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By Prasad Kummarapurugu, Maija Teijonsalo, Sirkka-Liisa Jamsa-Jounela

There has been a significant progress in the use of mathematical modeling and simulation in the minerals industry in the last decade. Process models have moved from academic world to important industrial tools. This paper reviews the status of mineral processing simulators and recent progress in simulator development and applications is discussed. The simulation for process design and optimisation is now an established technique, as evidenced by its increasing use of practising engineers through commercially available simulator software. The paper presents a systematic approach to the process study procedure for the control system development, clarified by practical case examples calculated by SimCon - a novel steady-state simulator for mineral processes. Examples of the application of SimCon in drawing flowsheets, calculating mass balances and making simulations for grinding and flotation processes are presented. At the end of the paper, the state-of-the-art and the future of computer-aided pro- cess study at mineral processing plants is discussed. Keywords: Simulators, modelling, object oriented programming, computer aided control system design

Jan 1, 1996

By G. Raspa

This article describes a procedure for calculating the recoverable reserves of stratified orebodies characterised by a thin and irregular layers. An application on the phosphate deposits in the N'Zeto region of the Popular Republic of Angola is also described. The procedure consists in building a block model of the deposit through the conditioned multivarial geostatistical simulation of small areal units. The recoverable reserves are then calculated and defined by applying to the model a selection processes based on measured geological/economic parameters taken from the drillholes: thickness of overburden and mineralised layers, economic grain-size fraction, grade. The procedure also takes account both of the geometrical constraints of the mining method and dilution. For reasons of confidentiality, a multiplier has been applied to the values adopted for the sampling data.

Jan 1, 1992

By B. K. Baird, P. C. Satchwell

The application of cutoffs during and after pit optimization is examined for a lower-grade multi-metallic copper deposit. Pit optimization requires calculation of the net revenue associated with each mining block, incorporating parameters such as metal prices, grades and expected recoveries, mining and processing costs, smelting and refining charges, and penalty element and royalty charges. Sensitivity analysis during pit optimization reveals which of these parameters have a significant effect on the total contained resource tonnage and total contained non-discounted revenue in the optimized pit. The cumulative effect of changing several of the more significant parameters is investigated. Application of a copper cutoff grade to a block inside the optimized pit could result in the less than optimal extraction of the resource. A block with copper grade below the applied cutoff could be economic due to the presence of other metals. Conversely, a higher copper grade block may be sub-economic. The relative merits of applying a copper grade cutoff, “equivalent grade” cutoff and dollar value per ton cutoff to blocks inside the optimum pit are discussed.

Jan 1, 1999

By J. Dorsey

In 1910, Colonel Boyce Thompson, who owned Inspiration (now Cyprus Miami) and various other mining interests, formed the Magma Copper Company and leased the Silver Queen claims around Superior, Arizona. At the same time, he purchased other claims around the Silver Queen claims from what was then called the Magma Mine. The mine continued to operate until 1982 when Newmont Mining Company, who owned Magma Copper Company, shut down the operations due to high costs and low copper prices. When Magma was spun off by Newmont as an independent company in 1987, new studies of Superior were started. It was clear from these studies that the mine had been shutdown and over 1400 employees laid off for two basic reasons: first, as a resu1t of a mine plan that was technically flawed and second, be-cause of very high production costs mainly due to the low productivity from a very high cost work force. During 1989 a plan was formulated to re-open Superior with the determination to over-come the problems that resulted in closure. A new mine plan was developed and a management style developed that promotes team work and high productivity.

Jan 1, 1992

By Edward C. Dowling

Cleveland Cliffs and affiliated companies have established a commitment to the development and use of integrated process control. Substantial capital investments in process control, coupled with the dedication of human resources to effectively use the information, have generated meaningful business results. Improvements in productivity, operating costs and product quality have been realized. This paper presents an overall process control and information strategy, specific case studies, lessons learned and the current view of the next steps in the continued journey toward integrated process control and information management.

Jan 1, 2000

By Shigeru Sarata

Working places in underground mines are formed by digging. The main feature of underground working places is that they are surrounded by rock. Digging through rock, which is main operation of mining, generates great reacting force. In many cases, supports are required to maintain a roof. Working places change their location with progress of mining operation. Therefore, for automate the work in such environment, a locomotive mechanism which can endure great reacting force, can support effectively the roof and floor, and has high moving performance in rough environment, might be required. In narrow underground environment which is surrounded by rock, it is possible to generate great fixing force by means of a jack which is set between the roof and floor or both side wall it is usual to apply a jack as anchor post for fixing machinery or reacting force. Self advancing supports widely used in long wall faces in coal mines could be said an example of locomotive mechanism with propping up fixing method. However it is difficult to say that ordinary self advancing supports have enough adaptability for various condition of the roof and floor. New locomotive method for underground working place 'Swing Phase Locomotion' is proposed. It is achieved by mechanism based on frame type support and synchronous control of jacks. Furthermore, to achieved high adaptability to various conditions of the roof and floor, another walking mechanism has been developed. The mechanism employs propping up jack as its legs.

Jan 1, 1989

By John L. Stauffer, Allan Lipton, Kim Leitzel, Lesley Gaydos, Laurence M. Demers, Douglas C. Kuhn

Eicosanoids and cytokines produced by the alveolar macrophage (AM) are key mediators of pulmonary inflammation and fibrosis resulting from occupational exposure to mineral dust. In order to determine if eicosanoid and cytokine production are altered by chronic inhalation of coal dust, we compared the production of prostaglandin E2 (PGE2), thromboxane A2 (TxA2), leukotriene B4 (LTB4), interleukin 1 (IL-1), tumor necrosis factor (TNF) and platelet-derived growth factor (PDGF) by cultured AM from non-smoking normal human volunteers and coal miners. Inhibitors of eicosanoid biosynthesis were administered to AM from coal miners in order to determine if a link between eicosanoid and cytokine production exists in these cells. Basal PGE2, TxA2, TNF and IL-1 production by AM from active miners was increased compared to AM from normal volunteers. However, the production of these eicosanoids and cytokines by AM from former coal miners was reduced compared to control AM. Administration of the cyclooxygenase inhibitor, suprofen, and the lipoxygenase inhibitor, nordihydroguaiaretic acid, reduced PGE2 and TxA2 production in miners' AM but had no effect on LTB4, IL-1 or PDGF production. Specific inhibition of thromboxane synthase by UK38,485 was associated with a significant reduction in TNF production in active miners' AM but had no effect on PGE2, LTB4 or IL-1 production. The prostacyclin analogue ZK96,480 also specifically inhibited TxA2 production in active miners' AM. The results of these studies suggest that coal dust exposure is associated with alterations in AM eicosanoid and cytokine production which may be relevant to the development of pulmonary inflammation and fibrosis. In addition, the lack of effect of inhibitors of PGE2 biosynthesis on IL1 production in miners' AM suggests the production of these intercellular messengers may not be linked in AM chronically exposed to coal dust.

Jan 1, 1991

By M. Ge, C. Mborah

"The acoustic emission/microseismic monitoring (AE/MS) technique has widely been used in the mining environment for the monitoring of rock mass stability. A successful implementation of the method is hinged on being able to accurately determine the P- or S-wave arrival which is then used in the determination of the source of an event. Determination of the arrival phase is usually performed visually by a human expert. However, the mining environment is characterized by high noise levels and different noise types of varying intensities. Therefore, performing manual phase picking on time series data acquired from the AE/MS monitoring system can sometimes be tedious and time consuming if not impossible. In this paper, a proposal for improving manual P-wave phase arrival picks is discussed. The method involves the filtering of the AE/MS data using a stationary discrete wavelet transform (SDWT) method. After filtering, appropriate scales/levels of the multi-level decomposition process are then selected for further processing. The first step in the picking process after filtering, requires the computation of the signal power and the root mean square (RMS) using the signal amplitudes at each scale. The preliminary P-phase arrival time is picked using the results of the calculated power and RMS values respectively. The calculated RMS values are then superimposed on the calculated power values to determine the final arrival picks. If the arrival time picks obtained by both methods coincide or are within 5 to 10 sample points, the pick is considered reliable. The accuracy of the method was verified using AE/MS data from two datasets obtained from two separate underground mines. The results of the study showed that the picking method is reliable and robust. Based on the data studied, it can be concluded that the method will help reduce the time usually spent in processing AE/MS data from mines. INTRODUCTION A successful identification and location of the source of acoustic emission/microseismic (AE/MS) events is mainly dependent on the onset time of the P-wave phase. In many seismic networks, initial picks are performed by picking algorithms followed by manual picks by human experts. If the waveform signal-to-noise ratio (SNR) is low, the P-wave onset time picks by the human expert is generally reliable and accurate [1]. However, for waveforms with high SNR, picking of the P-wave onset could be a major challenge. Also, due to the volume of data acquired daily, manual processing could be stressful and time consuming [2]. These challenges continue to provide motivation for alternative means of providing reliable and efficient ways of improving manual phase picking. The AE/MS technique has been an intergral part of safety monitoring in mines [3] due to its capacity to identify zones of instability in a monitoring area. To obtain an accurate source of an AE/MS event however depends on the quality of the data used for P-wave phase picking [4, 5]. AE/MS data from mines are generally contaminated with excessive background noise generated by the different mining operations. The AE/MS signals of interest are mostly buried in background noise which makes it difficult to pick the P-wave phase arrivals [4]. Processing AE/MS data acquired in noisy environment remains a major challenge due to the weak nature of AE/MS signals [6]. As noted by [4] most of the data recorded in the mine environment are mainly due to events not related to AE/MS events of interest. The complexity of data in this type of environment makes the detection and picking of P-wave arrival by human experts a very difficult task."

Jan 1, 2017

By Dongxu Jia, Chen Cao, Shuangwen Ma, Jun Han, Huibin Ma

Coal bump, or coal burst, is one of the catastrophic disasters in underground coalmine. Among them, approximate 80% of recorded destructive burst events were occurred in mining roadway. The bump panel is often formed by hard coal seam and hard main roof; however, the cause and course of the bump events are not understood yet. This study provides a fundamental theory for the causality and progress of a coal bump event occurred in longwall roadway. Considering hard roof condition commonly existed in bump panels, we think that the abutment pressure induced by suspended roof behind the working face is the trigger of a coal bump event occurred in the roadway. Once high abutment pressure is concentrated on the hard coal seam around the working face, the roof and the coal around the working face form a seesaw-like structure, which leads the roof in front of the working face moving upwards. The movement of roof uplifting in front of the working face is a well evidenced phenomenon in practice, namely, roof rebounding, which causes unloading of the normal stress on the roof-coal interface around the roadway. A rib coal block bump mechanical model has been developed to establish the critical equilibrium equation of the coal block. Result shows that, the force source of coal bump is the horizontal ground stress perpendicular to the rib surface; and the slippage of the coal block is caused by the unloading of the normal stress acting on the roof-coal interface. Based on the causality and consequence theory of coal bump developed in the paper, several new prediction and prevention measures have been developed, including roadway design and in-tunnel reinforcing methods. The commonly used prevention measures in present have also been discussed. This paper presents a comprehensive explanation of coal bumps occurred in longwall roadways, from abutment pressure at working face forming seesaw structure to roof rebounding leading slippage of the rib coal mass into roadway, which provides a fundamental theory for coal bump causality mechanism and prediction and prevention technology.

Apr 26, 2022

By Pengfei Wang, Guorui Feng, Shufeng Zhang, Yuxia Guo, Tingye Qi, Dian Li

"Based on the geological conditions of the No. 10203 mining face of the Xinyang coal mine, a numerical model of the longwall backfilling face is built using the FLAC3D software to calculate the limit broken length of the key strata. Based on the deformation laws of the immediate roof, the backfilling parameters are determined. Furthermore, the movement laws of the overburden strata with different volume filling rates (0, 40, 60, 100, and 100%) and with different layout forms of the filling strip (under a volume filling rate of 60%) are analyzed. The results of the numerical modeling show that the stress of the two sides of the working face and the deformation of the overlying rock are gradually reduced with the increment of the volume filling ratio. In view of the deformation of the roof strata within the allowable range, a volume filling rate of 60% is selected to simulate and analyze the filling effect under different layout forms of the filling strip. The filling width, stress concentration area, and layout form of the filling strip are the key factors to control the movement of the overlying strata. In addition, the probability integral formula is used to calculate and predict the ground subsidence on the filling area, which confirmed that the backfilling mining method is fully applicable in the Xinyang coal mine. The results of this study provide a certain theoretical basis for the determination of the filling process in the field.INTRODUCTIONIn China and other coal producing countries, gob is managed using the caving, filling, supporting, and slowly sinking methods (Zhang, Zhou, and Zhang, 2009). With the continuing development of the concept of green coal mining (Guo, Deng, and Zou, 2004), the filling method, which is safe and environmentally friendly, has been widely used in the field. On one hand, this method could reduce waste rock and other waste discharge. On the other hand, it could effectively slow the surface subsidence. Recently, strip-filling mining mostly adapted the arrangement of the strip backfill with equal intervals and widths (Xie et al., 2004), but the reasonability of this arrangement should be discussed. To arrange the intervals and width of the strip-filling body reasonably, Feng et al. (2019) put forward the “constructional backfill mining (CBM)” concept. The CBM is a type of backfill mining with low backfill rate, strong structural stability, and good backfill effect. The targets of the CBM include the efficient usage of solid waste resources in mining areas to reduce the backfill cost, the improvement of backfill materials and backfill technologies to increase the backfill efficiency, and rational planning of backfill and mining scheme to reuse the underground mining space. The determination of proper width and intervals for the strip-filling body is the main content of the CBM. Strip-filling mining using cemented coal gangue backfilling is the main method to undertake overburden of the overlying strata and to slow down the surface deformation. It also plays an effective role in cost reduction (Xu et al., 2007). This study focuses on proper determination of the strip-filling body parameters according to actual geological conditions by a simulation. It provides an appropriate reference for backfill mining in the Xinyang coal mine."

Jan 1, 2019

By Sebastian Avalos, Julian M. Ortiz

The long-term mine scheduling is the optimal decision on how to extract and process the mining reserves. The resulting plan is mainly driven by economic, metallurgical, and geological factors. Accounting for their uncertainties leads to a robust solution and the feasibility for economic-risk quantification. In this work, we model the spatial uncertainty of grade distributions of multiple correlated elements, by using a multivariate morphing transformation. The result is a set of multivariate geostatistical realizations of the grades, which honor the conditioning data, the direct and cross variograms, and the multivariate statistical distribution, inferred from a set of samples. These models are the input in a reinforcement learning framework, adopted to train a deep neural network that considers the grade uncertainty and leads to an optimum mine plan after training using deep Q-Learning. Mining and processing capacities, as well as economic parameters and metallurgical constraints, are incorporated as the reinforcement learning environment rules. The method is validated on a real deposit, providing insights for future applications.

Jun 25, 2023

By William T. Folwell

INTRODUCTION - CURRENT RAISE BORING PRACTICES Raise boring is a comparatively new tool to the underground mining and construction industries. Underground raise boring, in this country, had its beginning in the early 1960's, in the iron mines of Michigan. These first raises were bored 40 in. and 48 in. in diameter with maximum lengths of approximately 200 ft. Since the late "sixties", the raise boring machine has been accepted by the mining industry as an important machine to increase excavation rates, provide adequate ventilation airways, improve safety, and reduce costs, to name a few of the benefits. The construction industry is now accepting raise boring techniques for hydro-electric power projects, water supply projects, tunnel projects, waste water projects, etc. Raise drills are now capable of boring raises to diameters as much as 12 ft, in the softer rock types. Raise lengths range from 200 ft to as long as 1700 ft. Bored raises, in general, are bored at dip angles ranging from 45º to 90º, depending on the requirement of the raise. The general practice is to drill the pilot hole down to an opening below and up ream the pilot hole to the required diameter. The pilot hole (9-7/8", 9", 11", or 12-1/4" diameter) is generally drilled with compressed air to remove the cuttings. In the event that ground water is encountered and removal of cuttings is impeded, a foaming agent is added to assist in lifting the cuttings. When excessive water is encountered, water is used as the circulation medium and the cuttings are removed by pumping. During the reaming cycle, the cuttings fall by gravity and are removed from the bottom of the raise by conventional methods.

Jan 1, 1997

By Rod Heath

The Saskatchewan industry has the advantages of an ore body of a size and consistency unmatched anywhere else in the world, and large, efficient mines with production costs that compare favourably with those in other countries. On the minus side, Saskatchewan is remote from most major markets, and producers face a distribution challenge to reach the offshore markets which is the main focus of this presentation. One of the characteristics of the world potash business is that all of the major sources of production are located in the developed areas of the world, while there is no significant production in any of the highly populated developing countries. The major potash producers are located in Canada and the United States, in West Germany, France, Spain and the U.K., in Russia and East Germany, and in Israel and Jordan. There is currently no significant production in any of the countries in Asia (with the exception of Jordan where a plant is currently in the start-up phase), Africa, Latin America or Oceania, and all of these areas must, therefore, import a11 of their potash requirements from the producing countries.

Jan 1, 1985

By C. H. Bucknam

An interlaboratory testing program was undertaken in support of an ASTM standardization program for simultaneous combustion-infrared analysis for carbon and sulfur in ores and related materials. Statistical analysis results from the study are used to generate the within-laboratory and between-laboratory precision data needed for standardization of the methods. The interlaboratory precision statistics are also interpreted to estimate the uncertainty in calculation of net carbonate value classifications using a simplified quantitative risk analysis technique.

Jan 1, 1998

By K. J. Sollman

With an ongoing concern for safety and health in the workplace, NYCO® requested three medical evaluations be undertaken to study possible health hazards of wollastonite. Two of the evaluations were conducted by the National Institute of Occupational Safety and Health (NIOSH). One was in 1976 (Ref. 1), and the second in 1982 (Ref. 2). The aim of the two studies was to answer the following two questions: 1. Do wollastonite workers exhibit more respiratory abnormalities than workers not exposed to wollastonite? 2. Is there a relationship between prevalence of respiratory abnormalities and accumulated expo-sure time to wollastonite?

Jan 1, 1988

By Olivia Perkins, Shawn Sismondi, Adrian St. John, Vicky Potts

"INTRODUCTION An inherent aspect of any tunnelling project is ground risk: how it is identified, quantified and managed throughout the various stages of a project. Early identification of these risks, such as adverse ground conditions or potential obstructions is crucial; however specific identification of all risks will inevitably be limited by the extent of the desk study, ground investigation and accuracy of as-built information available, particularly in a densely populated urban environment such as London with a long and varied history of development. It is therefore crucial to have suitable plans and procedures in place for dealing with potential ground risk scenarios if they occur during construction work to ensure the safety of the workforce and to protect nearby critical assets. A number of experiences of potential ground risk were encountered during the Sprayed Concrete Lining (SCL) works on Crossrail contract C300/410 which was constructed by a joint venture of BAM Ferrovial Kier (BFK). The C300/410 works, undertaken in the heart of London, comprised of over 2.5km of SCL tunnels for Bond Street and Tottenham Court Road Stations and the Fisher Street crossover, as well as two 6.2km TBM tunnel drives between Royal Oak and Farringdon. BFK appointed Donaldson Associates as their SCL designers for the works; together they were responsible for excavation stability up to the point of ring closure. Despite the majority of SCL tunnelling works at Bond Street and Tottenham Court Road being through the favourable medium of London clay, there remained areas of local geotechnical challenges. Some of these were expected from the outset, some became apparent as works progressed from records of other nearby excavation works, and some were only encountered during tunnel excavation. Being located in the centre of London meant that there always remained a possibility of meeting some form of obstruction from previous structures. However, identification of all potential issues prior to the commencement of the works was challenging and proved to not be entirely possible. Through a series of case studies, this paper documents incidents where obstructions or adverse ground conditions arose. These scenarios all had the potential to cause safety risks, impact the tunnel design and/or construction methods and ultimately add time and cost to the works. The paper discusses how these challenges were overcome which utilised in part, a progressive risk reduction cycle, feeding back knowledge gained at all stages of construction into the approach for undertaking the works. It also examines what could be done in future to further reduce the ground risk through early identification, communication, education and appropriate contingency measures."

Jan 1, 2016

By Thomas S. Kovach

In today's competitive energy market, every effort must be made to assure the lowest possible production cost. 'rhi s. paper describes the cooperative effort between the coal producer and the utility customer to develop and install a fully integrated mine information management system at a 2.5 million tpy lignite mine in east Texas. A description of each item of the modules is included along with the problems encountered during development and how they were corrected. The system configuration is also described.

Jan 1, 1989

By R. L. Grayson

As a followup to a USBM-sponsored research project, the authors utilized the knowledge-base structure and system concepts from a Sun Sparcstation-based worker-scheduling system of the mine-management support system to develop a PC-based application. The new software adopts the nested-window concept to facilitate data collection and modification on personnel, including their availability and work priorities during a shift. The system can optimally allocate manpower on a work shift and can delineate supervisory training responsibilities. The various components of the software, including enhancements made to the original system, are described in detail.

Jan 1, 1997

By D. Doepker

The dissolution of metals from various metal/ non-metal mine tailings has been studied through column leach tests at US Bureau of Mines laboratories. Metal mobilization in unsaturated columns was consistently greater than metal dissolution in water-saturated columns. Leachate pH was also frequently lower when a leachant was passed through columns but showed a mixed residence-time dependence. On the other hand, metal and sulfate ion concentrations in the leachate increased with dry-cycle residence time. Results suggest that acid formation through atmospheric oxidation of pyrite may compete with non-acid-forming oxidation of other metal sulfides. The two processes lead to decreased pH and increased metal mobilization, respectively. Leach tests using sodium lauryl sulfate indicated that microbial activity was not a factor in these studies.

Jan 1, 1991

By Ernest K. Yanful, Paul H. Simms

The lysimeter is a useful tool for evaluating the performance of mine waste covers or liners. A major problem with its application is the possibility for preferential flow into or away from the lysimeter, if the lysimeter soil is finer or coarser than the barrier soil or sub-base soil. Analysis of a field lysimeter using a two-dimensional unsaturated-saturated liquid flow model suggested that preferential flow would occur and little or no water would be collected; however, in the field, the lysimeters collected significant amounts of water. A similar discrepancy was found between the observed and predicted water balance of a simple laboratory test simulating the lysimeter design. Vapour flow and partial flow, two phenomena not generally simulated in conventional flow models, are possible explanations for the difference between field and laboratory observations.

Jan 1, 2000