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By Z. Zhang, D. Bouchard, H. Blanchette, A. Lemieux

This paper describes quality control methodologies for the production of semisolid A356 aluminum slugs with the SEED process. A methodology based on destructive tests carried out with an apparatus measuring the force to slice the slugs is presented. The force measurements were correlated with the solid phase morphologies of the slugs and were validated against a non destructive methodology that consisted in monitoring the temperature evolution of crucibles to produce the slugs and the drained metal. Results from the destructive and non destructive methodologies are compared and discussed.

Jan 1, 2006

By Paul B. Batten

Shutdown is a generic term for what may be called an Outage, Turn Around (TAR) or Overhaul etc. Running a plant shutdown well has always been key to the financial contribution of a mine. However, something important has changed. The post pandemic reality is that it is harder to retain workers and many of those near retirement just didn’t come back to work. This is creating a shortage of experienced people and a workforce that changes employers easily. We are seeing the impact of this manifested in the erosion of established maintenance and supply chain processes that now struggle to yield the plant runtime that could once be taken for granted. The scope, cost and duration of a shutdown varies widely depending on the nature of the work and the equipment being renewed. The PM of an electric shovel might require a week of downtime and cost $100,000. A gold plant may need to go down for 3 days when its time to change mill liners and cost $500,000. A turnaround in a refinery can take more than a month and cost multi millions. Despite the huge differences.

Jan 1, 2023

By R. Loj

Katowice Coal Holding (KHW) is one of the largest coal companies in Europe. The company owns five coal mines with a daily output of around 60 000 tons of coal. In the Katowice city area, very good quality steam coal is extracted. The depth of mining varies between 400 and 1100 m and some of the mines rank amongst those most afflicted by methane in the Upper Silesian Coal Basin, with the methane hazard having a significant impact on production and safety. ?Myslowice-Wesola? mine, being a part of the Katowice Coal Holding is characterized by high methane and rockburst hazards. The mine is equipped with a modern surface drainage pumping station. At the mentioned mine, longwall 514 was selected for analysis of its methane emission. The longwall was extracting the thick seam 501 (over 4 m), at a depth of over 900 m, which was subject to high stress and high gas concentration conditions. At a distance of about 50 m above, seam 501 is covered by thin seam 416. The strata between these two seams are sandstone and mudstone layers. In the floor of seam 501, with a thin shale interlayer, is located seam 510, which is the thickest (over 10m) and richest coal seam in the Upper Silesian Coal Basin. In longwall 514 and it?s vicinity, methane was the dominant risk. For this longwall three methods of classical gas drainage were carried out. At first, drainage was undertaken using long boreholes from a cross-cut at level 665 m, located far from the production panel. Later, it was performed using typical boreholes drilled from the ventilation gallery (tail gate road). Finally, it was undertaken using a degassing drift executed in the upper coal seam 416. All of these headings, ie. cross-cut level 665 m, the ventilation road and conveyor road in seam 501 and the degassing drift in seam 416, were equipped with media for drilling and proper drainage pipelines. Due to the high rockburst hazard and some problems with caving, several kinds of de-stressing and torpedo blasts were carried out in both coal seams and roof rocks. The subsequent analysis and experiments allowed the establishment of some general rules for carrying out degassing operations effectively. The effectiveness of a degassing drift was demonstrated. In some instances, the system allowed more than 70% of the total methane released to be captured and fed into pipelines. The aforementioned blasts had a marginal impact on methane emissions and the efficiency of degassing methods. Cyclic drilling and regular switching of boreholes in phase with the mining progress and working face advance were shown to be essential.

Aug 1, 2013

By J. B. Hadaway

The operation at Phu Kham commenced design and construction in early 2006 and was commissioned in May 2008. This paper will examine and discuss the project from the inception of flow sheet development and equipment selection, equipment design and manufacture, construction, commissioning and ramp up to full production. The paper will touch on the strategies employed to achieve a short schedule and the efficient use of capital, but with the main emphasis on the grinding circuit. Various challenges during the early years of operation will be discussed including the effect of ore characteristics, including competency, on the performance of the grinding circuit. Actions to overcome these challenges and to enhance performance will also be discussed. Finally, current and future plans to improve the performance of the grinding circuit and the overall plant will be summarised.

Jan 1, 2012

"Dry crushing trials at pilot scale have shown that the IMPTEC Super-fine Crusher has the capacity to generate ultra-fine products from hard mineral assemblages presenting at either coarse or fine feed sizes. The super-fine crusher was introduced at the 27th International Mineral Processing Congress in Santiago Chile, with results from a range of duties, which demonstrated the crusher’s potentially expansive operating scope. This paper focuses on current preparations to progress the technology from pilot scale to commercial scale within a concrete production plant, where lead blast furnace slag will be crushed to ultrafine sizes to generate an active silica product for use as a supplementary cementitious material, which can replace Ordinary Portland Cement. A key objective of the operation is to demonstrate an economical route to reducing the cost of concrete production, improving concrete quality and reducing greenhouse gas emissions. The paper also highlights the potentially key contribution super-fine crushing can make to the long-term viability of iron ore beneficiation by simplifying comminution flow-sheets and reducing operating costs. There is every indication that the technology has the potential to feature universally in metalliferous and industrial mineral flow-sheets. INTRODUCTIONToday’s IMPTEC super-fine crusher is the successful end product of development work over 19 years and is the third particle size reduction device conceived, built and tested over that time. The concept evolved as engineering design progressively developed a mechanism capable of harnessing a highly efficient combination of fundamental particle breakage mechanisms. Early development trials at pilot scale indicated that super-fine crushing had the potential to establish a wet or dry, media free, low energy route to ultra- fine products from hard mineral assemblages. Having achieved some impressive results from open circuit pilot tests on fly ash and granulated blast furnace slag it became clear that the cement industry may well provide opportunities to apply the technology commercially. Following expressions of interest from local cement and concrete plant operators, IMPTEC negotiated an agreement to undertake commercial trials with a SFC 350 super-fine crusher installed on site at a concrete supply plant in South Australia. Super-fine crushing scope was recently expanded following further expressions of interest from research groups involved in the processing of iron ores. Pilot trials are progressing in these areas."

Jan 1, 2016

By Eurípides do Amaral Vargas Jr., J. A. de Mello Franco

"It is frequently necessary to excavate a tunnel for Civil Engineering purposes, or wells for petroleum exploitation, in laminated rock mass like schists or phyllites or in highly foliated gneisses. The determination of the pre-existing in situ stresses is essential, in order to assure the stability of these excavations. In most cases, the pre-existing triaxial stress field is arbitrary in relation to the tunnel or well axis. For these rock masses the concept of Generalised Plane Strain can be correctly utilized.There are closed form solutions for the calculation of stresses in anisotropic rock masses under Generalised Plane Strain conditions (Lehknitskii, 1981 and Hong , 1994). Based on these analytical solutions, established for the cases of Generalised Plane Strain, a synthetic problem will be formulated: the theoretical in situ stress tensor acting on this rock mass will be determined, with the aid of Bayesian Inverse Problem Techniques, as developed by de Mello Franco (2009). Additionally, the reliability of results obtained will be evaluated, in accordance with the research performed by this author. INTRODUCTIONThe Inverse Problem Technique, as developed in the paper, is based on the definitions and concepts obtained from the current literature and used for the solution of Inverse Problems, but the innovation to be presented is the utilisation of Bayesian Techniques and the determination of the reliability of the results obtained. This will be shown in a synthetic example where the determination of the in situ stress tensor, from strain measurements in a drill hole is supposedly performed. It is assumed that this drill has its axis arbitrarily placed in relation to the rock mass. Generalised Plane Strain conditions will hold for use with problem. The equations of Beltrami – Mitchel, in agreement to Lekhnitskii (1981) and Ong (1994), will be used in this synthetic case, for calculating strains, hypothetically measured in the hole before the final excavations. Finally a synthetic example for the determination of the in situ stress in a fully anisotropic rock mass, based on Bayesian Techniques and its reliability, developed in de Mello Franco (2009) is presented."

Jan 1, 2015

By G. P. van Greunen

"The rehabilitation of underground excavations has been undertaken as long as mining has existed. The conventional methods have proven to be dangerous, time consuming and expensive. During the construction of Styldrift Mine at Royal Bafokeng Platinum several vertical and horizontal excavations had to be rehabilitated. With a zero tolerance attitude towards working in unsafe conditions, together with a non-negotiable timeline to construct and ramp up the mine, the project team could not rehabilitate these excavations using conventional methods. This paper details the approach used to rehabilitate excavations using remote methods and how it was adapted to suit varying operating conditions and requirements - ensuring that no person ever entered an unsafe excavation before it was fully rehabilitated and safe. INTRODUCTION Styldrift Mine is an expansion project of the Royal Bafokeng Platinum group. It is located in South Africa in the North West Province some 10 km south of the Sun City resort (Figure 1). The mine consists of a twin shaft system (Main Shaft and Services Shaft). Capital construction of the shaft and associated infrastructure started in 2009 and is projected to be completed during 2020. The designed steady state production capacity of the shaft is 230 ktpm of Merensky ore. Production ramp-up commenced in 2017 with steady state production set to be achieved 36 months later in the fourth quarter 2020.Merensky Reef was intersected at a depth of 600 m below surface and the shaft design has a mean mining depth of 630 m. The project was approved for execution in 2008 on the basis of a suitable mine design and bankable feasibility study. One of the main excavations that required rehabilitation was an underground reef silo, Silo 4. It is a key piece of infrastructure on the critical path to allow steady state production at Styldrift Mine to be achieved. During construction excessive scaling within the silo along its 64m length necessitated urgent rehabilitation to be able to meet the ramp-up schedule. The criticality and urgency of these excavations prompted the project team to reduce the risk of failure while ensuring safe and cost-effective rehabilitation. This paper will focus on the rehabilitation of Silo 4 while capturing the essence of the learnings of all the excavations that were rehabilitated remotely."

Jan 1, 2019

By Sean Hillacre, Arthur Lieu

NexGen’s approach to uranium processing design including the crushing/grinding and leaching of raw ore through to yellowcake precipitation and tailings management focuses on minimizing surface footprint, freshwater consumption, and human radiation exposure. Applying the concept of best available technologies economically achievable (“BATEA”), NexGen continues to research, evaluate, test and validate various advanced technologies that can be incorporated into the Project design, including distinctive tailings storage techniques. Additionally, NexGen is proposing that tailings generated from the mill processes be used as cemented paste backfill of stopes, as well as stored in a purpose-built, Underground Tailings Management Facility (“UGTMF”) comprised of several dedicated chambers. The paste backfill method of tailings storage is used globally, however, constructing purpose-built tailings chambers in waste rock is a new concept in uranium mining, which would typically be cost prohibitive for most projects given the expense to develop non-economic material for the sole purpose of storing tailings. The Rook I Project is uniquely positioned to implement the UGTMF due to robust Project economics and favourable technical setting which provides NexGen with the opportunity to set an elite standard for tailings management. When compared to conventional surface tailings management facilities, storing tailings underground as cemented paste reduces geotechnical, geochemical, environmental, and human health risks associated with tailings management. Additionally, the UGTMF vastly reduces the area of surface disturbance and allows for progressive decommissioning during the life of mine operations.

Jan 1, 2020

By Chao Yang, Liguo Tian, Yan Yang

"The Jinfeng gold mine is one of the three gold mines that Eldorado Gold has in China and it is the second largest gold mine in China. The mine is located in a relatively remote and mountainous area in the southwestern Guizhou province. The orebody is similar to the Carlin type deposit in Nevada. The mill throughput was designed to treat 3,600 tones per day. The ore comes from open pit mining and underground mining, and is fed to one-stage jaw crushing. The crushed ore is stockpiled, reclaimed and then fed to the SABC grinding circuit. After classification with hydrocylones, the ore is floated, and the resultant concentrate is oxidized biologically in a process known as BIOX®. The oxidized concentrate is then washed in a CCD circuit and finally leached with cyanide in a CIL circuit for gold extraction. Jinfeng produces about 180,000 oz of gold per year.This paper introduces operations and modifications of SABC circuit over the past three years, and then describes some technical characteristic of the SAG mill and other circuits in the processing plant.Major modifications and improvements on the SABC circuit are described in the paper, including:1. Impacts of grinding ball and mill liner with respect to material selection, quality, hardness, manufacturing methods, and interactions between mill liner and grinding ball.2. Effect of milling operation parameters on milling efficiency.3. Impacts of SAG mill scats and modifications of grate size to improve mill throughput.4. Design and construction of a pebble crushing system, and recycle the crushed scats to the SAG mill to improve mill throughput.With the above-mentioned modifications, 20% increase over the design in mill throughput has been realized over the past three years, and operating cost has been significantly reduced. However, some issues still remain, and thus process modifications and technical innovations are still needed."

Jan 1, 2012

By P. G. Smith, A. Axiuk

The objective of this paper is to present, from a practical perspective, a review of the most relevant maintenance procedures that are accepted or prescribed to be the most effective in optimising service life potential and to ensure continued safe use of steel wire ropes for shaft mining applications. The paper will address the most common operational issues encountered in the care and operation of shaft ropes for both conventional drum hoists and multi-rope friction winders. For each distinct maintenance procedure presented, a limited amount of theory is discussed to identify the underlying mechanisms at play that must be addressed and to emphasize the logical basis for the recommended course of action. It is recognised that each installation is unique and that the recommended maintenance procedures may not always be practical or cost effective from an operations standpoint under select circumstances, however the intent remains to promote industry best practices for the knowledge and benefit of the mine hoisting community, from experienced maintenance personnel to new entrants to the industry alike.

Jan 1, 2023

By Steve Scott

Outline of Talk Seafloor Massive Sulfides (SMS) and Seafloor Sedimentary Sulfides (SSS) Ocean mining of SMS (Nautilus Minerals) Environmental issues Summary

May 1, 2013

By Paul Toor

The operation of SAG mills is variable over time due to their continually changing liner shape, mass and subsequent load motion. However, this tends to be poorly accommodated in liner design and mill control, with only limited compensation made for this influence, usually in the first few weeks after a new liner is installed. With ever-increasing ore competency, increasing energy costs and decreasing ore grades, simplified design and operational approaches that compromise the achievable mill efficiency are no longer adequate. This paper presents a methodology that has been developed to measure and account for the changes in mill performance as the liner wears. This involves monitoring all liner profiles ? in other words the three-dimensional liner shape - over the life of the liner, then conducting controlled surveys at different stages of the liner wear life, and correlating the mill performance to the liner profiles. The measured liner mass is modelled to provide an ongoing meaningful load mass measure that excludes the liner mass.

Jan 1, 2012

By Håkan Schunnesson, Kirsten Holme

"When mining high grade, narrow ore bodies, the mining method often implies a very detailed knowledge of the ore contacts to avoid unacceptable ore loss and waste rock dilution. During the past decade, the use of microprocessor based drill monitoring equipment has become an accepted technique, even for percussive drilling. On the basis of the recorded drill performance, such as penetration rate, torque pressure, thrust etc., a fast evaluation of the lithological sequence of the ore zone can be made. In order to evaluate the potential of percussive drill monitoring to pro-vide detailed information of the geometry of the ore body, the technique was tested in the Viscaria copper mine in Sweden during 1996.To provide understandable information to the mine geologist, great emphasis was placed on the separation between the drilling response generated by variations in rock conditions from variations caused by the operator and the drill system. Due to the complicated geology in Viscaria, the drilling response presented to the geologists was separated in two independent signals, one representing the hardness of the rock and one representing the in homogeneity(fracturing) of the rock. With those signals a good separation between different rock types in the ore horizon was achieved.The experience from the Viscaria copper mine is that drill monitoring not only can be used to locate contacts between rock types, but also to characterize rock conditions and, often, also to specify the exact rock type present. Because it is possible to get the drill monitoring information very quickly it is a valuable complement to diamond drilling for increasing the specific knowledge of the geology and the ore body."

Jan 1, 1997

By Abdelhak Bentriou

The choice of tool for the first well of an oilfield or gasfield is an important factor, given that we will be drilling with the same type of tool for the entire phase and explains why we need to have another type for comparison based on the efficiency of the tool and its ability to crush the rock, and the wear of different types of tools. Development of theoretical and practical tests to determine the optimal regime for drilling is required to take into account the characteristics of rock layers crossed. Classification of boring tools is based on the geometry of the teeth and depends on the hardness, the abrasiveness of rocks as well as their hydraulic system, but it is better to classify them according to the working conditions with a coefficient designating a discriminant. This is called physical characteristic of the drilling tool. The goal is to designate each element of the tool by a coefficient. Results were obtained from laboratory tests. Modeling the initial rate of progress by different types of tools allowed us to determine an adequate mathematical model of the speed initial progress in clean conditions. Using experimental data and statistics we have established the mathematical model of the average speed of progress as a function of time. With these equations we can determine the wear evaluation and analysis of these factors as an approach to classification according to their characteristics. The main equations for the selection of drilling tools will be based on the optimization of drilling parameters for each type of tool. After analysis, we choose the tool that gives a better forward speed with an optimal load and axial rotation.

Aug 1, 2013

By George Kellock

Introductory The Alberta Provincial Government has contemplated a revision of the Mines Act for some time past, and it is understood that a definite decision has now been made to do this at the next session of the Legislature. The Operators' and Miners' organizations of the Province have been asked, or at least have been given the opportunity, to submit their views and ideas relative to the proposed changes. The operators have already drafted out a number of changes which they feel would improve the Act from the standpoint of safety and practicability, and this paper has been prepared so that the general membership of the Rocky Mountain Branch of the Institute, which is composed largely of the operating and certificated officials of the mines, might have an opportunity to discuss, criticize, and improve upon the suggested changes which the operators are putting forward.

Jan 1, 1929

By David Weiss

There is significant interest in magnesium alloy castings because of their low density and high strength-to-weight ratio. Lightweight, structural materials are in demand for aerospace components, hand tools, electronics enclosures and have found increased use in automobiles. Increased use of magnesium will depend on the resolution of a number of materials issues and development of more robust and economical casting processes. Most magnesium components are produced via high-pressure die-casting. High levels of porosity generally prevent die-castings from being used for structural applications. Structural castings are usually produced using sand casting, a relatively expensive casting process. Some work has been done on development of lower cost structural casting processes, such as lost foam casting, permanent mold casting or low-pressure casting. New programs are also emphasizing improvements to the die casting process. Research and cost reduction needs are discussed with respect to current programs and future components.

Jan 1, 2006

By Kenichi Fujino

Severe disasters have struck Japan in recent years. Following these disasters, construction robots have played important roles in investigation and restoration work in the disaster regions. To be applied in this way, construction robots require many functions according to the purpose of their use in each case. There are clear differences in the functions and usage conditions required by investigation robots and those required by execution robots. These differences will be important when designing and operating construction robots in the future. This report introduces a volcano exploration robot and unmanned execution system as examples of construction robots used for investigations and executions respectively. Based on this, the report organizes important characteristics of construction robots and explains differences in the concepts of disaster investigation robots and disaster restoration robots. Because they are used in harsh natural conditions and do not have any execution functions, efforts are made to clarify the fact that investigation robots have to overcome many problems such as mobility. When a construction robot is used, the scenario of the operation of the construction robot (execution plan) is extremely important, and in addition, it is necessary to clearly define the way it will be used according to the purpose of its use and specification conditions. In a plan for an unmanned execution system, it is possible to mitigate several strict prerequisite conditions by proposing a well-constructed execution plan. For example, the execution efficiency of an unmanned execution system can be improved by effectively using a temporary road.

Aug 1, 2013

By S. Minamiguchi

Grain refinement is effective to enhance strength and ductility of metallic materials. However this advantage has not been utilized fully for magnesium alloys in industry because microstructure control through thermomechanical treatment is difficult owing to their poor deformability. The authors proposed a high-speed heavy-reduction rolling for production of Mg alloy sheets. It was found that the deformability is significantly improved at high speed and that the thickness can be reduced 60% by one-pass operation even at room temperature without fracture at the rolling speed higher than 1000 m/min. In this study, commercial AZ31B sheets were rolled at 2000 m/min between room temperature and 350°C, and quenched immediately after the rolling. The sheets rolled at 200°C show the finest recrystallized microstructure with the mean grain size of 2.2 Rm. They show outstanding mechanical properties with the tensile strength of 293 MPa, and the elongation of 25%. It is concluded that high-speed rolling is very advantageous for grain refinement and improvement in mechanical properties as well as deformability and productivity.

Jan 1, 2006

By Ken G. Kress

Syphons can be a simple, reliable and proven alternative to otherwise more complex pumping systems or low level outlet works. In a simple form they consist of a pipeline constructed over the top of an embankment or high topographic feature, connecting a source pond to a receiving pond or channel (see Photograph 1). The syphon action is initiated by removing air from the pipeline (priming) using simple devices which can be purchased ?off the shelf?. Once primed, the syphon flow rate can be controlled or stopped using conventional gate, valve, orifice plate or other devices. Repriming is not required even if the flow is stopped, provided the syphon is not drained. A limiting factor in considering a syphon as a design option is the maximum lift (i.e., vertical distance from source pond level to summit of syphon) which is approximately 9 metres, or less, dependent on syphon pipe features and site conditions. Pipeline syphons can be quickly constructed from readily available materials including steel, polyethylene and PVC pipe. They are particularly well suited to many of the unique conditions often encountered at minesites. This paper identifies situations that can sometimes be best resolved using pipeline syphons. It provides basic principles for pipeline syphon design and includes case histories of their successful application.

May 1, 2001

By H. Dundar

An extensive testwork was performed around the HPGR plant at GoldFields Ghana Limited Tarkwa Gold Mine. The HPGR was used to prepare the feed for heap leaching. The circuit was configured in such a way that the edge material from the HPGR discharge was recycled for further crushing while the product from the centre reported to the heap leach section. The set-up of the Polysius HPGR provided an opportunity to study the effect of different design and operating variables. This paper will discuss the results from the tests performed to assess the effect of rolls? speed and applied pressure on the capacity and the grinding efficiency of the HPGR. Applying different pressure values appeared to have an influence on the amount of edge material recycled.

Jan 1, 2012