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By R. Schulz, K. King

Concentrating Line 6 just went down again. The control room operator checks the graphic display. Only one piece of equipment shows an alarm. Clicking on the ball mill icon, he discovers the culprit was the low flow lube switch. The flow looks okay now, but it is the third time this week the switch has stopped the line. Maintenance is called, the switch replaced and the line is up running again. Sending the right person to the right spot immediately can save hundreds of hours of downtime every year. This paper discusses the principles behind implementing smart First-Out Fault Detection to dramatically reduce equipment downtime in new, or existing control system architectures. Methodologies are presented to maximize the system benefits, while minimizing development costs. Case histories are presented for a number of successful implementations in mineral processing plants.

Jan 1, 2001

By W. H. Van Niekerk

The metal zinc has been around since only about 1400 AD. This may sound like a long time, but when compared to fellow base metals copper and lead, which were discovered in 5000 and 4000 BC respectively, it is evident that zinc is a fairly new kid on the block. This may also be the reason why many new facts and benefits of zinc are still being discovered. For instance, it has been discovered only in the last few decades that virtually no life on earth is possible without zinc. In this address it will be shown that zinc is not only very useful to mankind, but is in fact vitally important for all forms of life. It will be shown that zinc is natural, zinc is essential for life, zinc protects, zinc contributes to the well-being of society and that zinc is fully recyclable. It is therefore hoped, that by the end of this address, zinc will no longer be viewed only as the metal that is responsible for the nice colour of roofing sheets and steel buckets, but may indeed be man?s best friend.

Jan 1, 2005

By Bin Tang, Suping Yao

In the last decade, the copper industry in China has developed rapidly and attracted the world’s attention. The production capacity of refined copper has grown remarkably from 4.578 million tons in 2010 up to 9.029 million tons in 2018, accounting for about 40% of the global refined copper production. And now, China has become the biggest refined copper producer in the world. This paper summarizes the application of modern copper metallurgical technologies such as Outotec flash smelting/converting technology, Cyclone smelting technology, TSL (ISA/Ausmelt) smelting/converting technology, Jinfeng side blown smelting and Baiyin side blown smelting technology, Chifeng side blown smelting and continuous top blown converting technology, SKS bottom blowing technology, Dongying two-step smelting technology, copper electrorefining with high current density, etc. in China’s copper industry, analyzes and compares the characteristics of those technologies and presents the great efforts of China’s copper smelters in adapting to the increasingly strict emission standards and improving economic benefits of copper smelters. INTRODUCTION China has been the biggest refined copper producer in the world for many years. China produced million tons of refined copper in 2018, accounting for 40% of the copper smelting production in the world, and of which, roughly, 70% of the copper concentrate was imported, mainly from Chile, Peru and Australia. ICSG (International Copper Study Group, 2017) shows clearly the position of top 20 countries of copper production and copper mine production (Figures 1 and 2). Blast Furnaces, Reverb Furnaces and Electric Furnaces dominated China Copper Smelting for quite long time till 1980s. The first modern copper smelting technology (flash copper smelting) was introduced into China in 1980s, then followed by Noranda, Ausmelt and ISA. Since then, China copper smelting technology stepped into modern time. Since 2000, old processes (Blast Furnace, Reverb Furnaces and Electric Furnaces) were phased out and replaced by modern smelting technologies. China Copper Production has been increasing dramatically (Figure 3).

Jan 1, 2019

Objective To develop safety training tools for mine safety and health professionals that fill gaps in currently available materials. Background Over the past 4 years, NIOSH has developed and released a series of training videos targeted at underground mine safety. These videos were developed in close cooperation with the mining industry and safety training professionals and were intended to provide realistic, interesting, effective training to both new hires and experienced miners. The videos cover the mining cycle, starting with the breaking of the rock (Handling Explosives in Modern Mines), making certain the work area is safe after a blast (Rock Falls— Preventing Rock Fall Injuries in Underground Mines), installation of ground supports and recognition of failed supports (Miner Mike Saves the Day), and hauling both ore and materials in the mine (Hazards in Motion). A separate video (Hidden Scars) captures the story of a fatal rock burst through an interview with a miner who nearly died and who lost his partner in the accident. These videos have been extremely popular in the mining industry and are being used across the nation as well as in 18 other countries. Two of them, Rock Falls and Miner Mike Saves the Day, have won Alice Hamilton awards, NIOSH’s highest recognition for Excellence in Occupational Safety and Health, in the Educational Materials category. Approach A recently completed independent evaluation of the SRL mining videos identified five themes that mine safety trainers consider necessary for successful training materials: high quality, credibility, accurate content, effectiveness, and an engaging nature. All of the NIOSH videos were rated very high for each theme. Using these measures of effectiveness, a more difficult challenge has been undertaken. Much has been written in the mining industry about the coming turnover in employment. The average age of miners in the United States is approaching 50, and many of the “experts” will be leaving the industry as they reach retirement age. The mining industry, like many industries involving skilled labor, relies heavily on a master-apprentice relationship between new hires and older miners. New hands learn from experienced miners. Their learning falls into three primary categories—they learn what’s important to know, they learn how to do things correctly and safely, and they learn the culture.

Mar 1, 2002

It is widely accepted that particles stabilise flotation froths and that stable froths result in improved flotation performance. Predicting the effect of particle addition on froth stability is, however, challenging. Dynamic surface tension measurement using maximum bubble pressure presents an attractive technique to investigate the effect of surfactant and particles at the air-water interface. The range of bubble lifetimes that can be studied (typically 0.1 to 60 s) is analogous to variations in air rate in flotation cells, and the corresponding changes in surface tension give an indication to the diffusion and adsorption rates of particles at the interface. In this paper, we use dynamic surface tension measurements to investigate the effect of particles on bubble surfaces at the microscale and link this to bulk froth stability measurements carried out using a froth column. Using the maximum bubble pressure method, the results show that the addition of particles results in lower surface tension, both at the dynamic (i.e. short) bubble lifetimes and towards equilibrium (i.e. 60 s bubble lifetime). This corresponds with the bulk froth stability measurements, where the three-phase system yielded more stable froths than the surfactant only system. Furthermore, increased particle loading at the air-water interface, whether through higher surfactant concentrations or lower air rates (longer bubble lifetimes), gave lower surface tension and higher froth stability. This demonstrates the link between bubble loading and froth stability. It is proposed that the maximum bubble pressure technique can be used to predict froth stability for two- and three-phase systems, enabling the effect of particle loading to be accounted for and quantified. Moreover, the technique has the potential to allow rapid determination of particle and surfactant diffusion at the air-water interface and prediction of the corresponding effect on bulk froth behaviour.

THERE are certain facts that the mining industry in Australia is faced with at the present moment which may be accepted as axioms. The industry is at a low ebb, as evidenced by statistics. Metals form the basis of all modern industries, and are necessaryfor the welfare of Australia. Mining is a wasting asset. Every ton of ore extracted is one ton less which c.annot be made good, and it should be our duty to get as much profit froin that ore as possible, otherwise there is a permanent loss to the country.The metal market cannot be controlled by Australia; it is more or less an international matter. Australia has not been thoroughly prospected. There are no mines being developed that are likely to replace those which are being depleted.Our mining engineers are as capable as those in other parts of the world, and have made good where they have been given a chance. There is no one cause for the present depression; there are several, more or less, interwoven. Of course, the war has had an adverse effect, but that has only dislocated things temporarily; it upset our markets, influenced the price of metals, and affected the labour market and cost of stores. Labour troubles made their appearance before the wave of unrest swept over the world. The cause of labour discontent must be investigated, and if possible removed. As each industry has .its·own problems, miners must inquire into their special problems, as there is no sovereign remedy that will suit all cases.It is obvious that we cannot mine ore if we do not know where it is; therefore, the first thing is to discover workable deposits.

Jan 1, 1919

Project developent proceeds by increasingly detailed studies addressing overall project returns through an analysis of the substance, risks and costs associated with the following elements: ò Reserves ò Mining ò Processing ò Infrastructure ò Environmental Impact ò Product Market Computer-based expertise has a potential to ò Capture perishable expertise, making this available for shared access and so reducing the cost of human experience ò Consolidate know-how for optimising process operations, bringing consistency of judgement and advice to decision- making by making the rules, facts and preferences explicit ò Allow assignment of the basis and authority of decisions, so experts can pass routine expertise down the line, freeing their time to generate more. ò Force a review of expertise when creating the knowledge base.

Jan 1, 1989

By M. F. Handley

Sequential grid mining has been employed as the primary mining strategy at the AngloGold West Wits Elandsrand Mine since the inception of stoping operations from the sub-vertical shaft system in 1988. Little has been published on sequential grid mining as a mining strategy since, and the purpose of this paper is to describe sequential grid mining, its history, its implementation at Elandsrand, and the outcome to date. The results obtained using sequential grid mining have been evaluated from seismic data, productivity statistics, and rock related accident statistics. Comparisons with neighbouring mines namely Western Deep Levels and Deelkraal, have been made to substantiate the improved conditions observed at Elandsrand, and to compare sequential grid mining directly with longwall mining in similar conditions and at similar depths. Sequential grid mMining is shown to be cost-effective, more flexible, and safer than long wall mining in similar conditions, at least on the Ventersdorp Contact Reef in the western part of the Carletonville Goldfield. More work is necessary to establish it as the favoured mining strategy at depths exceeding 3000 metres, and for reefs other than the Ventersdorp Contact Reef.

Jan 1, 2000

By Y X. Xue, J Pan, D Q. Zhu

In order to reveal the correlation between the fundamental sintering characteristics of iron ores and their real sintering behaviours, a comprehensive evaluation index is proposed based on the measurement of four high temperature indexes, ie assimilation temperature, liquid phase bonding strength, liquid fluidity and calcium ferrite formation percentage, and the sintering pot tests of single ore fines and their blends. The results show that both the lowest assimilation temperature and liquid fluidity of ore blends appear to be the linear superposition of those of single iron ores except for the liquid phase bonding strength and calcium ferrite formation percentage. Furthermore, the tumble index of the sinter product obtained from blended iron ores also corresponds to a linear superposition of that of single ores, but not for the solid fuel rate and productivity. The comprehensive strength index YT exhibits a credible linear positive correlation with the four high temperature reactivity indexes, whereas the comprehensive productivity index YP possesses a lower correlation with the four high temperature reactivity indexes. The comprehensive strength index YT developed can predict the tumble index of the sinter product quite well, but the comprehensive productivity index YP cannot be used to evaluate the productivity effectively.CITATION:Zhu, D Q, Xue, Y X, Pan, J and Shi, B J, 2017. Correlation between high temperature sintering characteristics and sintering behaviours of iron ore fines, in Proceedings Iron Ore 2017, pp 123–132 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 24, 2017

Longwall mining originated in the early 18th century in the county of Shropshire in England, where it was known as the longway method. Its name implies the extraction of the seam over a long continuous length or wall of exposed coal. Until the late 19608 and early 1970s the use of the longwall system with a few exceptions was confined to the United Kingdom and Europe. It was not until the early 19708 that the highly productive longwall faces we now know, were developed and the application of the longwall system extended to Australia, South Africa, United states of America and other parts of the world. The modern longwall face has three major components, namely: +         the machine to break and load the coal +         the face conveyor; +         and a system of roof support.   This paper reviews the development of longwall mining technology. The parameters directly influencing the production 'of a modern longwall face are considered, as are the possible constraints to the further development of the longwall system.

Jan 1, 1991

By S C. Dominy

The grade of ore at Marvel Loch mine is directly related to the presence or absence of shear zones and quartz-sulfide-rich hornblende (¦ diopside) veining within areas of plagioclase alteration. An experienced geologist can identify these features in hand specimen. Practical rules have been developed to assist this visual identification. The structural sites and styles of alteration and veining most conducive to gold mineralisation have also been determined. The work has enabled a better understanding of the geological controls on mineralisation at Marvel Loch, and has clarified geological understanding for optimisation of grade control modeling, ore block mark-ups, and minimisation of ore loss and dilution during excavation. In addition to this, it has enabled a detailed understanding of mine scale structural controls, geometry and relative grade relationships.

Jan 1, 2003

By M. Beus, S. Inverson, B. Stewart

Abstract Recent ore pass failures have underlined the need for improved designs, standards, structural mon¬itoring methods and better hang-up prevention and removal tech¬niques. Researchers at the Spokane Research Laboratory of the Na¬tional Institute for Occupational Safety and Health (NIOSH) are investigating methods to improve safety during the transport of ore in ore passes. Design criteria and hang-up prevention and remedia¬tion strategies involve studies of the effects of static and dynamic ore and waste-rock loads on chutes, walls, gates and support structures. Particle flow analysis methods were used to simulate the response of various ore pass designs to a wide range of ore loading condi¬tions. A full-scale mockup of ac¬tual ore pass and chute assemblies was duplicated and tested for load response. Data from a particle flow code and the mock-ups were com¬pared Loads on an active ore pass chute were measured.

By Derek Ettie

"In the Hydrometallurgical processes, the presence of the so-called "crud" is a constant challenge in solvent extraction. Crud is a stable emulsion which forms along the interface between the aqueous and organic phase. The spread is influenced by the following parameters: first, wind blows the dust and impurities into the open sedimentation tanks. Second, the undissolved solids such as sand transported in the PLS causing problems in conjunction with incorrect agitator design.The crud fraction can decisively impact the efficiency of the hydrometallurgical extraction because the phase interface can constitute a large fraction and the sedimentation tanks cannot react flexibly to it. In the downstream process of the series-connected sedimentation tanks, they are thus all contaminated with crud. At the same time, the necessary mass transport is significantly impeded at the phase boundary between organic phase and aqueous phase due to the crud formation.The transfer of the organic phase into the electrolysis cell can result in a "burnout" of the cathode. The carryover of this electrolyte into the extraction can cause problems with the pH regulation. The carry-over of the organic components into the raffinate also leads to contamination of the leaching circuit. The continuous treatment of the crud with a 3-phase decanter centrifuge is extremely effective in combating this problem. This technology splits all three phases from each other and they are consequently continuously separated. All subsequent process steps exhibit a stable, uniform effectiveness. The main advantage for the customer is that fluctuations in the process are eliminated and the organic phase can be recirculated back to the extraction. The recycling of the solvent alone justifies the investment in less than 6 months as examples from South Africa and Chile show.To operate solvent recovery in daily operation fully automated online at the optimum limit, the decanter centrifuge is equipped with a concentration-dependent pond adjustment called DControl® by this means, we can guarantee our customers the maximum possible solvent recovery and minimize the solvent costs in this process step. This system is presented in detail in this paper."

Jan 1, 2014

This paper provides a review of the chemical reactions occurring in the submerged arc processing of chromite ores. The excavations of industrial furnaces have shown that the charge, as it descends through the furnace, passes through a number of distinct reaction zones. Each zone is characterised by differing process conditions and reaction products. The phase equilibria, reaction steps and mechanisms occurring as the charge progresses through the furnace are examined, and the potential influences of these factors on the process outcomes are discussed.

Jan 1, 2004

By Douglas Bartley, Jay Elkin

The state of Pennsylvania was at one time one of the leading coal producing states in the east. However, legislation and industry trends over the last 10 years have adversely affected the amount of bituminous coal mined in Pennsylvania and the whole eastern United States. The application for and approval of a new mining permit is a very costly and arduous task. When a new mining operation is established it is crucial that nothing within the operator’s control causes the operation to stop producing. This paper discusses the action taken by a small mine in Pennsylvania when their blast induced vibrations rose to levels that typically would have resulted in a total mine shut down by the regulatory body governing such operations.

Jan 1, 2003

By J. W. Langford

A more effective method of fracturing and chipping the formation is necessary to significantly increase the productivity of blasthole drilling with a roller cone bit. The conventional rotary blasthole bit engages the formation and initiates spalls, chipping and fractures in the formation at a rate dependent on the amount of pull down force applied by the drill. The rotary speed of the drill increases the number of fractures and creates drilled chips that are removed from the hole by the air circulation. An engineering project was motivated to develop a low pressure, low impact downhole percussion hammer to provide an overstrike force to a blasthole bit, in addition to the conventional pull down force and rotary speed. The objective of the project was to utilize existing rig air packages in the range of 50-110 psig and provide an overstrike force to the bit in the range of 1100-1500 impacts per minute. Laboratory testing performed on Barre granite achieved, on average, a 40% improvement in rate of penetration. This performance has been confirmed in actual blasthole drilling in copper and iron ores mines. During the testing phase, additional unexpected benefits have also been realized.

Jan 1, 2011

ALTHOUGH the development of the various flotation processes during the last 8 years has been so revolutionary, this development has been, until recently, entirely confined to the separation of the gangue from the mixed metalliferous sulphides.The desirability of finding some method of separating the independent sulphides from such a miXture, by means of flotation, has long been recognized. ThIS need was emphasized when the slimes resulting from the grinding of Broken Hill sulphide ores were for the first time successfully dealt with by the Mineral Separation Company's process on the Central mine. This process proved the practicability of separating the sulphides of lead and zinc as a mixed concentrate from the gangue present in slime. Although this was a very notable achievement, the process has not been generally used, owing to the mixed lead and zinc concentrates resulting from the treatment being acceptable neither to the zinc nor the lead smelters.Although the introduction of eucalyptus oil in minute quantities as an emulsifying agent has simplified the work of the subsequent tabling of mixed sulphide concentrates, rendering unnecessary the burning off or removal of the oil, there will always be a considerable quantity of slimy product too fine to settle on the moving surface of the concentrating machines, and therefore requiring other means for its division into lead and zinc concentrates.

Jan 1, 1912

By Edith Lafontaine

Modern underground mines operate fleets of mobile production equipment including drill jumbos, long-hole drills, load-haul-dump machines, trucks and bolters. Their availability has a substantial impact onto production cost and thus onto mine profitability. Through appropriate collection of pertinent data and information, use of adequate performance measures and their analyses, mine operators can identify the most promising and cost effective opportunities to get more from their equipment and to reduce the overall cost. This paper presents results of the study aimed to review and analyse means and measures used to quantify equipment availability and its contributing factors (reliability, maintainability and maintenance support) in several Canadian underground mines. It overviews current reporting procedures, sources, quality and quantity of the data and information collected as well as examines performance measures and their definitions used by the surveyed mines. Problems concerning data acquisition as well as meaningfulness and usefulness of the above mentioned metrics are also discussed. The paper concludes with some suggestions and recommendations concerning several aspects of equipment availability assessment. It is believed that the latter may become a more useful tool for mine operators in their efforts to reduce production cost than it seems to be the case at present.

May 1, 2007

By R Shaw, M Hidding

The design of primary sample cutters for high-capacity conveyors is critical to achieving a correct sample, both in collecting the sample and ensuring smooth sample discharge flow. Modelling usually occurs at the design stage and requires extensive experience to achieve the correct result. However, it is difficult to confirm the effectiveness of the cutter design until after installation. Even with high-speed video, confirmation of complete sample capture is difficult, especially if the material characteristics change over time. Recent investigation using discrete element method (DEM) simulation to model the flow of the ore into the cutter and observe how it interacts with the cutter has revealed some interesting design requirements not observed in the past. By including DEM modelling, the correct design and optimisation of the cutter can be more accurately determined prior to commissioning.CITATION:Hidding, M and Shaw, R, 2017. Modelling ore flow in the design of high-capacity sample cutters, in Proceedings Eighth World Conference on Sampling and Blending , pp 145–150 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2017

By T. G. Sieber, T. D. Tiemann

The extraction of quartz from siliceous iron ores by dissolution in sodium hydroxide solution has been described in detail in AIME Transactions. l923 data reported covered the temperature range from 230-416°F, where a continuous increase in the amount of silica extracted with increase in temperature was found. It is the purpose of this paper to describe some unexpected results of more recent work exploring principally the range of 500600°F where higher rates and greater amounts of silica extraction were antici-p ted. In brief, the experimental procedure consists in digesting the ore under pressure in solutions of sodium hydroxide, filtering the suspension and weighing and analyzing the dried residue for iron content. The amount of extraction is calculated from the weight loss or from the iron analysis of the residue and that of the original ore.

Jan 1, 1969