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By R A. Pax, B Cornish

Increasing the throughput of the MMG Century operation by over 25% from past practice to preserve cash flow close to the end of life of mine has revealed new throughput and load dynamic instabilities in the SAG mill causing significant time averaged loss of production. A twelve microphone array around the SAG mill (Pax, 2014) using the non-contact acoustic measurement methodology (Pax, 2011, 2012) has been used to diagnose the new dynamics. Dynamic acoustic noise signal information allows discrimination of the behaviour of the steel balls and the rock. Determination of mill load, toe and shoulder angles, water holdup, and proxies for mill load are possible.The instability was diagnosed with the help of an abnormality in the liners/lifters of the SAG mill with one row of lifters having a slightly increased in-mill life compared to the rest. The steel shoulder angle is observed to be disturbed cyclically at a rate of precisely one revolution at low throughputs of 750 t/h. However, at throughputs closer to 1100 t/h, the cyclic signal disappears indicating additional dynamics to randomise the repetitive behaviour of the mill charge. The cyclic signal has been used to operate the SAG mill with improved stability at 1100 t/h by adjusting the feed water addition rate.This paper presents and discusses these results and proposes the suggested origin of the extra dynamics. A small consistent aberration of the lifters circumferentially provides a useful detector of stable mill operation and a novel sensor for the dynamics of the internal operation of a SAG mill.CITATION:Pax, R A and Cornish, B, 2015. A novel measurement for the internal operation of a semi-autogenous mill using acoustic sensors – a case study, in Proceedings MetPlant 2015, pp 120–128 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 7, 2015

By Pratoomkhuan N. Lertsgoon

A large underground cavern with dimensions of 25m × 175m × 49m (W×L×H) was excavated in sandstone and siltstone to house 4 units of hydropower generator and was completed in 2000. In feasibility study stage, the property of the siltstone which governs the ceiling of the cavern was questionable due to slaking phenomenon. Parameters on rock properties for design were back calculated from actual ground response measured from a trial excavation. For safety of construction, comparison between prediction and actual ground responses during excavation had proceeded. The prediction was provided by means of PHASES and PHASE2 software and the actual rock response was detected by the provided monitoring system.

Jan 1, 2003

By Narong Thasnanipan

This paper presents the outcome of the contest on the prediction of the static axial load capacity of diameter 1.20m bored pile founded at 46m below existing ground. The test pile was constructed by wet-processed method and instrumented with vibrating wire strain gauges. Different methods used by the contestants in prediction of load-settlement characteristics are described and compared with actual load test results. Load-displacement behavior of test pile is found to be better than expected. Major difference between prediction and actual test is the higher frictional resistance of Second Sand Layer achieved in the actual load test. The hyperbolic load transfer method used by one of the contestants was applied to back-analyze the load-displacement characteristics of the test pile at different conditions.

Jan 1, 2006

Investigation of the Classification Operation in a Coal Pulverising Vertical Spindle Mill Coal pulverisation in power plants is a major electrical energy consumer. In 2006 more than 41 per cent of world electricity generation was from coal where pulverisers use 0.5 to 1 per cent of gross generation. Therefore, pulverisers are an important target for optimisation not only for reducing costs of power generation but also for reduction of greenhouse gas emissions. A better understanding of the operation of pulverisers is an essential requirement for their optimisation. However, little information is available, other than operating experience, on the performance of pulverisers and how these react to changes in operational variables. This study investigates the effect of changes in coal and airflow feed rates on the classification performance that occurs in an industrial scale ball-and-race vertical spindle mill in which the pulverisation and classification processes are linked together due to the separator classifier being an integral component within the pulveriser. In order to decouple the breakage and classification processes, samples were cut from upward flowing streams through sampling ports drilled on the pulveriser body at different locations. Specific sampling tools were developed. Samples collected from the pulveriser were size and density fractioned to distinguish the differences in behaviour of the components, namely coal and mineral matter. The coal flow rates on dry basis within the mill and around the separator classifier were calculated by mass balancing the multi-component data. The difference in classification behaviour of components during pneumatic transport was confirmed. The response of the circulating load in the mill (~600 to ~1100 per cent) as well as the dependency of fineness of the streams to the operating variables was demonstrated. The approach taken in this study has proved that development of a classification model for a vertical spindle mill pulverising non-homogeneous materials, eg coal, requires treating these materials as multi-component/composite substances.

Sep 13, 2010

By L. Mukka

The existing main mine ventilation system for the production areas to the Kiruna mine was constructed during the period 1994-1996 and extended with 4 more shafts, including fan stations, for the sea ore body from 1997-1998. Two papers have been presented from this project at the 7th US Mine Ventilation Symposium in 1995 and at The 6th International Mine Ventilation Congress in 1997. In 2005, pre-studies for a new main haulage level were started. Different haulage methods were presented including ventilation systems. The pre-studies showed that the existing ventilation system, including fan stations for the new main haulage system in the production area, could be extended. However, a new system for the central area, which was not in the initial investment program, would be needed. In the beginning of 2006, a decision was made to design a new ventilation system for the central area to make it possible to get air to the development work for the new main haulage system, independent of the haulage method. This system was operational by the beginning of 2007. The new main haulage system, which was decided to be located on level 1365 m, only requires that the existing shafts be extended - the capacity of the fans seems to be enough. However, the problem is that the existing level 1045 m and the new level 1365 m have to be in operation in parallel for approximately 7-8 years. The challenge for the moment is determining how to ventilate the production areas for both levels at the same time, while simultaneously constructing the extended system. This paper will describe the problems associated with the extension of the main ventilation system and some potential solutions for these problems. The new main haulage level 1365 m must be in operation by 2012.

Jan 1, 2009

By R. Marrill

Mining is a complex and intensive industry. Extracting raw material with different shapes, sizes, chemistry from the earth?s crust and transform them into a standardized and high quality final product is a big processing challenge - which involves energy and control on large scales. Not only is the physical work challenging, the mining industry today is facing unprecedented challenges: Decline of mineral grade and reserves, cost escalation for new developments and modernization, regulations, safety, lack of skilled people, and market uncertainty are the new constant. It is clear that process control and management of electrical power will be of increasing importance to the recovery rates the mine will achieve. The objective of this paper is to provide a quick vision about future trends and evolutions in technology related to these fields and their impact on Electrical Safety and Control of the mineral recovery. The paper will cover trends in safety, energy management and efficiency, communications of data, control room evolutions, plant integration, other control technologies, and we will examine how these technologies provide information and the benefits of aligned reporting systems to address current industry challenges. More than just the trends or breakthrough concepts, current technologies are available today that can be applied in the mineral recovery operations now to help overcome anticipated future challenges will be presented later in this document. Finally, a brief discussion to look at some real tools to help make real time changes to the process while maximizing recovery and optimizing cost.

Feb 27, 2013

By Stephen C. Tadolini, Gabriel S. Esterhuizen, Anthony T. Iannacchione

A Major Hazard Risk Assessment (MHRA) was developed in Australia after a series of mine disasters in the 1990’s. A MHRA is used to help prevent major hazards, i.e. fire, explosion, wind-blast, outbursts, spontaneous combustion, roof instability and chemical and hazardous substances, from injuring miners. A MHRA is a structured process that identifies the characteristics of major hazards, assesses and ranks the risk they present, and evaluates engineering and administrative controls to mitigate them. These controls typically consists of a broad spectrum of prevention, monitoring, first response, and emergency response techniques and helps to move an operation from a reactive to a proactive approach towards safety. This paper documents a MHRA performed at an underground mine where strata instabilities and fire hazards may threaten the condition of its escapeways. The objective of this MHRA is to 1) identify what hazards could affect the egress through the mine’s escapeways, 2) determine what unwanted events pose the greatest threat for the mine, and 3) recommend a plan to prevent or recover from the potential disruption of egress through the escapeway. The plan provides information on the key existing controls that should be monitored and audited, and makes recommendation of new potential controls to further reduce related risks. By documenting the use of MHRA to this specific ground control issue, this paper provides a framework for others to judge the merits of this approach and to help design and perform these activities.

By L. W. Hamel

"DUST CONTROL - GRANISLE COPPER LIMITEDINTRODUCTIONGranisle. Copper Limited is located in the north-central region of the Province of British Columbia, approximately 200 road miles north-west of Prince George. Mill startup was in November, 1966, at a rate of 5,000 tons per day, expanded to 13,000 in 1973. The primary crushing rate is 1,200 tons per operating hour, and the secondary 750, and they can be operated jointly or separately.DUST COLLECTION SYSTEMS There are seven dust collection systems ventilating the crushing and grinding complex. The individual pickup points are depicted on Figure 1 -""Crushing Plant Flowsheet"", and Figure 2 - ""Concentrator Flowsheet"", e.g. 1A, 1B, 3C, etc.System No. 1 - Primary Crusher The feed rock box of the Allis-Chalmers superior 42-65 primary crusher is ventilated by 19,000 CFM of air exhausted directly to atmosphere by a Sturtevant 426 M fixed discharge fan.No. Dust Pick Up Point CFM lA Crusher Feed Rock Box 19,000System No. 2 - Primary Crushing and Screening System No. 2 ventilates the primary crushing and screening equipment. A total of 19,000 CFM of air is exhausted by a Sturtevant 426 M fixed discharge fan through a Howden Type S - size 75 cyclone locally modified for wet scrubbing."

Jan 1, 1976

By Valentin Choquenaha Bombilla, Oscar Alvarez Muiloz

"Tintaya’s basic production line is copper concentrate, which has an important gold content. The process used is flotation; the objective of the metallurgical department is to obtain the best results in the copper recovery without neglecting the gold, using very specific reagents. Copper recoveries are considered high, nevertheless every day emphasis is placed upon increasing those recoveries. Regarding gold, optimum recoveries could not be achieved with flotation; and implementation of a gravity circuit was considered.According to microscopy studies, the coarse and very fine grains of gold in native form are lost to tails. The native gold due to its high specific gravity is concentrated at the underflow of the cyclone, remaining in the circulating load of the circuit. It reaches three times the concentration compared to the head grade entering the ball mills. This re-circulation generates very fine and laminated gold particles inside the ball mill, passing to the classification stage making a short circuit to the overflow of the cyclone.The very coarse gold particles as well as the thick flakes of gold do not react favorably to the conventional flotation process; thus studies that have included gravity separation have been conducted to increase the gold recovery. Part of the research included concentrating tables, jigs, and Knelson Concentrators. The Knelson Concentrator proved to be the best selection in terms of metallurgical performance and recoveries considering the throughput and operation conditions of the Tintaya Plant.The gravity concentration circuit with the Knelson Concentrator was commissioned in BHP Tintaya in October 1998, as per the flowsheet shown later on. Presently the global gold production surpasses any estimated expectations.Present efforts are directed towards showing the evaluation and optimization of the different parameters that govern the performance of the Knelson concentrator, as well as illustrating the difficulties and successes throughout the operating period.In the first year of operation 200 tons of gold concentrate have been produced with an average concentrate grade of 320 gramdton, having paid back in full the cost of the automated KC-XD- 48 Knelson Concentrator, the peripheral equipment, and the cost of the installation."

Jan 1, 2002

By P. Wells, P. Quinn

"A moveable flotation miniplant was designed and constructed at the research laboratory of Inco Technical Services Ltd. to address the need for flowsheet development with a limited amount of ore (such as drill cores). It consists of one rod mill, two regrind ball mills, one vibratory screen, 24 flotation cells of various sizes and two Venturi aerated flotation columns. The setup has continuous monitoring capability for pH, dissolved oxygen, oxidation-reduction potential, conductivity and temperature in conditioning tanks and flotation cells. Various options regarding flotation reagents, circuit configurations, and fineness of primary grind and regrind can be readily evaluated. The throughput of the miniplant is 20 – 30 kg/hour ore.Unit operations such as flash flotation, magnetic separation and gravity concentration can also be evaluated as an integral part of an entire flowsheet development.This communication describes the basic design features of the miniplant and some examples of applications are given.INTRODUCTIONInco operates numerous mines in Sudbury and Thompson and will shortly bring the Voisey’s Bay mine into production. It has long been recognized that the ores from different mines or from different depths of the same mine can give different responses in flotation. There is a growing need to properly evaluate the ores before feeding the mill to maximize the return of the mine/mill operation. Inco Technical Services Limited at Sheridan Park, Mississauga, Ontario has developed a batch laboratory procedure to address this issue. The results are considered in the overall economical assessment of new mine operations.For ores that cannot be processed by the existing mill operations or that will be processed by a new mill, it is necessary to develop a flowsheet that can maximize the economical return of the mine/mill operation. While recognizing the importance and contribution of the laboratory batch flotation procedure, it does not generate reliable data for flowsheet simulation and design. A full-scale pilot plant campaign is normally required to obtain the design data but often this is not possible due to a limited amount of ore obtainable from the drill core. A small-scale pilot plant (mini pilot plant or miniplant) capable of processing 20-30 kg/h ore can provide this data prior to a full-scale pilot plant campaign. A miniplant can also be used to optimize the circuit configurations, reagent additions and recycle options of process water before pilot plant work and can be used to test a different flowsheet configuration for an existing mill before re-piping a plant circuit."

Jan 1, 2003

By Ji-He Wei

Keywords: stainless steel, AOD refining, side and top combined blowing, mixing characteristics, water modeling The fluid mixing characteristics in the bath during the side and top combined blowing AOD (argon-oxygen decarburization) refining process of stainless steel have preliminarily been studied on a water model unit of a 120 t AOD converter. The geometric similarity ratio between the model and its prototype (including the side tuyeres and the top lances) was 1:4. On the basis of the theoretical calculations for the parameters of the gas streams in the side tuyeres and the top lances, the gas blowing rates used for the model have more reasonably been determined. The influence of the tuyere number and position arrangement, and the gas flow rates for side and top blowing on the characteristics has been examined. The results demonstrated that the liquid in the bath underwent vigorous circulatory motion during gas blowing, without obvious dead zone in the bath, resulting in a well mixing effectiveness. The gas flow rate of the main tuyere had a governing role on the characteristics, a suitable increase in the gas flow rate of the subtuyere could improve mixing efficiency, and the gas jet from top lance could make the mixing time prolong. Corresponding to the oxygen top blowing rate specified by the technology, a roughly equivalent and good mixing effectiveness could be reached by using six side tuyeres with an angle of 27° between each tuyere, and five side tuyeres with an angular separation of 22.5° or 27° between each tuyere. The relationships of the mixing time with the gas blowing rates of main-tuyeres and sub-tuyeres and top lance, the angle between each tuyere, and the tuyere number have been obtained.

Jan 1, 2005

By William H. Schiffbauer

This report details a microcomputer-based control and monitoring network that was developed in-house by the U.S. Bureau of Mines and installed on a continuous mining machine. The network consists of microcomputers that are connected together via a single twisted-pair cable. Each microcomputer was developed to provide a particular function in the control process. Machine-mounted microcomputers, in conjunction with the appropriate sensors, provide closed-loop control of the machine, navigation, and environmental monitoring. Off-the-machine microcomputers provide remote control of the machine, sensor status, and a connection to the network so that external computers can access network data and control the continuous mining machine. Because of the network's generic structure, it can be installed on most mining machines.

Jan 1, 1993

By Tom Short

"Construction blasting covers a very extensive variety of explosive applications. I will discussseveral of these with you and then show slides from my collection, starting in 1956, which will betterillustrate the types of blasting under discussion."

Jan 1, 1991

By Rob D. Morrision, Paul W. Cleary

"The best accepted method for design of autogenous and semi-autogenous mills is to carry out pilot scale test work using a 1.8 m diameter by 0.6 m long pilot scale test mill. The load in such a mill typically contains 250,000-450,000 particles larger than 6 mm, allowing correct representation of more than 90% of the charge. This scale of DEM model is now within the practical range of standard workstations running an efficient DEM code.This paper describes various ways of extracting collision data from the DEM model and translating it into breakage and wear estimates. Account is taken of the different breakage mechanisms (impact and abrasion) and of the specific impact histories of the particles in order to assess the breakage rates for various size fractions in the mills. These impact histories have the potential to be directly related to breakage as they most resemble the single particle breakage tests which are used by the JKMRC to calibrate more traditional population balance models for variations in ore behaviour. However, the specific impact histories also show a background of many low energy collision events within the mill. This Background may constitute what is usually regarded as “abrasion” breakage. As might be expected, high impact events are concentrated in the toe of the charge and near to the mill shell where the forces associated with the load bearing on each particle is more concentrated."

Jan 1, 2003

By William E. Ford, Edward Salisbury Dana

Secondary Twinning. - When there is reason to believe that the twinning has been produced subsequently to the original formation of the crystal, or crystalline mass, as, for example, by pressure, it is said to be secondary. Thus the calcite grains of a crystalline limestone often show such secondary twinning lamella?. The same are occasionally observed (Ilc, 001) in pyroxene crystals. Further, the polysynthetic twinning of the triclinic feldspars is often secondary in origin. This subject is further discussed on a later page, where it is also explained that in certain cases twinning may be produced artificially in a crystal individual - e.g., in calcite (see Art. 282).

Jan 1, 1922

By Thomas Barczak

A cooperative study was conducted with Emerald Coal Resources, L.P., an affiliate of Foundation Coal Corporation, and the National Institute for Occupational Safety and Health (NIOSH) to evaluate the effectiveness of (partially) pre-driven longwall recovery rooms supported with pumpable roof supports. This paper evaluates the load transfer mechanics associated with the advancement of the longwall face into the pre-driven recovery room and the widening of the room to recover the longwall shields. The results show that the yielding of the panel fender produced uncontrollable convergence that caused yielding of the shields and stiff pumpable roof supports when the face was approximately 10 ft from the recovery room. The shields continued to yield until the face advanced into the recovery room. Convergence in the pre-driven recovery room typically reached 6-8 in once the pumpable supports yielded and shed load through a declining residual load capacity prior to being cut out by the longwall shearer. Roof deformations occurred beyond the 32-ft horizon with total deformation ranging from 2 to 4 in, indicating that standing support was necessary to help control the span as the longwall face advanced into the pre-driven recovery room. Stability improved as the pumpable supports were cut out, thereby reducing the span between the shields and the outby pillars. In the end, the shields were successfully recovered under stable ground conditions. However, a disconcerting discovery was the load shedding of the outby pillars as the recovery room was mined into. It is postulated that this may be due to the progression of the rear ?abutment? moving toward the recovery room as the panel fender and standing support in the recovery room yield and shed load. This behavior was not expected with a relatively narrow room that is fully supported with standing support. If this mechanism is indeed occurring, the width of the room and performance of the standing support becomes even more critical. Premature failure of the support can lead to excessive convergence on the shield line that cannot be controlled even with modern shields, resulting in roof instabilities that can lead to catastrophic results.

Jan 1, 2007

By Boleslaw A. Klosinski

Drilling of a pier hole is accompanied with stress releasing in the surrounding soil and often with loosening of soil at the pier base. In effect the drilled piers are more deformable than driven piles of comparable dimension. The bearing performance of a pier may be considerably improved by properly executed base grouting. Various techniques of base grouting are used; many of them were described by Bruce (1986). The grouting devices are often placed within the pier. Alternatively the soil at or under the base is treated by cement or chemical grout. Preloading of the base subsoil by use of a special grouting cell is considered as the most effective way. Treatment of the ground below pier base with cement or chemical grout may be also useful. It may be performed immediately after the pier construction or during service, as a measure for increasing the pier capacity.

Jan 1, 1995

By J. A. Yeats

This paper describes the loading to 25MN of a 1.2m diameter bored cast-in-situ test pile founded in the Thanet Sand which was base grouted. The pile was sleeved over the major portion of its length to test primarily the base response of the pile. The results are presented and compared with similar pile load tests in Thanet Sand.

Jan 1, 1989

By M. Ahrens

Gearless mill drives (GMD) are a well established solution for grinding applications in the minerals and mining industries. The paper describes the functionality and technical features of such drive systems as well as the development and the progress of GMD systems over the years. With an increasing installed base and many drives operating for many years, there is an increasing need to modernize or revamp existing GMD installations. The first installations of GMD took place in the cement industry and have demonstrated that ringmotors can achieve a lifetime well above 40 years, if maintained properly. The life cycle time of many other components, especially electronic parts, is usually shorter. It is therefore necessary to replace aged or out-dated components early enough in a planned manner in order to reduce the risk of component failures and the related shutdown times. Modernization upgrades can range from minor software updates to a revamp of the cycloconverter. The paper describes typical examples of such upgrades and shows the most important aspects that need to be considered.

Jan 1, 2008

By L. D. Schmidt, Wm. Seymour, W. S. Landers

"INTRODUCTION The relative value of the various individual physical and chemical properties of coke as a measure of its performance in the blast furnace as aroused considerable controversy but it is generally agreed that uniformity in these properties is extremely important if maximum mum pip-iron production is to be attained. The control of,the bulk density or weight per cubic feet of the coal charge in the coke ovens is a major, and frequently overlooked, factor in producing a uniform product and in efficient operation of the coke plant.This report presents a brief discussion of the general problem of bulk-density control and the results of tests on samples of coke-oven charges from several operating plants experiencing difficulties due to lack of adequate control. These tests covered the effect of moisture and oil content on the bulk density of the coal. Some tests on the effect of a wetting agent and furnenous of gained were also made. A description of the methods used to determine the bulk density of the coals studied in this investigation and of the methods used to apply oil to the coal at byproduct-coke plants are included in this product. No theoretical analysis of the data presented in this report, because the primary purpose of the investigation was to obtain data of immediate practical value to the plants concerned."

Apr 1, 1945