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By Michel Ruel, Ali Soltanzadeh, Benjamin Légaré

High fidelity commercial process simulation packages can be used at different stages of a greenfield project, from initial plant design to operator training in the later stages. However, there are several factors that make the software less attractive for small and medium size brownfield projects, such as the licensing cost and the fact-finding manpower required for model design and simulator maintenance. In this paper a different approach is described. The knowledge gathered from operating personnel was used to implement higher level models based on plant data, operating heuristics, and experience rather than detailed component-level models. The computing platform used was a low-cost, well-established, control system vendor-independent software. Throughout this paper we demonstrate the success of implementing this model-based approach using two industrial examples. The first example is a simulation of the carbon monoxide (CO) distribution system at a metallurgical complex. The purpose of this simulator was to test new control strategies and PLC programs prior to implementation. CO being a toxic combustible gas, validation of the suggested control system changes was necessary for plant safety. Simulation of specific operating conditions helped alleviate concerns and improved plant-wide acceptability of the new operating philosophy. The second example is a boiler simulator at a petrochemical plant. The operator training simulator (OTS) was designed as a platform for experienced operators to practice handling rare or abnormal conditions. A customized medium-fidelity model was developed for this targeted application where the cost of a full scale high-fidelity model could not be justified.

Jan 1, 2016

By Fernando H. Muge

The first application of dynamic pro¬gramming to the problem of grade control and scheduling was by Muge et al (1979) and Ribeiro (1982) who applied it to the simple, two-dimensional case of longitudinal open stoping using two sublevels. In this paper the formulation of the problem is extended to cover the general case applied to a cut-and-fill mining method. The criterion for optimization is the total deviation of the average, grades of mining blocks from the overall average panel grade (or the average grade of a set of mining panels or the mine processing working point). This means to schedule the operation by removing a certain number of mining blocks at a time, subject to the geometric (mining) constraints, and such that the total deviation of average block grades from overall average grade is minimum. The method can be applied to complex orebodies with several ore characteristics and the deviation of each one of these characteristics can be further constrained by specifying maximum values. The method can also be generalised in order to take into account any necessary geometric constraints used to define the mining method. In this paper a case study is presented concerning the mine planning of a complex sulphide orebody located in the South of Portugal. As input for the definition of the mining sequence, a geostatistical numerical model of the orebody was built based on a previous ore typology. The short term planning is used to assess specific mining sequences and the production scheduling is performed on the basis of an objective function (e.g. minimization of grade fluctuation).

Jan 1, 1989

By W. C. Meyer

Surface tension and its control are important in the concentration of ores by froth flotation, both in terms of producing the proper bubble size distribution and to render the ore surface of interest hydrophobic such that adhesion to a bubble will take place. The influence a substance has on surface tension has traditionally been measured using static, equilibrium techniques. Yet many applications such as flotation involve rate-related effects of surface tension where equilibrium values are not reached. In the time frame of 1 - 300 seconds, aging effects have been noted for bubbles formed in dodecylamine acetate solutions; a slow decrease in surface tension occurs until an equilibrium value is reached, as studied by Finch and Smith (1972). Since stationary bubbles do not exist in flotation cells because of the turbulence generated by agitation and aeration, it is more likely that the chemical composition of the bubble is determined during its formation, under dynamic conditions. The chemical composition is extremely important because the induction time required for a particle-bubble entity to collide and adhere to each other is augmented by favorable surface tension (wetting) proper- ties between the surface of the particle and the bubble air-water interface or envelope, as considered by Mackenzie and Matheson (1963). Finch and Lyman (1976) have established that the probability of a "permanent" attachment taking place during this contact time is aided by the ability of an oil droplet (viz. bubble) to relieve non- equilibrium surface tension effects which are involved in the water-thinning process. This Maragoni effect, or surface elasticity, can be considered in the context of particle agglomeration addressed by Kao and coworkers (1975). Water drainage leads to the formation of a collector-frother meniscus appearing between the colliding entities, arising from their combined partial immiscibility in the water phase and promoted by hydrophobic bonding within the interface. Together they constitute a liquid bridge whose force of attraction drawing the particles together is proportional to the interfacial tension existing between the water phase and liquid bridge. This adhesive force shows an approximate linear decrease with separation distance until rupture occurs, that is, FX = Fmax (1 ? X/Xr) (1) for a distance of separation X and rupture distance G. The greater the surface elasticity of the bubble, the greater will be the rupture distance and the better will be the force of adhesion. Since van den Tempel (1965) has related surface dilational properties of bubbles to the elasticity, E, of the film as

Jan 1, 1983

By R. C. Ford, W. L. Niccoli, J. B. Finley

All mining operations are superimposed on natural hydrologic systems. As a result, mining operations are influenced by natural hydrologic processes and require water management systems to successfully conduct mining activities. Managing water and mining-related solutions is a critical task at all stages of the mine life because of the time-dependent nature of natural and mining-related flows. Effective operation of the mining water management system requires a “systems” approach that integrates the time-dependent effects of all water and mine solution handling components. This paper discusses the concept and application of dynamic systems modeling to address the time dependent nature of mining water management systems.

Jan 1, 2002

By B. K. Baird, P. C. Satchwell

The application of cutoffs during and after pit optimization is examined for a lower-grade multimetallic copper deposit. Pit optimization requires calculation of the net revenue associated with each mining block. The calculation incorporates parameters such as metal prices, grades and expected recoveries, mining and processing costs, smelting and refining charges, and penalty element and royalty charges. Sensitivity analysis during pit optimization reveals which parameters have significant effects on the total contained resource tonnage and total contained nondiscounted revenue in the optimized pit. The cumulative effects of changing several of the more-significant parameters are investigated The application of a copper cutoff grade to a block inside the optimized pit could result in the less-than-optimal extraction of the resource. A block with a copper grade below the applied cutoff could be economic due to the presence of other metals. Conversely, a higher-copper-grade block may be subeconomic. Also discussed are the merits of applying a copper-grade cutoff, an "equivalent-grade" cutoff and a dollar-per-ton cutoff to blocks inside the optimum nit.

Jan 1, 2002

By B. K. Baird

The application of cutoffs during and after pit optimization is examined for a lower-grade multi-metallic copper deposit. Pit optimization requires calculation of the net revenue associated with each mining block, incorporating parameters such as metal prices, grades and expected recoveries, mining and processing costs, smelting and refining charges, and penalty element and royalty charges. Sensitivity analysis during pit optimization reveals which of these parameters have a significant effect on the total contained resource tonnage and total contained non-discounted revenue in the optimized pit. The cumulative effect of changing several of the more significant parameters is investigated. Application of a copper cutoff grade to a block inside the optimized pit could result in the less than optimal extraction of the resource. A block with copper grade below the applied cutoff could be economic due to the presence of other metals. Conversely, a higher copper grade block may be sub-economic. The relative merits of applying a copper grade cutoff, "equivalent grade" cutoff and dollar value per ton cutoff to blocks inside the optimum pit are discussed.

Jan 1, 1999

By B. K. Baird, P. C. Satchwell

The application of cutoffs during and after pit optimization is examined for a lower-grade multi-metallic copper deposit. Pit optimization requires calculation of the net revenue associated with each mining block, incorporating parameters such as metal prices, grades and expected recoveries, mining and processing costs, smelting and refining charges, and penalty element and royalty charges. Sensitivity analysis during pit optimization reveals which of these parameters have a significant effect on the total contained resource tonnage and total contained non-discounted revenue in the optimized pit. The cumulative effect of changing several of the more significant parameters is investigated. Application of a copper cutoff grade to a block inside the optimized pit could result in the less than optimal extraction of the resource. A block with copper grade below the applied cutoff could be economic due to the presence of other metals. Conversely, a higher copper grade block may be sub-economic. The relative merits of applying a copper grade cutoff, “equivalent grade” cutoff and dollar value per ton cutoff to blocks inside the optimum pit are discussed.

Jan 1, 1999

By G. M. Dowo

The widespread environmental damage caused by slimes dam construction requires rehabilitation as one of the key management strategies towards land restoration. From the time when Mhangura Copper Mine in Zimbabwe was shut down in 2000 due to viability problems, no follow-up studies were carried out on the slimes dams to assess their development with respect to ecosystem function and longterm recovery. The ecosystem function analysis (EFA) method was thus employed to achieve this end. EFA is a monitoring procedure that establishes how well an ecosystem functions as a biophysical system through the use of rapidly assessed field indicators. The field procedure makes use of simple visual indicators that are related to various soil surface processes. Conventional sampling methods are used to collect the vegetation data. The data was first analysed using landscape function analysis (LFA) software packages and then with various multivariate statistical techniques. In total 27 species were recorded from 14 families; 21 of them occurring in the acacia woodland and only 8 on the slimes dams. Hyparrhenia sp. was the dominant grass on Dam 5 and Imperata cylindrica dominated Dam 6. Acacia saligna was the most abundant tree species on the dams. The tree layer on the slimes dams was not as developed as the grass layer. The rehabilitated slimes dams converged with the natural woodland for the LFA indices of stability, nutrient cycling, and infiltration, which suggested a high level of functionality. The main factors affecting the sustainability of the rehabilitation are postulated to be fire, grazing, and tree harvesting. The study contributed to the importance of, and methods used for, assessing ecosystem function on rehabilitated slimes dams in Zimbabwe, which are often ignored as most efforts focus on the establishment of vegetation on the dams. Keywords ecosystem function analysis, EFA, mine tailings, rehabilitation, monitoring, Mhangura Copper Mine, ecosystem function.

Dec 1, 2013

By Sloan GJ, Lysnar RD

Since the of Bergstrand's Geo-dimeter in 1946, and Wadley's Tellurometer in 1956, there have been numerous Electromagnetic Distance Measurement (EDM) instruments produced throughout the world by a variety of companies.This form of measurement has not merely replaced other methods of measurement, but has caused considerable change of emphasis in survey techniques. Major control surveys are now being accomplished using trilateration instead of triangulation. The surveying of open cuts or engineering work may be done in a fraction of the time and, in the majority of cases, to a greater degree of accuracy than with older methods.It is surprising that with this new tech-nology and development of EDM equipment which is compact, easy to use and no longer so expen-sive, no advance has been made in underground surveying. If we look at equipment being used by the majority of mining companies, we see that there have been very few changes since the Second World War. Very little research has been carried out to enable the surveyor to do his work more easily in conditions which, at the very least. are hazardous.

Jan 1, 1984

By R. S. Sandhu, L. E. Baker, W. Y. Shieh

The finite element method of analysis was introduced by Clough.1 Within a short period, it has developed into a powerful solution technique in structural and continuum mechanics. It has been used to solve boundary value problems in two and three-dimensional elasticity.2-5 Anisotropy and heterogeneity of materials were allowed for at the earliest stages. 1,4 Its application has been extended to allow for cracks,5 creep and viscoelasticity, 6,7 incremental construction,6-8 nonlinear elasticity3,9 effect of joints in rock,10 and to materials with different behavior in tension and compression.7 Because of its versatility, the finite element method has found increasing application in the field of rock mechanics. In fact, several of the more significant developments have been motivated by problems in this field. Elasto-plastic material behavior based on the incremental or rate-type theory of plasticity rather than the deformation theory was considered by Reyes and Deere11 A material law based on a generalization 12 of the Mohr-Coulomb criterion was used. In this chapter, the formulation of material laws developed by Reyes and Deere 11 is used. An efficient analysis procedure, incorporating recent developments in finite element analysis, is developed for plane-strain conditions. To demonstrate its effectiveness, the procedure is applied to three cases, one for which an exact solution is available, another for which field observations had been made, and a third one for which a parallel study was made, using an accepted limit-equilibrium method.

Jan 1, 1970

By J. Norman Bulkley

As electrical power is used to a greater extent on the Rand than in any other mining center, it is thought that a short description of the methods used and results obtained may be of interest. In comparing Rand practice with that on other fields, several general factors should be borne in mind: First, the mines are all working on large tonnages of low-grade ore (average. $6.50). The annual crushing rate is about 27,000,000 tons. Second, the mines are all grouped udder the financial and engineering control of mining houses, so that the results of a group, rather than an individual mine, are open for study, and practice follows more uniform lines. Third, coal of fair quality (about 12,000 B.t.u.) can be obtained for $2 to $3 per ton., Good supplies of condensing water are, however, scarce, and have to be carefully stored. Power Supply Power is supplied by the Victoria Falls & Transvaal Power Co., Ltd., and its subsidiary, the Rand Mines Power Supply Co. Both companies, which are practically one from an engineering point of view, operate the following stations, all feeding into the same system.

Jan 2, 1916

By J. Norman Bulkley

Discussion of the paper of J. NORMAN BULKLEY, presented at the New York meeting, February, 1916, and printed in Bulletin No. 110, February, 1916, pp. 355 to 373. GRAHAM BRIGHT, E.. Pittsburgh, Pa.-On p. 265 mention is made of a change from steam hoist to electric hoist. The arrangement mentioned, of using a geared motor, and having the gearing and counter-shaft in a separate, self-contained unit, and then connecting that to the hoist by means of a flexible coupling, is very good. Sometimes, however, it is necessary to change a geared hoist over to an electric hoist. 'In that case the motor could be either direct-connected to the countershaft or geared to the countershaft, making a double-reduction gearing. Trouble has been experienced with this method on account of the hoist not being designed for electric drive. It may be of a rather light construction which will not stand the forces obtained by steam operation, the maximum being determined by the steam pressure which can be obtained in the cylinder. With motors of hoisting types, torques, can be obtained, which are so far in excess of anything that the steam engine could give, that this sometimes results in disaster when a motor is applied to a hoist of that type. If the operator gets a little careless, he may overstrain the hoist, And cause damage, so that this question should be looked into when changing from a steam hoist to an electric hoist. The hoist should be rugged enough to stand the torques which may be attained by careless operation, in which case, instead of using a three-bearing motor, with a pinion between two of the bearings, it is much better to arrange for a two-bearing motor, arranging for a coupling through a flexible coupler. In another place trouble is mentioned as due to the vibration of a geared hoisting motor. That can be overcome by supplying a flexible coupling between the motor and the hoist proper. You will find, if a flexible coupling is furnished, that the motor troubles will largely disappear. K. A. PAULY (communication to the Secretary*), Schenectady, N. Y. -This paper is deserving of careful consideration by all interested in general electrical mining problems and the recommendations made should be given weight because of the author's long experience in dealing with various problems encountered from the beginning of mine electrification.

Jan 5, 1916

By K. H. Singh, J. N. Szuck, J. A. Riddell

"Hydraulic rock drilling equipment has been in use at Falconbridge over the past two years in both production and development situations. This paper deals with the experience gained in the application of hydraulic drilling in the company's mines and discusses the benefits and problems encountered during their use. The paper primarily focuses on technical, operating, maintenance and economic aspects of the machines, and does not attempt to compare the performances of different machines from the various manufacturers.IntroductionThe Sudbury Operations of Falconbridge Nickel Mines Limited are comprised of five operating mines and two mines under development. All the production comes from underground mines, mostly at depths below 1000 metres. The company, faced with increases in operating costs and difficult mining conditions, has continued to seek solutions with the help of new mining technology.The development of electric-hydraulic drilling machines in Europe had been pursued with great interest and, in 1979, a decision was made to test these machines to prove their technical and economic viability under operating conditions. Since then, a number of electric-hydraulic machines have been evaluated in different situations and currently nine hydraulic machines are being used in the company's various mines. These machines are comprised of two-boom drilling jumbos for development, one-boom machines for longhole drilling and a large-hole-diameter drilling rig for blasthole drilling. One hydraulic jumbo has also been used in a cut-and-fill stope."

Jan 1, 1982

By Shuji Owada, Mayumi Ito, Idemitsu Kosan Co. Ltd., Takehiko Nishimu, Sadayuki Shinozaki, Takashi Ando, Tomoe Ota

"fElectrical disintegration (ED) by high voltage electrical pulse is a relatively new technique which was demonstrated by Tomsk and Mekhanobr in the 1960’s and has been investigated in detail by Andres in the 1990’s. In the ED, the electrodes should contact to the targeted material and the energy of high voltage pulse is charged directly to the material. It has been reported that the ED is quite efficient to improve liberation of composite materials, because electrical current passes often through the conductive part and/or along the phase boundaries. Theoretically, the energy required in the ED should be lower than in the other mechanical breakage methods, because breakage occurs basically by tensile strength in the ED while in the other mechanical methods it does mainly by compressive strength which is generally ten times or higher than tensile strength.Coal, involving many kinds of mineral matters, is considered to be one of the targets for the ED to apply to. In Japan, national “Hyper-Coal Project” is now running, in which ultra-clean coal (less than 200ppm of ash, 0.5ppm of Na and K, and 2ppm of Ca) is planned to produce by combining advanced coal preparation and liquefaction technologies for the purpose of direct injection of coal combustion gas to turbine. The ED is one of the major techniques to be developed in this project, since mineral matters must be liberated before introducing to the following advanced separation processes. Liberation is important also for the utilization of middling coals generated from usual coal preparation plants. The application of the ED to the middling coals is considered effective for upgrading these coals with higher liberation degree and less energy input."

Jan 1, 2003

By Shuji Owada, Mayumi Ito, Takehiko Nishimura, Toru Yamashita, Sadayuki Shinozaki, Takashi Ando, Tomoe Ota

Electrical disintegration (ED) was applied to Nantun coal (China) in order to improve liberation of coal substance for the pretreatment of producing “Hyper Coal” of which the combustion gas was planning to inject directly to turbine for power generation. It has been found that many cracks generated in the ED were existent at phase boundaries with mineral matters and liberation of coal substance became much higher than that in mechanical comminution methods such as roll crusher. Since the ED occurred more easily (with lower voltage applied) for the coals of higher mineral content, it is considered that this method could make a better contribution especially to comminute middling coals. We also found that the ED technique could apply not only single particles but also to coal particles assemblage, keeping almost the same or higher disintegration efficiency. In the mineral matters, Si and Al components were preferentially well liberated by the ED.

Jan 1, 2003

By M. P. Tixier

Abstract In a review of the application of electrical logging in Canada, examples are .given of long and short distance correlations by means of the electrical logs. The use of MicroLogging for the determination of permeable and porous formations is explained. The question of log analysis for the quantitative determination of fluid saturation and porosity is .discussed. An example is provided to illustrate the significance of the resistivity gradient. The advantages of the new method of the Laterolog are shown, chiefly for the case of wells filled with high-salinity mud. Introduction Electrical logging techniques developed rapidly in Canada at the time an intensive drilling activity started for the exploitation of the Devonian series in Alberta, namely, at the beginning of 1947. The conventional service was soon thereafter supplemented with the latest technica1 improvements. Canada has been among the first regions to take advantage of MicroLogging*, which has proved a most powerful .tool for the investigation of permeable and porous formations; also, the more recent development known as the Laterolog has ?been introduced in Canada. The Laterolog provides a better determination of .the formations, particularly in the case of salty mud where the conventional logging is greatly handicapped. The various methods of electrical logging are now commonly known in oil industry and have been described in numerous publications ( 1) ( 2) (3).

Jan 1, 1951

By S. Le Fevre

THE application of electricity to the mining and beneficiation of the magnetic iron ores of the Mineville, N. Y., district, on Lake Champlain, has resulted in economies and enhanced quality of product, without which only a comparatively small quantity of the present output could be marketed. The output of the Witherbee, Sherman & Co. mines is about 700,000 tons per annum, and of this about four-fifths is treated by magnetic separation to increase the iron content and reduce the phosphorus. The use of electricity for the magnetic separation of the ore from the gangue is therefore of primary importance, and makes possible the application of electric power for mining and preparing the ore for concentration: The fact which speaks loudest in favor of the application of electricity is this: It is possible for about 25c. per ton of shipping ore to furnish all the power required to put the ore on cars. This includes mining a hard ore underground, from a depth of 900 ft., hoisting to surface, crushing to 4 or s in. in size, and separating from the gangue. This also includes lights about the works, and all miscellaneous power, such as about the shops. The first plant for the generation of electric power for use at Mineville was completed in 1903, and was one of the first for the application of electricity to mining iron ore. This was a Nordberg compound condensing steam engine, direct connected to a 750-kw. alternating-current generator, 3,300 volts, 3 phase, 25 cycles. All the plants added later use the same-current but with higher voltage. The map, Fig. 1, shows the power plants and the transmission system; Figs. 2 and 3 are views of the shaft houses and the mills.

Jan 6, 1914

By Susheel R. Kolwalkar

A significant increase in the side shear capacity over a period of time is often observed in case of driven piles. This phenomenon is referred to as ?setup? or ?freeze?. This phenomenon cannot be predicted based on the knowledge of the engineering properties of soil. Different kinds of mechanisms have been proposed in order to explain set-up in cohesive soils. In engineering practice, set-up is incorporated in design on the basis of empirical formulae and depends to a large extent on personal experience and judgment of the design engineer. Set-up is a natural process which cannot be accelerated by any existing practice. A research was initiated to investigate the mechanism of pile set-up in clayey soils and explore the possibility of accelerating the set-up process by an electro-kinetic method. The system chosen for the present study consists of a prototype steel pile driven in kaolinite clay. A laboratory test program was developed at Cleveland State University in order to meet the goals of the proposed research. Results obtained from these tests are very encouraging and show pile capacity increase of 200% within the first 5 days of electric gradient application versus those that experience natural set-up. In this paper, theoretical considerations and laboratory test results are presented and discussed.

Jan 1, 2008

By L. Ya Agapova

Emissions from pyrometallurgical processing of copper concentrates are usually subjected to wet scrubbing. The washing sulphuric acid so produced contains up to 0.2 g/L of rhenium, which is recovered by solvent extraction in the form of crude ammonia permeate (NH4ReO4). The mother liquor, obtained from the sulfuric acid wash, contains up to 35 g/L of rhenium and significant amounts of impurities. Crude rhenium salt is commonly processed by double recrystallization to produce marketable salt. A ton of high grade NH4ReO4 can be produced using 3.0-3.5 m3 of mother liquor. We propose an efficient technology of mother liquor pre-treatment aimed at removal of water-soluble organics with subsequent electrodialysis. Electrodialysis of mother liquor in a multichamber electrodialyzer resulted in the production of pure rhenium acid, from which a marketable NH4ReO4 is precipitated using ammonia solution. Multiple steps of recycling consisting of dissolution of NH4ReO4 salt, rhenium acid production from NH4ReO4 salt by electrodialysis and precipitation of NH4ReO4 from rhenium acid made it possible to upgrade the purity of obtained rhenium compounds by 1-2 orders of magnitude. A rhenium metal powder of 99.997% purity was produced by high-temperature reduction of high-purity NH4ReO4 with gaseous hydrogen. Rhenium metal powder of high purity can be produced from sulfate solutions of NH4ReO4 by non-platinum anode-based membrane electrolysis processes also. Keywords: rhenium, mother liquors, membranes, electrodialysis, rhenium acid, ammonia perrhenate, reduction, powder, electrolysis

Sep 1, 2012

By J. E. Gebhardt, S. Chander

Significant advances have occurred in the use of electrochemical techniques for sulfide mineral flotation research. The techniques have been used singly or jointly with other characterization methods. When used in combination with other methods, the electrochemical methods provide a means to control the state of oxidation of the surface. Various analytical methods are employed for characterization. The methods that have been used include wetting, x-ray photoelectron and fourier transform infrared spectroscopies. The electrochemical methods include voltammetry and transient electrochemical techniques of galvanostatic polarization and AC impedance spectroscopy. The challenge for the future lies in the utilization of this knowledge in plant operations so as to increase the overall efficiency of flotation separations.

Jan 1, 1989