI, Atta Ur Rehman, SHUAI HAN, MUHAMMAD TARIQ, NIAZ MUHAMMAD SHAHANI

The analysis of mine safety indicators using a scientific method can improve mine safety and assist management in making informed decisions. This research establishes a mine safety evaluation index and proposes an integrative evaluation model based on the entropy weight and grey clustering methods. The index consists of 27 indicators classified into seven criteria: working environment (A), miners’ attributes (B), safety policies and education (E), prevention and control (F), and monitoring and supervision system (G). Using Pakistan’s mine safety situation as a case study, the proposed model categorized the indicators into five safety levels (very low, low, medium, high, very high) for the present situation and for their relevance in terms of future safety improvement. The results show all of the criteria falling into the very low level for the current mine safety situation. Three of the criteria — C, E and G — are identified as having very high levels of significance for future safety improvements.

By M Wortley, A Cantarutti, G J. Clarke, C

As part of a broad program to optimise the performance of their grinding circuit, BHP Billiton Cannington have installed an OCS¬ Expert system together with three VisioRockÖ online particle size analysis cameras. The main purpose of the system is to stabilise grind size and feed to the flotation circuit. This particular application of OCS¬ is the first installation to incorporate Metso Minerals Process Technology-Asia PacificÆs (MMPT-AP) Dynamic SAG/AG Mill Model, which is able to predict numerous mill parameters that were previously unable to be measured with the existing plant instrumentation. Integrated into the logic of the control algorithm are online vision based, particle size measurements of the AG mill feed and recycle crusher product. This paper will describe the history of the project from initiation to date, the model and OCS¬ logic configuration, and demonstrate the significant benefits realised at Cannington mine.

Jan 1, 2007

As part of a broad program to optimise the performance of their grinding circuit, BHP Billiton Cannington have installed an OCS© Expert system together with three VisioRockTM online particle size analysis cameras. The main purpose of the system is to stabilise grind size and feed to the flotation circuit. This particular application of OCS© is the first installation to incorporate Metso Minerals Process Technology-Asia Pacific's (MMPT AP) Dynamic SAG/AG Mill Model, which is able to predict numerous mill parameters that were previously unable to be measured with the existing plant instrumentation. Integrated into the logic of the control algorithm are online vision based, particle size measurements of the AG mill feed and recycle crusher product. This paper will describe the history of the project from initiation to date, the model and OCS© logic configuration, and demonstrate the significant benefits realised at Cannington mine.

Jan 1, 2007

By Ola Lindahl, Mark Irving, John Hutchings

"Blasting is a process starting with a geometric description of the block of rock and ending with a pileof fragmented material. A key step in improving the productivity and quality control over the processis the integration of blast planning software, explosive delivery control systems, and blast recordingwithin one seamless customer solution."

Jan 1, 1997