Search Documents

By F Jullian, L Jofre

Many maintenance managers find it difficult to justify investments in maintenance improvement initiatives. In part, this is due to a tendency by mine managers to regard maintenance purely as a cost centre, and not as a process able to influence productive capacity and profit. It is also hindered by a lack of alignment between commonly used maintenance performance measures and key business drivers, and the lack of formal business training amongst maintenance professionals. With this in mind, a model to assist maintenance managers in evaluating the benefits of maintenance improvement projects was recently formulated. The model considers four cost saving dimensions. These are: 1. reduction in the cost of unplanned repairs and maintenance,2. increased or accelerated production and/or sales,3. spares inventory reduction, and4. reduction in over-investment in physical assets and operating costs. This paper discusses the application of this model and a number of numerical examples are given to justify investments in maintenance improvement projects having varying objectives.

Jan 1, 2006

By R Miller

The enrichment of magnetite to haematite and haematite-goethite leads to a coincident magnetic low and gravity high within the banded iron formation. Palaeochannel deposits of pisolitic limonite can be expected to provide a relative magnetic high and gravity low in a sinuous geometry. Detrital iron deposits of conglomerate, scree or ‘canga’ might have indistinct magnetic response but will usually have a relative gravity high.These signatures provide clear discriminators detectable by a joint gravity and magnetic survey.The combination of airborne gravity gradiometry and magnetometry is particularly powerful in detecting and discriminating targets, as well as mapping lithologies and structure, across a wide variety of iron ore deposit styles. It provides detection capabilities in a platform capable of rapid, complete coverage with minimal access issues. This approach has been used in FALCON™ airborne surveys for iron ore exploration in the Great Lakes, USA; the Middleback Ranges, South Australia; and the Hamersley Basin, Western Australia.The complex magnetic properties of iron formations (particularly remanence, anisotropy and depth of weathering) prevent this approach from being simple. The use of vector residual magnetic intensity (VRMI), calculated from the measured total magnetic intensity (TMI), assists by reducing the complexity due to the different directions of the remanent and induced magnetic fields.Estimations of the density to magnetisation ratio via the pseudo-lithology calculated from the VRMI and gravity gradients provide a useful method of capturing the discriminatory power of joint magnetic and gravity gradient data.

Jul 11, 2011

By F C. D Michelin

As mines get deeper, the critical underground temperature limits will be exceeded, and an increasing number of mines will need to implement, expand or modify cooling systems. Surface cooling plants have many advantages over underground cooling such as efficient heat rejection, and lower relative capital cost; however the delivery of cooling through long underground distances can result in lost refrigeration capacity before the chilled air reaches the areas it is needed most. Refrigeration plants are therefore often overdesigned in size and capacity to compensate for underground losses.More mines are now utilising real-time monitoring and automated control of ventilation airflow and fan systems to ensure the conditions underground are safe and productive, and power consumption is efficiently managed. There may be significant opportunities to extend ventilation monitoring and control into the refrigeration delivery and control system.Energy reduction is an effective way to reduce costs and CO2 emissions, which is an increasingly important part of corporate governance. More efficient refrigeration control is a further step toward reducing energy consumption. This paper looks at an added step in how real-time monitoring can assist in controlling the output and chilled air delivery of a cooling plant. The requirements, implementation, benefits and challenges will be discussed.

Oct 12, 2022

By Walsh V

The Australian economy has been adversely affected by the hesitation in developing countries to commit to the construction of .new coal-fired power stations. World coal trade which was expected to grow at an appreciable rate has stagnated, world export coal prices have plummetted, and facilities in place in Australia for the production and export of coal are being underutilized. While in some countries this hesitation has been caused by a reduction in electricity load growth, another cause has been the unduly long lead-time imposed on developing countries by the conventional "Banker's Approach" to the planning and initiation of commitments to finance and construct coal-fired power plants. In some countries electricity growth has been met by increased usage of indigenous energy resources, even though this involves costs in excess of imported coal-fired power generation. The avoidance of foreign exchange commitments in these cases can however be desirable. In many other developing countries however, fuel oil continues to be used for power generation at a cost in foreign exchange of up to 50% above the total cost of coal fuel plus capital to construct a new coal-fired power station. The conventional "Bankers Approach" to new power station planning imposes the need for successive feasibility studies to satisfy the normal processes of international development lending agencies. No feasibility study can however, show how keen vendor countries may be to win major power plant contracts; and no feasibility study can determine whether the power station eventually procured will be one of the more reliable, at better than 80% availability, or one of the more unreliable at worse than 60% Availability.

Jan 1, 1987

By D Smith, D Reid, D Bradshaw, C Brough

The Merensky Reef at Northam Platinum Mine in South Africa is characterised by a high degree of variability with respect to reef elevation (difficult to mine), as well as mineralogy and texture (difficult to process). Development along strike and down dip of multiple reef types has led to unpredictable run-of-mine characteristics that pose problems for the mineral processing circuit at Northam. Following mining terminology, Normal, Transitional (NP2) and Pothole (P2) Merensky reef types can be defined, and this geometallurgical study aims to characterise and understand the relationship between their mineralogical characteristics and laboratory scale batch flotation performance. The plagioclase-rich NP2 reef ore is the easiest ore to process in terms of capacity for high mill throughput as well as flotation performance. The lack of very fine-grained disseminated sulfide textures in the NP2 reef ore results in better liberation characteristics relative to the Normal and P2 reef types. Consequently, chalcopyrite, pentlandite and sulfide recoveries are highest for the NP2 reef ore. The lack of ferromagnesian minerals in the NP2 reef ore also results in the recovery of the least amount of floatable gangue during flotation tests. The Normal and P2 reef ores are similar to each other, with an orthopyroxene-rich mineralogy with associated alteration minerals. The P2 reef is also characterised by the highest sulfide content and degree of pentlandite liberation. Chalcopyrite, pentlandite and pyrrhotite liberation is only significantly increased by a change in grind for the Normal reef ore. The change in grind, however, only significantly affects pentlandite flotation performance and overall froth stability for the Normal reef ore. However, for all three ores, a small change in grind has a detrimental effect on pentlandite flotation performance.

Jan 1, 2008

By Flann R. C

A small modification to current industrial practice should lead to better nickel powders for use in alloying, electroplating, and powder metallurgy. Nickel powder compacts sold for alloying are not always suitable for electroplating applications, since some presently used commercial powders will expand on sintering. Further, such nickel powders are unsuitable for use in the production of powder metal parts, because of expansion during heating of the near-net-shape preforms. Research in these laboratories has enabled the elimination of expansion, and led to techniques for the production of compacts suitable, in particular, for commercial use in both alloying and electroplating. The techniques include: powder pretreatment, cold pressing and sintering, hot pressing, and hot pressing and sintering. In this way compacts are readily prepared with densities of at least 93 per cent of solid nickel, and these, when used as anodes in Watts general purpose and bright baths, give both cathode current and plating efficiencies of 90-98 per cent.

Jan 1, 1979

Detailed observations were made for two existing continuous miner and shuttlecar systems. A simple model for the shift average cycle consisted of three time components - delays, mining and transport. Cycle improvement and productivity improvement factors are derived and used to predict the theoretical improvement which the observed cycles could achieve. Various strategies of action ranging from short-term optimisation through to long-term planning for continuous haulage systems are evaluated. High potential for improvement is shown for a wide range of operating conditions. An overview is presented for systems, currently available or under active development, which can accept coal directly from continuous miners and offer continuous haulage to the surface. Systems are broadly classified as mechanical-roof mounted, mechanical-floor mounted and hydraulic transportation.

Jan 1, 1982

By Tonegato S, Wood M

The lack of objective data on roof bolting machines, bits, rods and overall system has created the need for an objective assessment of roof bolting. This work outlines a test rig for such objective assessment of component parts of the roof bolting system.

Jan 1, 1986

During the development of Lorca tunnel project in the South-East of Spain, an in-site study has been done, with the purpose of obtaining the characteristics of the different lithological units through twenty-two parameters for the design of the tunnel excavation and support. In the paper both the different works developed and the different methods and criteria followed in the obtention of the parameters are described. The values of those parameters may be useful in similar cases. Also a summary-table of the parametrical characterization for the use in similar studies is given.

Jan 1, 1987

This case study describes various aspects of establishing a laboratory facility for testing chemically-cemented fill materials. The applicability of data obtained from such a facility related to mine conditions depends on many factors: kind of data, type of testing facility, sample parameters (composition, geometry, size, etc.). The equipment employed must be adaptable, to accommodate variations in sample size and properties. The design, construction and operation of the testing facility is described, and its application to fill samples prepared from sulphides and oxides both chemically and naturally cemented. The present system was selected following an extensive study of equipment available for testing materials in the fields of rock mechanics and construction materials. The strength testing' facility incorporates Linear Variable Differential Transformers for monitoring both lateral and axial displacements during sample compression. The output from these and from other related instrumentation can be recorded or fed direct to a computer, enabling stress-strain data to be printed out while the test is in progress. Also described are controlled environment curing facilities which allow samples to be cured or weathered under different temperature or humidity conditions to simulate long-term ageing and in place conditions.

Jan 1, 1973

By Kuzugundenli OE, Nagaraj DR

Organic complexing agents have received special attention over the past few decades in the search for reagents for improved flotation separation of minerals, especially non-sulphides. The majority of such reagents that have been proposed over the past few decades have remained largely a laboratory curiosity, except perhaps alkyl hydroxamates, because their selection is seldom based on commercial viability. In this regard, the choice of complexing agents such as oximes may be more realistic because of their widespread use in solvent extraction of copper. Our earlier studies have confirmed that they are also effective as collectors for copper oxide minerals, including chrysocolla which is the most difficult copper mineral to beneficiate. The flotation behaviour of chrysocolla for several structurally-related hydroxyoximes were studied as a function of pH and oxime concentration and the role of structural features examined. The structural changes studied included substitutions in both chelating and non-chelating parts of the molecule. The results indicated that, contrary to expectations, many of the structural changes in the basic molecule, salicylaldoxime, do not have a positive effect on collector efficiency. The reduction in collector efficiency is rationalised on the basis of possible steric factors affecting complexation and packing of the collector species on the mineral surface as well as effects due to changes in electron density brought about by substituents. Introduction of alkyl substituents on the oximic carbon of salicylaldoxime yielded the highest collector efficiency.

Jan 1, 1993

By Bowden MW

Sintering of lead-zinc concentrates is practised by Sulphide Corporation to provide both desulfurised lump sinter feed, for simultaneous reduction to zinc and lead in the Imperial Smelting Process blast furnace, and sulfur dioxide gas for sulfuric acid manufacture.Moisture control of feed mixes is of paramount importance in the sintering operation and improvements in this area have realised increases in overall plant performance.

Jan 1, 1985

By R-H Yoon

Increasing the upper particle size limit of flotation would allow operators to increase mill throughput, save operating costs, simplify flow sheets, and increase rate of return. However, coarse particle flotation is difficult for various reasons, of which bubble-particle detachment has been identified as the major limiting factor. In the present work, the process of bubble-particle detachment has been studied by directly measuring the forces required to detach air bubbles from hydrophobic solids. The measurements were conducted using a hanging balance apparatus. The measured forces were converted to detachment energies that can be compared with the work of adhesion, which in turn is a function of hydrophobicity, surface tension and contact area. The results were converted to detachment energies using the Young-Laplace equation for capillarity. In the present work, the solid surfaces were hydrophobised by coating them with octadecyltrichlorosilane and cetyltrimethylammonium bromide. The results show that bubble-particle detachment occurs in two steps. In the first step, air bubbles are deformed, while the three-phase contact (TPC) line is pinned, until contact angle reaches advancing angle. In the second step, the TPC line moves along the surface until solid/air interface is replaced by solid-liquid interface. In general, the energies of detachment measured in the second step are in good agreement with calculated work of adhesion. Thus, the energy required during the first step effectively represents an energy barrier for bubble-particle detachment. It has been found that the energy barrier varies with surface roughness and surface tension. The results of the present investigation suggest, therefore, that coarse particle flotation can be improved by control of particle hydrophobicity, surface roughness, and surface tension.

Jan 1, 2005

By D Pepper

Despite the limited literature regarding the pressure filtration of mine tailings (compared to the large number of papers published each year on paste thickening of tailings) the number of mines dry stacking filtered tailings is approximately equal to the number of mines storing tailings in paste form. Main drivers for filtering tailings are: water recovery, future rehabilitation costs for tailings storage area and permitting requirements. In arid climates, the cost and scarcity of water justify the capital and operating costs associated with pressure filters. Further justification for filtered tailings is the potential for progressive reclamation of the dry stack, which can proceed earlier and faster than the reclamation of a tailings dam.Filtered tailings must be transported to the storage area by trucks or conveyors. For dry stacking, 70 - 80 per cent solids content (by mass) is typically acceptable, however the primary goal is to provide a filter cake that is consolidated and dry enough to prevent bridging and build-up on the materials handling equipment. It has been observed that high average solids contents (~70 per cent) can be achieved while the centre of the filter cakes is still wet and sticky, presenting challenges for the transportation of the solids. Appropriate controls must be in place to ensure consistently easy to handle solids are discharged from the filter.FLSmidth has installed two fine coal tailings dewatering systems in the United States. One of these systems incorporates a Deep Cone Thickener« upstream of the filter press to minimise the amount of water that must be filtered, while the other tailings filter press is fed by a high rate thickener. The operation and performance of these filters is discussed and compared to the lab testing used to size the full-scale equipment.CITATION:Pepper, D, 2012. Operation of filter presses for tailings dewatering, in Proceedings 11th AusIMM Mill OperatorsÆ Conference, pp 241-246 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Oct 29, 2012

By Y V. Haarlem, P Coghill, N G. Cutmore, M Millen, I Carter

Due to the low concentration of gold, ore sorting for gold has always required measuring indirect properties, such as density or colour, to allow separation on a rock by rock basis. This only works on an ad hoc, by deposit basis and is likely to be least reliable where it is most required in low grade ores. One candidate technique, Gamma Activation Analysis (GAA) has been demonstrated to directly measure gold extremely accurately in powder samples of around 500gm and is used in the Chrysos PhotonAssay assay system. This method uses a linear accelerator (linac) to generate the X-ray radiation that activates the ore at low levels to emit a characteristic gold gamma ray that is then measured by a radiation detector. CSIRO is adapting this measurement technique to application on a belt at up to 800tph to measure pods of ore. The principal differences between measuring samples and an on-line measurement of pods are the requirement to measure coarse ore (<50mm), to measure a larger volume of ore as uniformly as possible, and to have an open-ended geometry with adequate shielding of the linac radiation source. These issues have all been addressed with measurements of coarse ore reported down to around 1ppm in sub-optimal test conditions. They have been demonstrated for <75mm particles with detectors capable of measuring a large volume geometry continuously. These are projected to allow measurements down to 0.3ppm in more optimum conditions for a 10 second measurement time period where the U/Th content of the ore is less than ~10ppm. Extensive Monte Carlo modelling has demonstrated that adequate shielding can be provided in relatively simple geometries with only 1 right angle transfer in the material handling. Steady progress is being made to reach the technical position required to trial an ore sorting system.

Nov 10, 2020

By Patridge A. C

A pilot scale laboratory investigation of manual slurry sampling methods representative of those used in the minerals industry is described. Samples were taken from slurries made up from silica particles of various sizes and in various concentrations from a stirred tank and from the discharge lip of a rectangular launder. Sampling methods from the tank included immersion flasks and several configurations of a suction probe. The launder was sampled using a conventional narrow-mouth ladle and also with a &apos;mouth organ&apos; stream splitter. Samples were analysed for overall solids concentration and size distribution and showed different but always significant and often large biases relative to the known overall composition of the slurry, the nature and extent of bias being dependent on pulp concentration, particle size, sampling method and sampling location. Results clearly show the very great difficulty of obtaining representative samples by simple sampling techniques, although the data suggest that errors can be reduced by using an appropriately designed and operated suction probe. Further work will be carried out with the objective of establishing guidelines for industrial sampling practice.

Jan 1, 1995

Largely inherited from the past and from strictly internal laboratory use, the certification of reference material using round-robin assaying is often insufficient for the use made today for external assay laboratory control by client parties. Certification often needs to be revisited on the basis of existing round-robin data, especially to derive reproducibility parameters to the end of establishing probabilistic performance gates for operational error detection on a batch per batch basis (ie batch-ærejectionÆ). The most common difficulty arises when only a few certification samples have been analysed in one single batch by each laboratory, so that the round-robin data do not contain the full variability that needs to be quantified. Existing certification data sets from properly submitted round-robin samples were studied using analysis of variance to derive a remedial method, leading to the proposal of default correction factors to restore full variability estimates when no other avenue is available.

Jan 1, 2008

Chlorine as a lixiviant for gold possesses a number of significant chemical and Idnetic advantages over cyanide but because of its corrosive and vaporous nature the method of implementation needs to be significantly modified. At comparable reagent concentrations the dissolution rate for gold in the C12/Cl- systems is some 10 - 100 times that achieved in the 02/CN system. The dissolution rate in the chlorine system is largely a function of the concentration of C12, Cl- and pH. Under conditions of low Cl&apos;, (less than 50 g/1), the dissolution rate begins to drop off dramatically over the pH range from 3 - 4. Increasing the level of dissolved chloride ions shifts the pH of this rate reduction to around pH 5 at 100 g/l NaCl, and to around pH 6 at 300 g/l NaCl.

Jan 1, 1991

Much of the data required for the evaluation of mine design is obtained from bore cores. It is essential to collect data that is useful and not to overlook features which might have adverse effects upon the mining practices and which might not be readily discernible to the untrained eye when examining bore cores. Interpretation of the data has progressed from the use of single-value properties, such as ultimate compressive strength or Young&apos;s modulus, to the utilisation of most measurable quantities. The simulation techniques used employ physical and mathematical models for prediction of mining conditions or strata behaviour. The application and capabilities of these methods to mine design are discussed.

Jan 1, 1977

The type of population encountered in the sampling of coal, ores and other products of natural phenomena is one in which the variance within a cluster of elements generally increases steadily as the size of the cluster increases. To enable estimation of variances of stratified random or systematic sampling for such populations one must model the serial correlation function or alternatively, the variogram function. The author has postulated a specific symmetry of the serial correlation function which leads to expressions with rich theoretical and practical implications. These expressions provide a spatial correlation function which explains power law relationships often observed in studies of dispersion variances. They also enable straightforward calculations of sampling variances. The importance of the role of finite population size in the equations leads one to examine previously held concepts of ælargeÆ and æsmallÆ sample populations. The model based on the symmetry postulate is a fractal model with the serial correlation function of a hypothetically infinite population being of the same form as that developed by Mandelbrot for discrete fractional noise. Techniques used in fractal mathematics apply, including box counting and fitting of a dimension function. The paper establishes a framework for the understanding of this fractal theory and demonstrates how to calculate sampling variances from the model variogram using simulated data fitting the model.

Jan 1, 2008