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By D. J. de Clerk

Global trends stipulate the need to optimize existing assets while reducing environmental impacts. This paper illustrates the procedure that was followed to achieve such goals at one of the coal burning flash dryer units at an Anglo American smelter. An in-depth study of the process and related literature led to the development and installation of a revised control philosophy. This system includes modifications to the existing regulatory control structure as well as a hybrid rule-based and model-predictive advanced process control (APC) layer. Since commissioning of the APC, this flash dryer?s average throughput has increased by more than 6%, despite higher feed moistures. Furthermore, even though coal consumption has increased slightly, operating efficiency has improved by close to 5%. This was made possible by improving stability of the drying column outlet temperature by approximately 40%, which in turn enabled selection of a more optimal setpoint. Recent data has shown that APC utilization now exceeds 95%. This is indicative of a successful controller installation with good site acceptance. The same philosophy has therefore since been rolled out to most of the other flash dryers in the group.

Jan 1, 2012

By Stephen Mansfield, Nathan West, El Khalil Seyed

In October 2017, a multi-bench failure occurred in the east wall of the Guelb Moghrein copper and gold mine in Mauritania. The failure extended 100 m (328 ft) vertically and horizontally and resulted in the sterilisation of ore, but no equipment or personnel were put in danger. The remediation plan successfully removed the failed material and the cutback resumed to a modified pit design, leaving ore reserves behind. In 2021 after completion of mining in another part of the pit, a plan was formulated to develop a narrow cutback behind the failed wall and recover the sterilised ore. Infill drilling defined a resource of approximately 2.9 Mtonne (3.2 Mton) of ore at 0.78% Cu and 0.67 g/t Au at a strip ratio of 5.5:1. The high strip ratio meant that it was necessary to mine thirteen benches of waste, or 156 m (512 ft) vertically, over a two-year period before reaching the first ore, with the cutback only being economically viable if all ore could be depleted at the end of the third year. The high economic risk of the project required a holistic approach to mitigate the risk of another wall failure, by addressing the following areas: 1. Pit Design: with help from an external Geotechnical Consultant, the pit design was optimised to include increased factors of safety, reduced stress points, lower overall slope angles and straight lined walls were replaced with curved walls. 2. Geotechnical Management: the site Geotechnical Superintendent worked closely with an external Geotechnical Consultant to better understand the structural geology. Slope monitoring was improved through an expanded network of prisms, regular in field inspections and the use of a slope monitoring radar. 3. Drill and Blast: new drill and blast designs were developed from first principles, consisting of production, wall control and presplit designs. Blast master polygons and bench development sequences were developed with consideration of the structural geology and the influence of the initiation designs. 4. Mine Operations: improving operational discipline was a critical factor that ensured the accurate execution of drill and blast designs and excavation to bench levels and pit limits. This holistic approach has enabled the safe development of the cutback down to the 936 RL (relative level), two benches below the point at which the previous wall failure occurred. Extraction of ore has occurred from the 960 RL, and due to faster than planned excavation rates, the cutback is expected to be completed ahead of schedule.

Jan 21, 2025

By D Genge, E Martin, T Goswami, M Rothery

Rio Tinto’s Hunter Valley Operations is a large open pit coalmine situated in the heart of the Hunter Valley in Australia. The Riverview West Pit has faced increasing production challenges in recent times due to decreasing dragline strike lengths and increasing environmental constraints on vibration, overpressure and fume generation. Conventional mining techniques would involve five to six production blasts per strip to recover multiple coal seams. Each blast event carries the risk of exceeding the strict environmental requirements. By working collaboratively with Orica, it was realised that the blasting method known as Stratablast™, in conjunction with advanced computer modelling techniques, could provide productivity gains whilst simultaneously providing more control over the environmental effects and the impact on nearby infrastructure.As a result of this change, the number of blasts per strip was reduced to one, with the implication that a great deal of care and forethought was needed to manage the increased challenge posed by multiple constraints in the proposed mining area. This innovative approach of combining throw and stand-up blasts allowed the extraction of all major coal seams in a single pass blast event. The blasts were initially designed with a large factor of safety to stay within environmental limits as they were over 1.1 km in strike length, with more than 800 holes and with a total charge weight of about 1000 t of bulk explosives. Furthermore, there were conflicting priorities around the desired blast outcomes. So far, 11 such blasts have been designed and successfully fired. After each blast, innovative design changes have been iteratively implemented to provide further control over environmental impacts, whilst continuing to improve productivity. As a result of these changes, blasts have progressively increased in complexity with the inclusion of features such as damage zones, mid-splitting, time gaps and different directions of firing. The consequence of this complexity is that the blast duration can be as long as 28 seconds to accommodate all components of the blast.This project has increased the productivity of the Riverview West Pit through blast design improvements and allowed the environmental impacts to be managed with far more control and predictability than would have been possible under a conventional blasting regime. There still remains room for further optimisation of mine productivity and this is being addressed through a process of continuous improvement.CITATION:Goswami, T, Martin, E, Rothery, M and Genge, D, 2015. A holistic approach to managing blast outcomes, in Proceedings 11th International Symposium on Rock Fragmentation by Blasting, pp 645–654 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 24, 2015

By Tom BoBo, Seth Gering, Jeff Loeb

Presenting a D&B feedback loop built on a well-designed blast, proven fragmentation analysis and blast monitoring solutions, underpinned by technology that not only increases profit from every blast, but also increases a mine’s purchasing power over one of the most expensive part of the process – explosives.

Feb 1, 2020

By K. Sample

Slope stability analysis plays an integral role in the design of various mining applications including waste dumps, heap leach piles, solution ponds, and tailings dams. Generally, limit equilibrium analysis using one of the several prevalent approaches is considered adequate. The density, saturation, and shear strength parameters of the materials forming the slope affect the failure mode and the calculated factor of safety (FS) against sliding. These parameters are generally based on laboratory tests. Field practices and construction procedures are often not completely simulated in the laboratory for various reasons (e.g. equipment limits, time and budget restraints, etc.). This paper presents a holistic assessment of slope stability analysis as practiced in mining applications, using example data from multiple heap leach projects. A sensitivity analysis is presented for variations in material properties, data interpretation, and computation methods. For each step in the design process, the possible variations in parameter values were identified and then used to perform traditional and probabilistic stability analyses. This simple, cradle-to-grave-type approach is used to evaluate the reliability of an example design, and the combined impact of multiple uncertainties on the factor of safety. Example Study The issue of addressing uncertainty in geotechnical design has been discussed in depth by numerous authors (Duncan 2000; Christian 2004; Whitman 1984; Christian et al. 1993). One may ignore the uncertainties involved in a design, take a conservative approach, rely on observational methods (Peck 1969), or attempt to quantify the uncertainty. Geotechnical projects in general, may include a combination of these methods. For important structures, such as heap leach pads, it is critical that sources of uncertainty in the stability analysis be acknowledged early on and considered in the overall design approach. As with any project, economics and other physical constraints, such as space limitation, often do not always allow for an overly-conservative, robust design. In an effort to quantify uncertainty and provide a sense of level of confidence in the safety and reliability of a design, probabilistic methods have been developed and implemented in many slope stability software packages. Reliability methods are often used in the design of open pit mine slopes, but not as commonly in designing heap leach pads and waste dumps. As an example, the stability analysis of a copper heap leach project is presented here to evaluate the effects of multiple sources of uncertainty and differing methods of data interpretation. Some of the parametric values, or the variation therein, are assumed on the basis of actual data from multiple heap leach projects, included in the paper as well. A generic representation of the example case study is shown in Figure 1. As depicted in the cross-section, the ultimate height of the design is 114 m (measured from the crest to the toe). The overall slope of the heap leach pad is 1.88 horizontal to 1 vertical (1.88H:1V), or 28°. The slope benches are considered in the overall slope. The example leach pad is founded on alluvial, colluvial and residual soils overlying weathered limestone. The ore to be placed on the pad is characterized as poorly graded gravel (GP) with average fines content (percent passing #200 sieve) of 4%. The liner subgrade is low permeability (fine) soil. The cover or the drainage material, placed directly above the geomembrane (between the liner and the ore), is crushed ore in this case. The phreatic surface was assumed to be 1 m above the base liner, which is what the collection system over the liner is typically designed for. [ ] In heap leach pads, typically, Linear Low Density Polyethylene (LLDPE) or High Density Polyethylene (HDPE) is used as the base liner. The decision is based on the elongation, strength and other requirements of the application as well as economic considerations. In this example study, the base liner was 80-mil single-side textured LLDPE. FIELD INVETIGATION AND SAMPLING When selecting appropriate values for the input parameters of the stability analysis, the level of uncertainty in the data and the assumptions that are made must be clearly identified and considered in the design. This concept has been emphasized through an extensive number of publications regarding geotechnical uncertainty and reliability (Christian et al. 1994; Duncan 2000; Christian 2004). The primary source of uncertainties involved in slope stability analysis for mining applications is inadequate geotechnical investigation, often lacking in a thorough assessment of in-situ material characterization and sampling disturbances. To emphasize this point, some background information is presented here. The tradeoff between the costs of a thorough site investigation versus the risks of design uncertainty has long been a challenging management decision in geotechnical projects. For mine sites, significant investment is typically made in exploration and estimating mineral resources and the geology of a mine site is often more thoroughly documented than other types of geotechnical projects. Nevertheless, the engineering properties of the soil and rocks relevant to slope stability receive less emphasis. Baecher and Christian (2003) observed that the areas of geotechnical concern, such as slopes and waste disposal facilities, are usually associated with mine costs rather than revenue, and therefore, significantly less money is devoted to their site characterization and laboratory testing. The expenditure for site investigations varies significantly from project to project, with higher levels of uncertainty and, therefore, the

Jan 1, 2009

By Russell C. Frith

This paper examines the design of longwall shields, focusing on those aspects that are critical to either their successful application or contribution to failure during longwall extraction. In many instances, longwall shields are assessed and designed along lines similar to that of roadway ground support systems, namely according to typical or normal geotechnical conditions. However it will be contended that for longwall shields, this is inappropriate because unlike roadway ground support systems, longwall shields cannot be supplemented with additional or secondary support in localised areas of adverse geotechnical conditions. In other words, the longwall shield needs to be designed according to what are judged to be worst case or adverse geotechnical conditions?the outcome being that a well-designed shield will be significantly over-rated for the majority of its working life. Therefore, it will be argued that the additional capital cost of such shield design can be readily justified as a prudent riskbased outcome that is essential to minimising future business risks due to strata instability on the longwall face. Shield geometry will be discussed, including such relevant factors as leg angle, inclination of the top caving shield, canopy ratio, operating height range, and tip to face distance. These are all well-established longwall shield design considerations and, most importantly, areas whereby inadequate design can render a longwall shield as highly ineffective. The issue of tip to face distance will be considered in detail, in particular, the extent by which it is an important geotechnical design consideration, the conclusion being reached that, in fact, it is not. The critical importance of maximising set to yield ratio within practical operating limits will be justified, the wisdom of this having been subject to questioning in more recent technical literature. Overall, the aim is to provide the industry with a set of suggested guidelines for future use when designing longwall shields and, hopefully, to initiate discussion on a subject that, unlike roadway ground support design, is not well covered in its entirety in the published technical literature.

Jan 1, 2013

By R M. Krek

The haulage system used to convey ore from an underground mine to a surface stockpile at the mine process plant is a vital component of the mine’s overall infrastructure and economic viability. The system selected has a significant impact on the set-up of the mine and the access to the underground mine. In turn, the set-up of the mine and the access to the underground mine have a significant impact on the system.A number of haulage technologies are available to transfer the ore from the underground workings to the surface stockpile, including hoists, conveyors, rail and trucks.This paper focuses on the shaft hoisting and inclined conveyor haulage technologies. These technologies have been used consistently to deliver ore from at depth and/or at high tonnage. Previous reviews of the appropriate vertical haulage systems have nominally been restricted to the respective systems only, with no consideration for any other scope or issues that may affect the selection. The selection of the appropriate vertical haulage system, whether shaft hoisting or inclined conveying, needs to consider numerous key factors.CITATION:Krek, R M and Northcote, A E A, 2014. A holistic viewpoint for selecting the vertical haulage system – shafts and conveyors, in Proceedings 12th AusIMM Underground Operators’ Conference 2014 , pp 289–296 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Mar 24, 2014

By H Arvidson, Rondinelli Sousa, Nic Pollock, Cesar Carrasco, Boz Elloy

Global public mineral reporting codes have driven strong governance of public disclosures of minerals information. Recently, we have seen an increase in disclosure of information related to Environmental, Social and Governance (ESG) issues, and governance of ESG information in mining companies has arguably reached a similar level of governance and diligence afforded mineral reporting. We define Resource Governance as the conjunction of environmental, social and minerals governance. A modern systems approach to Resource Governance, which combines mineral and ESG information, would provide not only reporting and governance capability, but also has the potential to sense/respond, predict, and manage ESG risks.

Feb 1, 2024

By A. Alwasel

Musculoskeletal disorders (MSDs) threaten the wellbeing and livelihood of a large number of construction workers incurring a significant cost to society. We present a new method to monitor and diagnose MSD risks in the workplace. The sensing unit of the system is an optical encoder encompassed within a non-intrusive exoskeleton to measure the joint angle of interest. This sensor can be applied to ball-and-socket and hinge-type joints of the human body, such as the shoulder, elbow, and knee joints. The system is contactless and does not require markers or cameras. Angle measurements are acquired directly without mathematical post-processing, thereby avoiding numerical noise and drift challenges. The system is a simple, robust, and deployable, but it currently lacks resolution of parallel degrees of freedom.

Aug 1, 2013

By Kathleen Madland Kowalski

In recent years the issue of human stress response in emergency workers has begun to receive attention. This paper presents a rationale for considering human stress as a significant factor in the management of emergencies. It discusses the concept of stress, Critical Incident Stress in emergency responders, and introduces the Critical Incident Stress Debriefing (CISD) process. It is suggested that, in a disaster, the CISD process can improve the effectiveness of response teams on site, their turnaround time on site, and post disaster time off the job. This paper, prepared by a US Bureau of Mines research psychologist, offers some ideas to the mining industry in general, mine rescue trainers, and more universally, to those responsible for developing emergency management plans.

By Kathleen Madland Kowalski

In recent years the issue of human stress response in emergency workers has begun to receive attention. This paper presents a rationale for considering human stress as a significant factor in the management of emergencies It discusses the concept of stress, Critical Incident Stress in emergency responders, and intro¬duces the Critical Incident Stress Debriefing (CISD) process. It is suggested that in a disaster, the CISD process can improve the effectiveness of response teams on site, their turnaround time on site, and post disaster time off the job. This paper, prepared by a US Bureau of Mines research psychologist, offers some ideas to the mining industry in general, mine rescue trainers and more universally, to those responsible for developing emergency management plans.

Aug 1, 1998

By E Garbarino, P Molina, V Badino

Given the ever increasing quantity of construction and demolition waste (C&DW), one of the most challenging issues presently facing policymakers and public administrators in Italy concerns how to organise and manage collection and recycling and to understand whether and to what extent recycled aggregate can complement natural building aggregates in a sustainable supply mix (SSM). The paper presents the results of a research aimed at analysing energy and environmental implications of the C&DW recycling chain in the administrative territory of Provincia di Torino in northern Italy. In respect of a population of about 2.25 million inhabitants, the annual production of C&DW in the area under study is 1.8 Mt. A combined geographical information system (GIS) and Life Cycle Assessment (LCA) model was developed, paying attention to the geographical location, land use, transportation network and avoided landfill: crucial issues for sustainable planning and management. Around 90 recycling plants were classified according to the size, typology (stationary, semi-mobile and mobile) and physical- mechanical characteristics of the recycled aggregate. Under different assumptions relevant to the delivery distance, and considering the typology and grade of recycled aggregate, as well as local availability of natural aggregates, it was possible to evaluate the geographical coverage of aggregates demand and to use LCA in order to identify and quantify energy and environmental indicators.

Jan 1, 2009

By S. M. Spottiswoode

The aim of the hybrid location method is to improve seismic event locations by reducing the effects of errors in the wave velocity of ray paths between each event and each recording site. We report on further enhancements made to the hybrid location algorithm, which is based on the double-difference method developed by Spottiswoode and Milev1and Waldhauser and Ellsworth2. The term ?double-difference? refers to the residuals between the observed and theoretical travel-time differences and are obtained using either picked arrival times or various measures of time differences obtained from waveform pairs. These residuals are minimized for pairs of earthquakes at each station while linking together all observed event-station pairs. An important enhancement is that the double-difference term uses the median arrival time residuals to reduce the effect of outliers on the system of equations. In addition, the hybrid locations are further constrained by considering events of known locations, in this case along lines of development blasts. We relocated some 20 000 previously located seismic events in the Driefontein 5E area; 5 800 of these events were considered to have been development blasts and we constrained their locations to lie on the straight lines joining about 2 150 survey pegs from the mine?s database. Relocated events were shown to distribute more closely around advancing faces than had been the case before relocation. Wave velocities from the development blasts show evidence of anisotropy.

Jan 1, 2005

By P. K. Davis

The results of a previous basic study of the flow and design characteristics of the hydrocyclone has shown that a recovery as high as 99% with a product rating of 0.95 can be achieved on a "batch?2 basis with a single, water-only cyclone if it is configured properly. The next logical step was to demonstrate continuous processing of gob for the efficient recovery of coal by means of a laboratory-size demonstration system. A project to design and construct such a single-cyclone system was also sponsored by the U.S. Department of Energy. A recovery of 93% with a product rating of 0.89 was demonstrated. The system design and the data taken are discussed.

Jan 1, 1989

By J. K. Grunig

A process consisting of leach, continuous countercurrent decantation, resin-in-column ion exchange, evaporative crystallization of beryllium sulfate, and decomposition of the sulfate was developed for Spor Mountain, Utah, ores. The process is metallurgically sound, has a minimum of process steps, and is applicable to a wide variety of beryllium ores. The most novel aspect of the process is a resin system of ion exchange which is highly selective for beryllium and which rejects substantially all impurities except for minor amounts of aluminum, magnesium, fluorine, and sulfate in addition to beryllium. The oxide from sulfate decomposition meets specifications of potential users.

Jan 1, 1982

By Toshiaki Akahoshi

Keywords: Wasted catalyst, Hydrodesulfurization, Ammonium vanadate, Ammonium molyb-date, Hydrometallurgical process. The fundamental reactions have been investigated in order to develop a hydrometallurgical process for recovery of molybdenum and vanadium from wasted catalysts generated in the hy-drotreating desulfurization of heavy oil. The principal steps of the process are a mild oxidation roasting of the waste catalysts at temperature around 500°C, leaching of the target metal components with dilute ammoniacal aqueous leachates, selective precipitation of vanadic acid, and ammonium molybdate precipitation. The selective recovery of vanadium as vanadic acid is successfully performed using ammonium sulfate as a salting-out agent. Recovery of ammonium molybdate is based on large dependence of solubility of ammonium molybdate in ammoniacal solutions upon temperature and ammonium salt concentration. In this process, the solution after recovery of vanadium and molybdenum is recycled to the leaching stage of the roasted materials, and the ammonium salts in the process liquor is in the repeated use. Employment of am-moniacal system makes it possible to operate the roasting at much lower temperature than that for the currently operating process.

Jan 1, 2005

By William Gleason

"It has been more than 10 years since Montana Resources’ copper/molybdenum mine has had a lost-time injury at its site in Butte, MT. With more than 350 employees and an average production of about 15.5 Mt/a (17 million stpy), which includes 29.5 kt (65 million lbs) of copper and 4 kt (9 million lbs) of molybdenum, the mine’s journey to a decade of exemplary safety is an impressive feat that has required hard work, commitment and, most of all, leadership from every level of the operation.It has not always been an easy journey, nor has it been one without scrapes and bumps along the way, but it is one that has produced stellar results. Mike McGivern, vice president of human resources, and Pete Steilman, safety manager at the mine, spoke with Mining Engineering about how the operation transformed from a site that was accustomed to collecting citations for safety violations to one that is now collecting awards for its safety record.Simply put, Montana Resources has made safety a value and the people its top priority.The operations faced many predictable challenges in 2003, when the mine was being brought back online after three years of sitting in care-and-maintenance status. It had been shuttered in 2000 because of low commodity prices and high operating costs, and, in the three years that the mine was idled, the equipment became dilapidated, and some of it was no longer in compliance. Less than half of the workforce returned to the site for the restart, and the team was challenged with getting the gears turning again to produce copper and molybdenum. But the most daunting challenge of all of was keeping the workforce safe during the transition.In the first few years of operation the mine racked up citations from the U.S. Mine Safety and Health Administration (MSHA) at an alarming pace, so much so that in May 2006, Montana Resources received a letter from the MSHA District Office informing the company that the operation was being placed on the Potential Pattern of Violations list due to its excessive citation history and high rate of significant and substantial citations. It was clear that something significant had to be done to change the course of action at the mine."

Oct 1, 2019

By Ruilin Yang

Kinematic approach of blast modeling refers to using the velocity, strain, or displacement as controlling parameters to model blasting, rather than the stress and the material constitutive relations. The rock stiffness or constitutive relations is very hard or impossible to obtain due to the complexity of the rock mass property.

Feb 1, 2020

By R. Yang

This paper presents a kinematic approach for blast modeling with examples of blast models that were developed previously. A kinematic approach was applied successfully in developing blasting models that can simulate all blast design parameters for field applications. Several applied blasting models have been developed and applied widely in the world. A kinematic approach to blast modeling refers to using measurements of kinematic quantities such as the velocity, strain, or displacement and well-established assumptions to model blasting phenomena, rather than being restricted to use first principal of physics, such as, the stress- and material-constitutive relations. The kinematic quantities are easy to measure in the field. Due to the complexity and inhomogeneity of rock mass properties, using first principles of physics, many parameters of rock and explosive properties must be involved, which are hard or impossible to quantify. This creates a major impediment when trying to simulate the total process of blasting based upon first principles of physics. The 3D kinematic model for muckpile formation was developed and applied to open pit blasts. The multiple blasthole fragmentation model developed during recent years has been applied successfully to many mine sites around the globe. These models are typical examples of blast modeling using the kinematic approach, which enables the models to catch major trends of the blasting process and explicitly simulate full blast design parameters and complex geometries. Blast modeling using the kinematic approach results in easy model calibration and validation against field measurements and effective applications to practical problems. Using kinematic models of the muckpile formation and the multiple blasthole fragmentation model, this paper demonstrates the merits of the kinematic approach for blast modeling. New developments of the models were also presented in the paper, which illustrate the potential of the kinematic modelling approach.

Mar 2, 2022

A kinetic model for leaching of various metals with different lixiviants in a batch system has been developed. Material balances for reactants and products at the solid/liquid interface were formulated and solutions to these balances were obtained in view of practical conditions. Special emphasis has been given to examine mixed controlled reaction systems where both heterogenous reaction and mass transfer play important role on the overall rate expression. The resulting kinetic expressions for either powder or rotating disc are discussed in light of experimental findings for various metals. Examples of the metal dissolution systems considered in this study include cobalt, nickel, copper and gold in acid, cyanide or ammoniacal solutions.

Jan 1, 1992