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By Randolph R. Dreher, Michael L. Schreder

"In recent years, FFE Minerals has designed, installed and commissioned several large grinding mill circuits. This paper discusses the issues related to the erection and commissioning of large grinding mill circuits. The three circuits discussed are Collahuasi in Chile, Minera Los Pelambres in Chile, and Century Zinc in Australia. These circuits include large SAG and ball mills with both gear and gearless drive arrangements, as well as, both trunnion and shell supported mills. Aspects of these features are discussed with respect to their impact on installation and commissioning. While the normal challenges of mill erection and start-up were experienced, there were also a few unexpected challenges encountered partly due to the large scale of the equipment. An overview of the equipment and design ratings of these circuits is also provided.COLLAHUASIOverviewThe Collahuasi mills were started-up in November of 1998. The site is located in the Andes Mountains at an elevation of 4300 meters. The grinding circuit includes two lines featuring one SAG mill and one ball mill for each line. The circuit features a recycle conveyor around the SAG mills with provision for adding a pebble crusher in the future. The design tonnage of the grinding plant is 60,000 MTPD with an ore BWI of 10.5 kWh/MT.The SAG mills are 32’ x 15’ (1 3’ EGL) with 10,800 HP drives. The drive arrangements are dual pinion through pneumatic clutches. The mills are driven by low speed synchronous motors with CCV variable speed drives. The SAG mills are trunnion supported and use hydrostatic lubrication. Feed to the SAG mills is via a rock-box type feed chute on a cart. The mills discharge on to trommel screens with a bucket wheel to remove the oversize.The ball mills are 22’ x 36.5’ (36’ EGL) with 12,500 HP drives. The drive arrangements are dual pinion through pneumatic clutches. The fixed speed mills are driven by low speed synchronous motors with GE Quadramatic load sharing drives. The ball mills are shell-supported and feature multi-pad bearings with hydrodynamic lubrication. The mills are fed via a rubber lined sump box with feed spout on a cart. The ball mills also discharge on to trommel screens. Twenty-six inch (26”) diameter hydrocyclones are in closed circuit with the ball mills."

Jan 1, 2001

By Brad E. Melanson

Because mine haul trucks consume considerable quantities of fuel, they are ideal candidates for the adoption of cleaner and cheaper fuels like natural gas. Impressive fuel cost savings will be realized in regions where liquefied natural gas (LNG) has cost advantage to diesel fuel, while also providing significant reductions of air contaminants and greenhouse gases. High Pressure Direct Injection (HPDI) of natural gas utilizes the diesel cycle combustion process and therefore retains the diesel engine?s high performance and efficiency characteristics. HPDI has been demonstrated in on-road Class 8 trucks since 2001 accumulating almost 10 million kilometres to date. The supply of LNG fuel will be an essential parallel aspect in the introduction of HPDI to mining. LNG can be transported to site as diesel is today, or may be produced on or near mine operations that have access to methane sources or pipelines.

May 1, 2006

By G. M. Behrend

"The mining and processing of mineral ores is a very old industry which is steeped in tradition. Rising demand for metals has recently forced the exploitation of lower-grade orebodies which require extensive beneficiation. The high capital expenditures involved, together with market pressures for high-quality concentrates and pellets, have forced the development of new process technologies which are heavily dependent on automatic process control. Development of suitable instrumentation has been rapid and it is being applied to mining processes today with a high degree of sophistication. The drive for higher efficiency and profitability goes on and has reached a level at which modern digital computers appear to be the only answer. However, the efficient application of a digital process computer is extremely complicated and is therefore approached by the mining industry with considerable hesitation.Some of the benefits promised by the digital computer can be obtained today by other means, which are more manageable and can provide immediate payoff. The result would be a building-block system which would utilize the digital process computer as its final component, to perform true plant optimization, free from routine chores."

Jan 1, 1971

By D. Wolfe, R. Cleminson

"The Aurora North mine has been operating for more than ten years, and is the source of over half of Syncrude’s bitumen production. The slurry systems at Aurora experience high rates of wear, and mission lengths on current slurry pumps are nominally 1500-2000 hours. Recent work has enabled a better understanding of the significant adverse effect of large particle impingement damage to impeller vane leading edges - which is the known life determining issue for Aurora hydrotransport pumps. A new pump design has been developed with a larger diameter impeller and increased vane lengths, and is expected to triple Aurora’s mission length for hydrotransport pumps.INTRODUCTIONSlurry Pumps are Critical Equipment at SyncrudeSlurry pumps are a critical component in Syncrude’s operations. In a typical Aurora application, each pump stage helps move over 8000 dry tonnes per hour of oil sand, plus an equal volume of process water that has been added to create the slurry. The average impeller life in oil sand hydrotransport service at Aurora has been nominally 1500-2000 hours, or 12-16 million tonnes of oil sand pumped. Generally, the slurry pump application at Aurora has proven very difficult to improve due to the unique combination of high sand abrasivity, 125 mm (5”) large particle top size (lumps), and high flow rate relative to basic pump size; a factor that results in higher than optimal impeller vane speeds for the service conditions.PROJECT BASISSlurry Pumps are the Reliability Bottleneck at AuroraSlurry pumps are currently the shortest-lived components that determine the overall system run length at Aurora, in Hydrotransport, Extraction and Tailings. Vibrating screens and piping had been previous bottlenecks, but their reliability has been improved through upgrades in equipment design and wear materials. Both vibrating screens and piping can now achieve 4000 hour mission lengths."

Jan 1, 2013

By M. N. Bassim, W. W. Tennese

"Concepts of linear elastic fracture mechanics were applied to study two cases of failure, namely an equalizing beam from a tandem rear axle of a highway tractor unit and the main beam of a flat bed trailer. In the first case, the presence of a crack, initiated by stress corrosion cracking followed by significant fatigue crack propagation produced a state of stress which was sufficient to produce brittle failure. Calculation of the fatigue life agreed with the number of cycles that the structure experienced before final fracture. In the second case, it was demonstrated that a combination of low temperature and high loading rate was sufficient to cause brittle fracture.IntroductionFailure analysis of engineering components has generally been carried out without the benefit of fracture mechanics. It is generally understood that real structures inevitably contain internal or surface flaws which under an applied load, may propagate to fracture. Fracture mechanics relates the applied stresses to the crack size in specified geometries. Since its introduction approximately thirty years ago, fracture mechanics has evolved as a design philosophy which can be used to develop fracture-safe designs. It can be also applied in analysis of failures, to ascertain if sound design and fabrication methods have been used."

Jan 1, 1985

By R. Filippone, Donald Leroux, Colin Hardie, G. Leichtle, Cesar Gomez, Jim A. Finch

"Bubble surface area flux (Sb) is the surface area of bubbles per unit time per unit cross-sectional area of flotation machine. The units are: (m2 bubble surface/s)/(m2 cell) or s -1. For bubbles of mean size db (m), s b = 6-Qg/A db where Qg is the gas rate (m3/s), and A the cell cross-section (m'). This parameter is now receiving wide attention as the possible key machine variable in flotation diagnosis and modelling. The concept is described and the potential use of sb is illustrated by work on flotation columns and mechanical cells. In column flotation of recycled paper, the dependence of ink recovery on s b was the same regardless of size of column or type of sparger. In mechanical cells, it has been established that the rate constant is related to Sb independent of impeller type.The use of s b is limited by the problem of measurement, primarily that of estimating db. A prototype probe designed to estimate db (and hence sb) based on conductivity measurements is described. Exploratory work with the probe in a mechanical cell suggests the promise of making estimation of s b routine.INTRODUCTIONFlotation is the result of interaction among variables associated with the feed particles, chemistry and the machine (flotation cell). Trying to isolate the effects of each aids in process diagnosis and is at the centre of attempts to model flotation. The machine variables that have been investigated include the air flow number, the power number and specific power (Harris, 1976). None have survived as the basis for predicting flotation response perhaps because they did not include directly the properties of the bubble swarm (or dispersion). Recently, Gorain (1 997) explored the relationship between the flotation rate constant and various ""gas dispersion"" parameters notably: superficial air rate (Jg = Qg/A, where Qg is the volumetric gas rate and A is cross-sectional area of cell), bubble size (db), gas holdup (Eg, i.e., the volumetric fraction of a cell occupied by gas) and bubble surface area flux (sb = 6.Jg/db). Of them all, Gorain et al. (1997) conclude that the latter, the surface area flux, correlated best with the flotation rate constant. This concept was adopted from column flotation where it was used to estimate, among other factors, the maximum amount of gas that could be injected (Finch and Dobby), 1990). Let's start by reviewing the concept. Following that some examples of where the concept has been applied will be described to illustrate the current interest and finally we will consider how to measure the surface area flux."

Jan 1, 1999

By D. Ingram

"PRIMARY DUST COLLECTOR A. 42,000 CFM James Howden Fan Z-6 Size 3650 Fan Dia 40"" HP 75It was found that the fan was not large enough to remove the air that was displaced by the trucks dumping. So it was removed and an enclosure was installed to isolate the gyro from the rest of the building.B. FANSJames Howden Fans Model RPM 3500 Series 357 FW HP 10These fans were installed when the first dust system was put into operation. It was found that the high RPM and extreme fan wear caused a major maintenance problem. These fans were replaced with Chicage Blowers Model SWS1 RPM 1180 Dia 36"".DRY CYCLONE COLLECTORS A.,Three four foot rubber lined cyclones. Four six foot rubber lined cyclones.All under flow. Water is controlled manually and gravity flows to a central sump box. From there it flows to the grinding circuit in the Mill.Cyclone under flow product runs between 100 and 200 tons of dust per 24 hours with a screen analysis 30% + 400.The cyclone under flow product is diluted to about 3 to 4%. Solids total gallonage approximately 400.B.,Elbair Wet Scrubber125 HP RPM 56042,000 CFM,Model PX861The Elbair collects the total product from the discharge. Of the Cyclone fans the under flaw goes to the Mill - the Elbair discharges stack goes to atmosphere.The Elbair wet scrubber had to be redesigned in order to keep it in service."

Jan 1, 1976

By Denis Thibodeau

his paper describes a study of an altered mining extraction and the resulting Rockmass response at VALE?s Creighton Mine. Typically, the deep mining zones have strict stope extraction guidelines to ensure safety and productivity; however, these guidelines offer low flexibility or few options for stope sequencing. The 402 O. B. being in a good rock mass, at moderate depth and stress regime at Creighton, offered an opportunity to drive a more flexible mining sequence with stopes and a pillar. A three-phased approach was used to mitigate risk of the mining plan: 1- Numerical modelling to fully anticipate rock mass response to the proposed mining sequences. 2- In situ seismic monitoring to collect stress and seismic activity data. 3- Analysis of the in situ data to correlate to the modelling results. The creation and the extraction of a pillar in the 402 O. B. was successfully completed. The recorded seismic activity agrees well with the numerical modelling since most of the seismic activity is localised in the hangingwall where the deviatoric stress corresponds to an early damage process. The moderate levels of deviatoric stress cause localised failure with low level of seismic activity.

May 1, 2013

By Peter White

Mine Planning Shaft Collar Shaft Sinking Raises Ramp Underground Water Storage

May 1, 2009

By J. Z. Cui

In this paper a statistical multi-scale method for the mechanics parameter prediction of the rock mass with random distribution of multi-scale cracks/joints is presented. First the micro-structure of the rock mass with random distribution of multi-scale cracks/joints is represented. Then the statistical second-order two-scale method for the mechanics performance predictions of the rock mass structure with random cracks/joints distribution is presented, including the statistical second-order two-scale expression on the vector-valued displacement, strain tensor and stress tensor, and the algorithm procedure of statistical multi-sale computation for the mechanics parameters. Finally some numerical results for mechanical parameters for the rock mass with random distributions of multi-scale joints/cracks by statistical multi-scale method are shown.

May 1, 2009

By Y. L. Su, S. Vongpaisal, H. A. Smith

"It is extremely difficult for a mine's central control room operator to control peakpower demands and to maintain normal materials handling operations at the same time. An investigation of the Falconbridge Strathcona Mine 's central control room has revealed that there are more than eight thousand possible combinations of ""situations"" that can arise. For such a circumstance, an expert system can become a very valuable tool to assist the operator in taking the most appropriate and timely action.A forward chaining expert system module has been developed for this application. The module is based on Level 5 ObjectTM software. It is graphics oriented and user-friendly. Training requirement is minimal.ForewordThis paper has arisen out of work carried out by YLS Associates and Falconbridge Limited as part of a contract between Falconbridge and the Department of Energy, Mines and Resources, Government of Canada, on the application of expert systems in mining operations.IntroductionThe electrical bill charged to large consumers by Ontario Hydro is based upon two elements: demand and energy consumption. The demand is the peak kilowatt level that the consumer has required during a monthly period. It is not uncommon for the demand portion to be as much as one third of the monthly bill. Energy consumption is the total kilowatt-hour s (kWh) consumed during the period.Ways to reduce the energy consumption part of the electrical bill involve utilizing energy-efficient equipment and operating machines in off-peak hours when a lower energy rate is charged. Maintaining the peak power below a critical level may require that simultaneous usage of major pieces of equipment be avoided. A 3000 kW skip run at an inopportune time could cost a company an extra $30,000 in that month's power cost.Potential disadvantages associated with peak power control are lost production due to work stoppage and increased operating costs due to the need to employ extra personnel. Most companies find these matters relatively easy to deal with and with incentives provided by Ontario Hydro, actively pursue this facet of energy savings (Harju , 1991)."

Jan 1, 1993

By M. Keen

The backfill system at Cleveland Potash?s Boulby Mine places waste filter cake underground in the form of a high concentration slurry in worked out areas of the mine reducing the mine?s environmental impact. The backfill system delivers slurry approximately 1100 m down the mine and up to 11 000 m horizontally underground. The Boulby backfill system is unique in that the placed backfill waste is not used for the usual purposes such as support, pillar extraction or reducing ventilation requirements. It was specifically implemented for environmental reasons. This influenced the design and resulted in some unique features of the system. A previous paper (Wilkins et al., 2004) described the design and commissioning of the backfill system. This paper describes the operational experience with the backfill system and backfill placement since commissioning in May 2003 and looks at lessons that can be applied in other backfill designs.

May 1, 2007

By R. Tipman, T. C. Burnett

"A general computer program has been written to calculate material balances using multiple regression techniques. The program can handle metal assays or size distribution data obtained in multiple surveys of the flotation circuit. The ""best fit"" weight split is calculated between the input and product streams by minimizing the sum of squares of the residual errors using all of the available data. The program includes an assay adjustment feature in which each assay is recalculated to fit the ""best fit"" mass balance. Thus assay or sampling errors can be easily identified. Also the assays can be statistically weighted so the most precise measurements are given the most influence on the material balance. The computer output reports the mass balance, the actual and corrected assays, the percent metal recoveries and the significance and confidence levels for the weight splits.The program enables a rapid and accurate evaluation of mass balances from large masses of data obtained in multiple surveys around a flotation circuit. The effects of changing process variables can be quickly evaluated with statistical confidence."

Jan 1, 1978

By J. A. Stewart

"A common problem in the mining industry involves the overloading of established conveyor systems. This overloading can have a number of causes, such as new production technology or a changing market condition which increases demand. An overloaded system usually spells disaster and leads to clean-up problems, equipment failures and lost production. The Cape Breton Development Corporation's Lingan Mine had a serious overloading situation on its underground coal clearance system, and equipment was being damaged and production was being lost. It was rectified, in part, by increasing the coal clearance capacity through the use of booster conveyors. This paper discusses the problems which led to this situation, the booster concept and the installation of the first unit at the Lingan Mine.IntroductionThe Lingan Mine is a submarine coal mining operation with an annual production of 1.5 million tonnes from three advancing longwalls. Coal is conveyed 3400m up a 13% slope to the surface. Designed and installed in the early 1970s, the system's 820-tonne/hour design initially proved adequate; however, by the late 1970sthe system was handling surge loads of 1640 tonnes per hour due to the introduction of new face equipment.The coal clearance system consisted of three 485-Kw, two 210-Kw and one 105-Kw conveyors. Each conveyor was designed for 820 tonnes per hour using 1050-mm, Type 10 belt with a 35-degree troughing profile.There were many effects of the overloading on the system:• Loading beyond the physical capacity of the belt resulted in spillage along the conveyor, which increased operational and maintenance costs.• Overloading of the drive components resulted in premature equipment failures.• Spillage at the drive pulley often resulted in damage to the belt and pulley lagging and, under extreme conditions, the conveyor would require partial unloading before it would operate. This was a particular problem under wet conditions because the 485-Kw conveyor drives were fitted with single-drive drums."

Jan 1, 1982

By Jun Wang, Bo Zhang, Wenqing Qin, Guanzhou Qiu, Xiaozhen Ma, Key Lab of Biohydrometallurgy of Ministry of Education, Fen Jiao, Central South University, Yansheng Zhang

"Arsenic contained in minerals sulphides such as enargite and tennantite can represent not only a significant penalty element in base metals production, but also a disadvantage to the environment through producing the toxic emissions to the atmosphere. The achieving separation of arsenic bearing minerals either at an early stage in floatation or from the floatation concentration is significantly beneficial to the economic. However, there was no feasible commercial method of separation at the flotation stage because of its similar flotation properties with many other copper sulphides. In this work, the selective floatation of enargite from copper sulphide concentrate containing maily covllite, chalcoctie, bornite and enargite was investigated. A low arsenic concentrate with As 0.2%, Cu 22% and a high arsenic bulk concentrate with As 7.65%,Cu 33.65% were obtained. It was indicated that Ca(ClO)2 is the effective depressor and the optimum floatation condition was obtained. Most enargite could be floated at pH 11 and controlling the pulp potential at 290 mV SHE. Furthermore, the arsenic removal from the high arsenic bulk concentrate by hydrometallurgy methods was study. The results showed that the reaction temperature and the concentrations of NaOH were the most important variables affecting the rate of arsenic removal. A low arsenic concentrate with As 0.24%, Cu 37.80% was obtained in the optimum leaching condition.INTRODUCTIONArsenic is mainly produced as a by-product of base metals smelting, in particular copper concentrate. China has imposed an upper limit of 0.50% arsenic for concentrates entering (Long et al., 2012). Arsenic amount of copper concentrate within 0.40% has also been imposed in China, and above which will be introduced about 50 RMB penalties per ton for each 0.10% increasing by smelters now. Therefore, it is necessary to remove arsenic from the copper concentrate.In copper concentrate, arsenic is mainly in the form of arsenopyrite (FeAsS), enargite (Cu3AsS4) or tennantite (Cu12As4S13). There are two types of arsenic in the separation of copper and arsenic: arsenopyrite and arsenic bearing copper mineral. It is easier to separate arsenopyrite from the copper sulphide by flotation in comparsion with the separation of enargite or tennantite from non-arsenic copper minerals (Pineda et al., 2015). The main difficulty in the separation of arsenic copper mineral from non-arsenic copper sulphides is their extremely similar floatability, which depends on the fact that tennantite and enargite contain high copper content (Pineda et al., 2015)."

Jan 1, 2016

By Donald Leroux, Colin Hardie

"New or improved mathematical models of mineral processing machines are published almost on a monthly basis. Often, these models can be calibrated from bench-scale test results and programmed using spreadsheet software to simulate different designs and operating conditions in open-circuit configuration. However, since mineral processing plants frequently operate comminution, separation and/or extraction machines in closed-circuit configurations, open-circuit simulations often have limited applicability.The simulation of closed-circuit configurations necessitates the programming of an iterative loop to bring the circuit to equilibrium. This can be done by using spreadsheet software but often requires advanced programming skills. As an alternative, LIMN® software, which simplifies the programming of closed-circuit configurations within spreadsheets can be used. This software was specifically designed to turn a Microsoft EXCEL® spreadsheet into a closed-circuit modeling and simulation platform with minimal programming.During the past few years, the Mineral Processing Group at the Noranda Technology Centre, has used this software for numerous projects which include the simulation of multi-stage cyclone circuits, closed-circuit regrinding and locked-cycle flotation tests. Using these projects as examples, the flexibility and the easy to use nature of the LIMN® software is demonstrated.INTRODUCTIONMineral processing engineers routinely have to make predictions regarding comminution and separation processes. Predicting the appropriate dimensions of equipment and the process response to changes in operating mode are probably the most common situations that they face. In all cases these predictions are expected to be rapid and accurate.Predictions made by engineers are frequently based on mathematical models. Many first principles, empirical, semi-empirical, steady state and dynamic models of mineral processes can be found in the literature. In fact, new or improved mineral processing models are continuously being proposed and in spite of this variety, process engineers often have to either develop their own or tailor existing models to suit their particular needs."

Jan 1, 2003

By R. G. Hamm

A brief outline covering the shovels and draglines in use in the open-pit mines of Western Canada, including British Columbia, Alberta and the Yukon, is given, followed by the procedure for the selection of the correct wire rope for each application. Such fa ctors as wire rope constructions, lay directions and types of cores are mentioned. Once the correct wire rope has been selected, there are variousfactors that can affect the service fife ofthe rope and the reduction ofdown-time during rope change-overs. Factors such as hairpin winding, types of Becket loops, and shovel drum and bail adaptors are described.

Jan 1, 1979

By B. Meddings, O. J. I. Evans

"This paper is mainly concerned with the present and probable future role of hydrometallurgy in the production of base metals.The economic and technological bases of the hydro-metallurgical plants built and operative in the mid-fifties are compared to those in production in the mid-sixties. The trends observed are extrapolated and some estimates made concerning the probable size and type of hydrometallurgical plants which will be operative in the mid-seventies.The impact of emerging socio-economic factors such as pollution control and the market demand for specialized metal products which favour hydrometallurgical recovery processes are also discussed."

Jan 1, 1971

By D. E. Keeley

Introduction Gunite is a mixture of sand and cement applied to any surface by being shot by compressed air through a nozzle, where it is wetted just before leaving the orifice. The mixture is transported through a hose from a machine called a 'cement-gun'(l). Guniting of rock surfaces has been standard practice at the Mcintyre Porcupine Mines, Limited, for several years. Where used on walls and backs of cross-cuts; shaft stations, and other rock openings, as an air seal, gunite has eliminated the necessity of constant scaling to keep rock from falling from these places, and, under worse conditions, it has been used in place of timber supports. This has been of definite help in reducing costs, promoting safety, and minimizing fire hazards. During the past year guniting has been quite extensively used here in the rock head-works of the new internal shaft, No. 12, sunk from the 3,875-foot level. Gunite is at present being applied to the stations of that shaft well below a mile from the surface. This paper describes the method of guniting as carried out at the McIntyre, and illustrates how, by the adoption of this process, mining problems connected with scaling and loose ground have been completely solved. It is hoped that the information presented may stimulate discussion and assist in the use of gunite in this and other mines. The guniting method of applying cement was first developed by Carl E. Akeley (2), Curator of the Field Museum, Chicago, in 1907, and was exhibited in New York at the Cement Show in 1910. The museum was located in one of the old World's Fair buildings, built of roughcast and in bad repair. Mr. Akeley, who was a man of inventive nature, set about devising means of applying cement to repair the walls. The cement-gun was the result. Mr. Akeley was a taxidermist of note, a sculptor, and also the inventor of the Akeley camera. In his work, he was in the habit of using fast setting materials to build up foundations for statues, etc.

Jan 1, 1934

By Unal Artan

It is well known in the robotics community that the ability to determine the position of vehicles in real time is a key enabling technology required for automation, traffic management, and to ensure safety in the presence of multiple vehicles. Because of this, the introduction of global positioning systems (GPS) has had a remarkable impact on the surface mining industry, enabling real-time tracking of mobile assets, improved safety, and production optimization. Unfortunately, satellite-based GPS is not available underground. This paper reports on the preliminary results of a study to develop a robust method for globally consistent mapping of large-scale underground mine environments. We believe that this may additionally become the first step towards the development of a novel underground positioning technology. Presented are preliminary results from data collected at two underground mines using an Atlas Copco ST14 LHD machine.

Oct 1, 2009