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By Ramón Alanís, Filiberto Orrante, Andrea Festa, Baldomero Gutiérrez, Fernando Cornejo

"SGS implemented two rules-based fuzzy logic expert applications on two grinding circuits operated by Peñoles Group in Mexico. Both expert systems are based on control strategies that push against process constraints to improve throughput. Based on proven methodologies, the projects also required some new approaches that led to permanent changes to the mill control strategy.This paper provides descriptions of the implementation, operation and performance of both expert systems. It also reviews how improved production rates were achieved through the use of a common set of expert technology tools. An overview of the resulting control strategies implemented on the two circuits is presented. The paper also discusses the identification of the process constraints within each circuit and how these constraints are used within the expert systems.INTRODUCTIONMexico-based mining company Peñoles Group and the Advanced Systems group at SGS, formally known as MinnovEX Technologies Inc., collaborated on the implementation of two expert systems in two grinding plants, both located in Northern Mexico.The primary objective of the expert systems was to increase throughput whilst still maintaining the cyclone overflow product size within an acceptable range. The secondary objective was to achieve a high level of utilisation of the expert technology.In order to achieve these objectives, SGS proposed a proven methodology which leveraged the existing operating and technical expertise at site through the client’s involvement in the design and implementation stages. The in-house operating and technical expertise of SGS was also brought to the project and implemented with the client’s approval at all stages. At both sites the final acceptance was defined upon meeting both process and utilization parameters.The development and deployment of rules-based fuzzy logic applications has matured as a technology and consequently, clear definition of process states and their place in the logic structure to control a given circuit are now transferable. The key to the robustness of the control logic depends on selection and tuning rules for maintaining stability and optimizing a given circuit. Application integrators need to have a standardized approach for timely integration and deployment; a critical component to avoid the common critiques that expert applications are idiosyncratic and difficult to maintain."

Jan 1, 2009

By Peter N. Calder, J. L. Workman

There are many opportunities for computers to assist in dragline mine planning. Three important areas particularly lend themselves to computer assisted study. These are overall mine design and planning, the computation and display of range diagrams and the calculation of production and production variability. The computation of range diagrams is of particular interest because of the importance of matching the dragline and site geometries. This paper examines the uses of range diagrams in dragline mining and illustrates the application of computer techniques to the computation using one such program as an example. The use of computer generated range diagrams for machine selection, pit design and in parameter analysis is discussed. Directions for further development are also provided. There is a great deal that can be done to additionally enhance the ability to provide accurate designs for the dragline operation. One area that needs special attention is the dumping of overburden around access ramps into the pit. This situation is one of the most difficult dumping sequences and affects machine selection and pit operation. It is also suggested that programs that simulate the production schedule of the drag-line would be useful. It is concluded that large overall mine planning programs are very important in dragline mining. However, smaller programs designed for a specific, task are also important tools in many cases. These are easy to learn and use, well adapted to the PC environment and provide useful information, both for design and for daily planning.

Jan 1, 1989

By L. Bbosa

Paper written on project work carried out in partial fulfilment of BSc (Hons) (Eng) (Mechanical) degree Discrete element methods (DEM) are being used to provide detailed impact histories of the particles in comminution devices, such as mills. To match this immense detail of information, far more informative breakage tests than those that are generally conducted are now required. The split Hopkinson pressure bar apparatus is used in this study, as it allows the calculation of breakage forces and absorbed energies. The geometry of rock particles has been identified as significant, so this project undertook to identify the influence of shape on the breakage pattern of blue stone. Comparisons are then made between the breakage pattern of angular rocks and rounded, milled rocks for single impact fracture and consecutive impact loading at low energy. Results of this experiment indicate that although breakage for both geometries occurs over a similar energy range, rounded particles have the greater probability of fracture because they absorb more of the impact energy for a given loading. Size distributions of progeny show that five pebbles or more are sufficient to predict the distribution of most particles in small energy regimes. Cumulative impact testing shows that considerably more energy is required to break a rock through cumulative damage than through a single impact?this is of considerable importance in the light of the indications from DEM simulations that most breakage in a mill will be from cumulative damage rather than single impact breakage.

Jan 1, 2006

By F. T. Cawood, C. C. Birc

The South African mineral resource royalty system, initiated in 2010, employs a hybrid ad valorem approach tied to profitability ratios. This rate is then applied to the total revenue from mineral sales. In this article we explore how the profitability ratio in the mineral resource royalty formulae interacts with the gold tax formula as applied to South African gold mines, devising a strategy for cut-off grade optimization. The study focuses on nine narrow, tabular-reef (Witwatersrand) gold mines. The approach involves a mixed-integer cut-off grade optimizer utilizing Excel Solver, incorporating relevant royalty and income tax formulae. Different mineral resource royalty cost scenarios were examined. Ignoring these costs in the break-even analysis lowers the cut-off grade but slightly boosts profits compared to considering expected costs. The developed optimizer model, recognizing the profitability aspect of the mineral resource royalty and income tax formulae, yielded a 6% lower cut-off grade than the base case. This is significant for increasing mine life. While the profit differences are marginal (0.2% compared to the break-even base case), substantial improvements were noted: a 6% increase in stope tons above cut-off grade, and a 4% rise in total revenue. Enhanced resource utilization (3% extra gold kilograms) reduces necessary development and overall costs, allowing for a reduction in the cut-off grade and ultimately, more profit.

Aug 8, 2024

By Scott D. Thomson

The client for this project specializes in the use of state-of-the-art technology to fabricate and assemble composites and metal-bonded structures for commercial and military aircraft programs. One of the key components for this operation at the client's plant is a highly precise computer-numerical-controlled router known as the Shoda Machine. This machine tool was installed at the plant in July 1998 for the manufacture and inspection of aircraft parts, and it is extremely sensitive to deflections. To monitor the occurrence of deflections, an internal laser system continuously checks the machine calibration. Deflections in excess of 5/1000-inch in the foundation on which the machine rests require costly periodic re-leveling and recalibration of this tool. Therefore, a significant problem arose when measured deflections during machine operation were as large as 20/1000-inch. In addition, the foundation was cracked in at least three places as a result of elastic foundation movement caused by dynamic loading as well as shrinkage and loss of base support. Deciding on a remediation procedure to alleviate or eliminate these problems involved the following important considerations: (1) achieving the client's need for reducing deflections to less than 5/1000-inch, (2) minimizing the repair cost as much as possible, and (3) reducing the time required for implementation of the foundation remediation solution. After evaluating the advantages and disadvantages of several alternatives, jet grouting was selected as the most suitable solution. The jet grouting program provided columnar elements of soilcrete to remediate the Shoda Machine foundation.

Jan 1, 2003

By Jozef F. Zurawski

Increasingly new interceptors or new Combined Sewer Overflow (CSO) projects require connections to existing tunnels. More often than not, the existing facilities are old, in poor or questionable conditions, without proper construction records or as-built drawings. Many cannot be easily inspected unless major construction effort provides flow by-pass for safe access. This paper provides general guidelines on how to approach the problem of assessing the condition of old tunnels, how to plan and design the connection with limited physical assessment, how to develop the scope of work for the bid documents and how to provide geotechnical guidelines and designs for the bid documents.

Jan 1, 2008

By Grafton Thrasher

For the proper discussion of this subject it is necessary to incorporate in this paper the substance of part of an article published by rite in Metallurgical and Chemical Engineering for January, 1915. CAST-IRON TEST PLUG, SHOWING LOW MOTTLED AND MOTTLED FRACTURES. Several years ago, while I was thief chemist for a malleable-iron company, it occurred to me that the mere regulation of silicon was not sufficient to produce the desired degree of chill. But only after repeatedly encountering this fact in befit open-hearth and air-furnace, as well as cupola metal, was I led to regard variation in the total carbon as the principal cause of disturbance; and I resolved to determine the total carbon as well as the sill on ill every heat, and by a carefully prepared test piece to gauge the approximate degree of chill. The test piece selected was a round plug, 2 in. in diameter and 12 in. long, cast on end

Jan 10, 1915

By J. A. Abols, P. M. Grady

Recovery via gravity is one of the oldest mineral processing methods available. Unfortunately, the use of gravity techniques for gold recovery has been in decline for the past century as more effective chemical processes such as flotation and leach/CIP have been developed. Recently, with the push towards more sustainable environmental outcomes, the benefits of gravity separation have become more apparent. While gravity as a unit process is not usually capable of achieving as high a recovery as flotation or whole ore cyanidation, a combination of gravity devices alone or in conjunction with these processes can offer significant advantages to the operator. This paper reviews the range of gravity devices available, their application and the results that can be achieved by maximizing gravity through the use of a combination of gravity recovery devices. Three case studies are provided.

Jan 1, 2005

The interaction between ore-bearing fluids and the siliciclastic rocks typically hosting orogenic gold deposits in Phanerozoic metamorphic terrains result in the development of a distinctive alteration halo. Along with petrological changes such as the replacement of chlorite by carbonate and the growth of sericite, characteristic geochemical modifications take place within this alteration envelope. These include variations in elemental abundances and more or less pronounced shifts in the H, C, N, O, and S isotopic signature of the ore system. æFingerprintingÆ these isotopic trends can provide exploration with additional vectors towards the ore zone, and yields valuable information regarding the source of the hydrothermal fluids and the solutes contained therein. Data from radiogenic isotope systems such as Sr-Rb, Ar-Ar, Xe-Ra, Pb-Pb, Re-Os, Sm-Nd, and U-Pb can constrain the kinematic history of ore-hosting structures, provide important clues concerning the absolute timing of gold emplacement, and enable the detailed characterisation of associated intrusives with respect to their magma source(s) and crystallisation age. Although high analytical costs, long turn-around times and the potential for misinterpretation prevent isotope systems from offering a æquick & dirtyÆ analytical method that would provide a significant advantage in exploration for orogenic gold mineralisation, the development of integrated four-dimensional ore genesis models depends heavily on constraints obtained from isotope mass spectrometry.

Jan 1, 2002

Innovative and Resource-Preserving Washing Processes for Primary and Secondary Raw Materials

Sep 13, 2010

By P. J. Brereton-Stiles, C. J. Hockaday, I. J. Barker, M. S. Rennie

This paper reports on studies that have been done on the electrical conduction in silicon, ferro silicon, and charge chrome furnaces. A system has been developed that can distinguish between normal resistive conduction and arcing, and this was used to quantify in particular the relative amount of arcing that takes place in these furnaces. It was found that silicon and ferro silicon behave similarly and exhibit a relatively large amount of arcing. Charge chrome on the other hand exhibits considerably less arcing, and the extent of this arcing is highly correlated with the tapping of the furnace. The arcing measurements can also be used online in the control of the furnace, both for the electrodes and electrical circuit, and for the raw materials.

Jan 1, 2007

By B. J. Sauer

Variable frequency drives (VFD’s), or adjustable frequency controls (AFC’s) as they are more precisely identified, have been available to the mining industry for over 20 years. However, in recent years as the push to cut production costs has become ever so crucial, AFC usage has become more widespread. This paper seeks to provide professionals in mineral processing plant design and operation with an introduction to AFC’s, insight as to why AFC control for AC induction motors can be advantageous, and specification and design considerations.

Jan 1, 2002

By Alex Naudts

Pre-excavation grouting is a predictable and reliable technique performed to prevent or minimize settlement in advance of, or during the tunneling operation. It safeguards the infrastructure above the tunnel alignment. Cement based suspension grouts and sodium silicate based grouts are frequently injected to consolidate and strengthen the formation and create a reinforced canopy above the tunnel trajectory. Grouting is typically performed through permeation and permeation in conjunction with hydrofracturing. Multiple injection passes through steel sleeve pipes are ideal, since they create an effective forespiling system to facilitate tunneling without causing unacceptable settlement, even with minimal overburden thickness. Ten pre-excavation grouting projects performed in the North America are discussed in this paper.

Jan 1, 2008

By W. C. A. van Niekerk, M. H. Fourie

The carcinogenic potential of chromium (VI) has been the subject of numerous environmental and occupational studies, from which many regulatory efforts emanated. Besides the regulation of levels of known toxic substances (e.g. Cr (VI)), the classification of dusts for regulatory purposes has thus far depended on broad definitions of particle size, mainly used to distinguish only between inhalable and respirable particles. In the past, ultrafine particles (less than 0.1 µm diameter) (PM0.1) were often regarded as a non-issue, because it was believed that significant doses would not deposit in the lungs. A growing body of scientific data is indicating that ultrafine particles are more toxic than their coarse counterparts. Increased toxicity can be related to the unique dosimetric aspects of the deposition and disposition of inhaled ultrafine particles. Secondly, ultrafine particles have a larger surface area per given mass. The increased surface area can act as a carrier for co-pollutants, specifically transition metals (including chromium) that could form a coat on the particle surfaces during particle formation. This suggests that the presence of ?inert? ultrafine particles in the environment may enhance the potential for exposure to reactive airborne compounds, including Cr (VI). These factors are particularly important when information on occupational epidemiology is interpreted. It is desirable to consider the particle size distribution, for example when occupational exposure to hexavalent chromium compounds is assessed. Since ultrafine particles are more toxic than coarse particles with the same chemical composition, it could be speculated that cancer slope factors might be related to particle size distribution. This is relevant not only to carcinogenic chromium compounds, but also basically for any particle-associated toxicants. In general, the probability of developing health effects associated with occupational toxicants is likely to be higher when these are associated with the ultrafine particle range.

Jan 1, 2004

By Michael Amick, G. Swan, R. Hill, C. Pritchard

Falconbridge, a major base metal producer in the Sudbury Basin of Ontario, identified a need to find a safe and cost effective replacement for welded-wire mesh used to support loose ground during underground nickel mining. Falconbridge took a methodical approach to the concept of a spray-on liner as a screen replacement proving the strength characteristics of the liner as a safe, cost effective, and suitable method of supporting ground. Compact, hydraulic mixing and spraying equipment have been developed and are in use at the Fraser mine. The Tekflex material has been approved as a wire-mesh replacement and has been in use since November1998.

Jan 1, 2000

By W. A. Naismith

On 16 July 2004, at 07:10 a collapse of about 1.8 million m3 (about 4 ½ million tons) took place on the north wall on Nchanga Open Pit. This collapse was the result of a developing instability that was first identified when the benches in this area were exposed during September 2002. The NOP geotechnical and survey departments closely monitored the development of the failure. Control measures were implemented to reduce risk to men and equipment. These measures were continually improved and adjusted in reaction to observations and changing conditions. The purpose of this paper is to describe in detail the monitoring results that were obtained both by traditional methods and the novel slope stability radar system (SSR). Difficulties encountered in establishing critical deformation levels and deformation rates that can be used to predict the onset of collapse are described. Details of the monitoring and control measures, which led to the successful completion of mining in the area, are also described in this paper.

Jan 1, 2005

By K Palmer

Alluvial platinum was recovered during gold mining operations in Maud Creek, a tributary of the Howard River. Average electron probe analyses give Pt 88.75, Fe 5.27, Ir 0.70, Os 1.06, Pd 0.34, Ru 0.14, Rh 1.29, Cu 1.06. Rare grains of a Pt-Fe-Cu alloy are also present and an unusual feature of all grains is the relatively high rhodium content which finds expression in segregations of rhodium arsenide, cherepanovite. Platinum is found in the Orepuki area of Southland, where it is probably partly derived from the mafic rocks of the Longwood Complex. Rocks of the Rotoroa Complex, similar to those of the Longwood Complex, form bedrock in Maud Creek and are possibly the source of the Howard platinum. Alternatively, it might be derived by glacial transport from the Matakitaki ultramafic block 30 km to the southwest. Origin from the Rotoroa rocks is preferred as, if the Matakitaki rocks are part of the Dun Mountain Ophiolites, they might be expected to contain osmiridium rather than platinum. The ratio Pt:Ir-Os has been widely used to distinguish low Pt:Ir-Os ophiolitic from high Pt:Ir-Os gabbroic assemblages. Mafic complexes such as Longwoods, Darran, Rotoroa, and Riwaka might be expected to show similar high Pt:Ir-Os ratios and be targets for platinum exploration. Detrital platinum examined from the Parapara area, Golden Bay is mainly osmiridium, with rare grains of rutheniridosmine, very similar in composition to that found in concentrates from the Kaniere dredge, West Coast.

Jan 1, 1987

By J. I. Mathis

"The failure that was utilized for developing this model was a double bench-scale failure, approximately 20 m in height, in the Misery pit at BHP Billiton’s EKATI mine site. The bench that failed was excavated in biotite schist. Due to previous problems with bench-scale toppling failures, this bench was excavated with a 70° inclined, 30 m deep preshear. Upon exposure, the wall was very clean with half-barrels commonly observed from the pre-shear operation.In August 2003, a bench failure of about 1000 t occurred in this pre-sheared biotite schist (Fig. 1). Upon examination it was noted that the foliation that paralleled and dipped at 70° into the face when excavated was approximately horizontal at the top of the failure (Fig. 2). While the failure mode itself appears complex, the failure was apparently driven by three factors:• a low-angle, low-frictional strength fault or discontinuity at the base of the failure area;• water either contributed meteorically from precipitation and/or from permafrost melt; and• foliation planes providing a viable toppling geometry once toe block motion began to occur.The above details are illustrated in Figure 3.After considerable thought and analysis, a model was postulated for the failure.It is thought that the entire failure had been triggered by displacement of a toe block (Fig. 4). This toe block is bounded on the back by foliation, the bottom by a low-angle, lowstrength fault, and the front by the bench face. Water pressures behind the bench face developed forces on the block as can be seen in Figure 5. These forces were sufficient to induce block motion. As can be seen in the relative shear strength diagram in Figure 6, only a small amount of water is necessary in the face to initiate block displacement. Note that in this figure, a simplistic piezometric pressure distribution was assumed."

Jan 1, 2004

By David R. Gossett

For the 22nd year, the chance to exchange knowledge, experience and business cards drew hundreds of mining and phosphate professionals for a two-day regional Phosphate Conference in Lakeland, Florida Nearly 400 people participated in the October conference, which focused on the phosphate industry?s future success. There were 41 exhibitors, 13 program advertisers and 23 sponsors among those supporting the conference. It was chaired by David Gossett, 2006-2007 SME Florida Section Chairman. In the opening panel session that he chaired, John Garlanger (SME) of Ardaman and Associates posed the questions; ?How successful has the industry been? How do we measure it and what factors contributed to the industry?s success? How long will the ethanol boom last? Can the industry obtain the permits it needs to mine for the next 30 years? Can the industry attract and retain the quality of workers it needs??

Jan 1, 2008

SAG Mill Grinding Design Versus Geometallurgy - Getting it Right for Competent Ores Smarter processing for the future, in the area of SAG mill design involves accurate grinding test data, completing final mill design in less than three months, and at a cost of less than US$80 000. More detailed variability testing on the other hand takes longer, is more expensive, and is used for throughput optimisation for an existing or newly purchased mill. This paper shows that SAGDesignTM testing is excellent for new SAG plant design due to relatively low cost per test and the ability to do more testing for a limited budget on larger projects. It also briefly examines a way to develop proper geometallurgical ore hardness information on every block in the mine model, from the more detailed analysis data.

Sep 13, 2010