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By F. A. Aplan, Richard R. Klimpel

This article discusses the role of mathematical optimization techniques as applied to the design and analysis of particulate processing plants. The emphasis will be placed on the macro engineering view of integrated multiple operation plants such as those that typically involve stages of size reduction, sol id-sol id separation, solids storage, chemical reactions involving sol ids, sol ids disposal, etc. The macro engineering view is chiefly concerned with balancing and optimizing the bigger picture of how various unit operations interact technical and economically with each other in an approximate sense rather than how a specific unit operation can be technically described and optimized in detail (micro engineering.)

Jan 1, 1991

By Dirk van Zyl

It can systematically assess if the control and management systems designed for protection of sensitive ecosystems are adequate. The results of the assessment can help to identify key elements in the project that pose higher risks due to uncertainties in design. These assessments can then be used to make recommendations to further manage and reduce risks as the project is developed. QUALITATIVE RISK ASSESSMENT The general principles of a risk assessment are well summarized by Kaplan and Garrick (1981): "In analyzing risk we are attempting to envision how the future will turn out if we undertake a certain course of action (or inaction)." Fundamentally, therefore a risk analysis consists of an answer to the following three questions: What can happen? (i.e. what can go wrong?) How likely is it that that will happen? If it does happen what are the consequences?" Risk assessments can be performed using various levels of sophistication depending on the amount and accuracy of data available. A qualitative risk assessment uses descriptors throughout to express the level of risk. The definitions of the descriptors are presented in terms of the magnitude or concentration of contaminants. The results of a qualitative risk assessment can be used to: a)Document the evaluation and decisionmaking process. Although differences of opinion may exist about the definitions of the descriptors, the process is well-documented; b)Express the relative risk associated with specific activities or design elements; and, c)Select those failure modes or release mechanisms that may result in significant risks. These mechanisms can then be further developed in quantitative risk assessments. A qualitative risk assessment can be performed in a systematic approach using four steps (Van Zyl, 1987): A qualitative environmental risk assessment can be used to describe the risks associated with the development of a new mine and to make an evaluation of the adequacy of its design for environmental protection. The relative magnitude of risk associated with selected failure modes and exposure/consequence scenario assessments is the final result of a qualitative risk assessment. These failure modes are based on site specific areas and components, and mining and construction phases. The four steps of a risk assessment (hazard assessment, exposure assessment, consequence assessment, and risk characterization) are used in the development of a qualitative risk assessment. Relative magnitudes (using a five point scale of negligible to high) for each step, can be quantified in a qualitative risk assessment. Development of the descriptors for the relative magnitudes in each step is a very important part of a qualitative risk assessment. The success of a qualitative risk assessment depends on the adequacy of the information base and the subjective judgements made in each step. The quality of the risk assessment is, therefore, dependent on the experience of the assessors. A mining project in a sensitive coastal environment is presented as an example to demonstrate the application of a qualitative risk assessment. INTRODUCTION Environmental impacts from mining operations have been a significant factor in the last century. This was especially the case prior to the development of a better understanding of environmental processes and the potential impacts of acid rock drainage (ARD), and associated heavy metals, or the uncontrolled disposal of tailings and waste rock (Smith, 1987). Much care has been exercised over the last two decades in designing and operating mines to limit the environmental impacts as far as possible. All new mines are specifically designed with mitigative methods to manage such potential environmental impacts. Attention is directed to ARD impacts, safe disposal of mine waste rock and tailings, transportation and storage of chemicals and fuels, and final reclamation. A qualitative risk assessment can be used to address all project systems and activities that may potentially pose a risk to the environment.

Jan 1, 1992

By Robert A. Jankowski, George E. Niewiadomski

INTRODUCTION The utilization of longwall mining technology in the United States has steadily increased since the first longwall plow system was installed in 1952. At the errs of FY 1992, some 76 coal mines were employing longwall mining systems for coal extraction, and approximately 78 shearer and 3 plow faces are operating nationwide at any given time. Although the number of operating longwalls has remained relatively constant over the last five years, longwall production levels have increased significantly during this period. During the same timeframe, the number of continuous miner sections has decreased by 13 pct., from approximately 1438 in FY 1988 to less than 1250 in FY 1992. According to Mine Safety and Health Administration (MSHA) data, the average production of longwall sections increased from approximately 2400 tons per shift (tps) in FY 1988 to more than 3100 tps FY 1992. In fact, the average production has more than tripled since 1978, when it was only 850 tps. Approximately 25 pct. of operating longwalls are capable of producing in excess of 4000 tps. Longwall production currently accounts for nearly 36 percent of U.S. underground coal production, compared to 4 pct. in 1978. These improvements are attributed to improved longwall equipment and increased availability, larger longwall panels and automation. While longwalls are highly productive and offer other advantages, operations employing this method of mining continue to experience dust compliance problems more frequently than other mining system. Although dust levels have remained relatively unchanged over the past five years, averaging 1.6 mg/m3 and 1.9 mg/m3 based on results of operator and inspector sampling, respectively, during FY 1992, approximately 25 pct. of the operating longwalls were in noncompliance during any given bimonthly sampling cycle. Although modest gains in longwall dust control technology have been made, these have been overshadowed by significant increases in production rates. As more coal is mined, more dust is generated (Figure 1). Therefore, the increase in longwall productivity has meant that far more dust is being produced which must be controlled. [ ] In view of the current compliance record, any efforts to further increase longwall output, as has been forecasted, must be accompanied by: (1) the reduction of dust levels at existing operations through the proper installation and maintenance of suitable engineering dust controls; and (2) the advancement of dust control technology for today's and future longwalls that will enable all face personnel o work in an environment that is free of excessive levels of respirable coal mine dust. MSHA'S RESPIRABLE DUST CONTROL PROGRAM Since 1972, federal regulations have required each coal mine operator to continuously maintain the average concentration of respirable dust in the mine atmosphere during each shift in the active workings at or below 2.0 mg/m3 through the application of environmental dust control methods. The regulations provide for further reduction in the dust standard whenever the

Jan 1, 1993

By Peter Schmäh

Pipe-jacked tunnels are considered for a large variety of applications from water and sewage, cable ducts to challenging pipeline crossings or landfall construction. In most cases, Slurry MTBMs are used to carry out these projects. Continuous further development of technological features for pipe jacking plays a key role to overcome feasibility limits and to meet increased project requirements. As tightened safety regulations in terms of accessibility and escape routes increasingly limit the options of small segment lining tunnels in the diameter range below 4 m, 13 feet, pipe jacking has partially taken over. During the last decades, a growing number of large-diameter and long-distance pipe jacking projects have been completed. Experienced contractors successfully use the technological capacity of the MTBM equipment. The machine and cutting wheel have to be designed according to the ground conditions. Bentonite lubrication and interjacking stations are key factors to keep push forces moderate. For long pipe jacking drives, a so-called push module can be installed in the machine can, to be able to switch from pipe jacking to segment lining in case the machine gets stuck. The overall aim is to provide clients and the tunnel construction industry with safe and economical solu- tions for successful project execution. This presentation will present international milestone projects and will also discuss the latest developments in automation, related opportunities and limitations, and the future of digitization and artificial intelligence in pipe jacking.

Jun 23, 2024

By Robert O. Vernon

The discussion of water and pit mining together is most appropriate. In fact, water can be considered a mineral and a well a narrow pit. Thus, of all the mineral resources mined, water is probably the cheapest, most valuable and least valued. The delivered price, including mining, transportation, storage and marketing rarely exceeds ten cents per ton, and our economy would cease without it. The time has come when the public must recognize that the extraction of a mineral resource from the land is a necessary and inevitable result of the industries? attempt to meet the demands of a growing economy. In so much of Florida, the lands mined can, with forethought and planning, be left as improved real estate, water conservation and management lands. On the other hand, the mining industries must face up to the need for the reclamation of land and compact with themselves, appropriate governmental agencies and with the mining states to restore mined lands to usefulness. Of limestone, sand, and clay 90 to 100 percent of the mined material is used, but with planning and specing, these pits, if they penetrate the water table, become valuable as real property. Phosphate, which returns about 70 percent of the mined materials to the pit, can reclaim the land for many purposes.

Jan 1, 1966

By C. J. Milam

Oil shale may not produce the same excitement of the gold rush days, but presently there is an "oil shale fever" among mining men. Such exotic equipment as 800-ton haul units, 75 ft. boring machines, and huge fully automatic multi-purpose jumbo drill units are only a few of the topics of conversation in the oil shale groups. I am dreaming, perhaps, but this type of exotic thinking will exuberate the advancement in mining technology and will only be tempered by the practicality and the availability of today's equipment.

Jan 1, 1975

By M. S. Duffy

To exploit the mineral resources of fine grained ore bodies the minerals processing industry is turning to fine grinding technology, of which tower milling has become an established part. However, compared to other mills relatively little is known about the operating mechanisms in tower mills. In all milling processes one of the keys to understanding how they work is in knowing how their grinding media move. To investigate the ball motion in tower mills a glass unit was therefore constructed and measurements taken of the movement of the grinding media. This paper describes the results from this study.

Jan 1, 1998

By C. I. Wilmot

The paper presents an update of the Paradise Peak mill after the first year of operation. Process revisions, equipment modifications and additions, and personnel requirements are discussed with a comparison to original design. All areas of milling are discussed including crushing, grinding, leach/countercurrent decantation (CCD), precipitation, refinery, and heap leach.

Jan 1, 1987

The major stages in the life cycle of a tailings facility include site selection, impoundment de-sign and construction, operation and closure. Optimum management of these stages requires an integration of all legal, engineering and environmental aspects in order to improve safety and minimize future potential risks for humans and the environment. This paper discusses the main factors involved at each stage and focuses on the stability considerations of the impoundment facility.

Jan 1, 2002

By Michael Fahey, Ravi M. Damodaran, Brij M. Moudgil

The flotation behavior of Florida phosphates was studied using statistical design of experiments to evaluate conditioning parameters and their effect on flotation performance. The solids loading, conditioning time and agitation speed during conditioning were identified as the important variables affecting the reagent coating onto particles. Flotation of the conditioned slurry was carried out at fixed collector dosage and flotation conditions. Phosphate recovery upon flotation was statistically modelled as a function of the conditioning variables. The results indicated that the conditioning variables had an interactive effect on the phosphate flotation performance. Statistical optimization revealed two conditioning regimes in which optimum flotation recovery was obtained. It was determined that optimal recovery can be obtained at lower conditioning energies.

Jan 1, 1995

By D. M. Ziebarth

"During the mid to late 1960’s, the underground potash industry in Saskatchewan was born. For the next four decades the industry operated at a steady pace supporting a large part of the world demand; until 2008 when the potash market heightened. Operators were motivated to capitalize on this increased demand, new mines were proposed while existing mines were planning upgrades. Potash Corporation of Saskatchewan (PCS) was one of the major producers planning upgrades to their production facilities quickly, including modifying the existing headframe and shaft at the PCS Cory Site to accommodate a new 1500 tonne per hour hoisting plant. Upon completion of the project, the innovative operations group continuously reviewed methods to increase production and reduce operating costs, allowing PCS to continue being competitive on the world market. This paper will describe the design challenges encountered during the development of the infrastructure around an operating facility whilst minimizing down time, schedule, capital and construction costs. This paper will also explore the strategy to increase capacity of the newly commissioned hoisting plant. BACKGROUND Potash production is a major Saskatchewan industry, and has played a significant role in the economy for over 40 years. Production commenced in 1962 when water problems were overcome at the International Minerals and Chemical (IMC) mine near Esterhazy, Saskatchewan. A surge of development by other companies resulted in twelve companies opening ten mines by 1970. In 1975 Potash Corporation of Saskatchewan was created by the government of Saskatchewan and shortly thereafter purchased several mines in Saskatchewan, including the Cory Mine (Cory), near Saskatoon. Cory has been in operation since 1968 and is located 12 km (7.5 mi) west of Saskatoon in central Saskatchewan. The mine is located in the center of the world’s largest potash deposit, 1,000 m (3300 feet) below surface. PCS has embarked on sizable capital expansions of more than CDN $7 billion. The Cory CDN $1.6 billion expansion was expected to raise operational capability of the site to 2.7 million tonnes per year, an increase of 1.9 million tonnes per year (MTPY). To achieve 2.7 MTPY of finished product and considering the 22.6% average production recovery1, 12 MTPY of ore must be hoisted to surface for processing. To deliver this rate required upgrading of the hoisting plant to 1500 tonne per hour (TPH). To accomplish this ambitious challenge, creative thinking, careful planning and a cohesive team was needed to work together to ensure the schedule, budget and most importantly the work was completed safely"

Jan 1, 2017

By Timothy J. Matthews, Ted Klemetti, Timothy J. Batchler, Daniel J. McElhinney

Unplanned tailgate collapses and difficult mining conditions in U.S. longwalls have necessitated the use of innovative tailgate support systems. Severe ground movement induced by longwall loading has caused operators to utilize secondary support systems that can match yield and strength requirements with expected ground reactions. Standing support performance requirements depend on the nature of the ground deformation behavior, and therefore require a good understanding of the interaction between the support and ground to achieve an optimum roof support system. Mining operations often employ standing support strategies that are unique to their mine. A support system that functions successfully in one situation could fail in another situation. It is important that the design and installation of the standing support systems provide the highest probability of preventing roof falls. Pumpable roof supports are currently being used to provide a safe working environment for longwall mining. A full understanding of the impact of these performance characteristics is necessary to optimize the support application and to provide a foundation for making further improvements in the support performance. Optimization of roof support applications helps to ensure the protection of mine workers by preventing roof falls due to inadequate support design. The load capacity and stiffness characteristics of a 27-in.-diameter pumpable support system was evaluated using the National Institute of Occupational Safety and Health (NIOSH) Mine Roof Simulator (MRS). Previously, tests to evaluate the performance characteristics were performed on a single pumpable support. The goal of this new research is to evaluate the performance characteristic effects of the pumpable support system and compare it to an individual pumpable test examination. This research of a pumpable support system configuration simulates the current installation practices in U.S. coal mines.

Jul 1, 2023

By E. R. Spencer, E. R. Bauer, G. P. Cole

Overexposure to hazardous noise has been found in most mining sectors, with up to 100% of the surveyed workforce experiencing a noise dose that exceeds the U.S. Mine Safety and Health Administration (MSHA) permissible exposure level (PEL). As a result, miners show elevated rates of hearing impairment of 70-90% by retirement age. To help manage noise exposures, the U.S. National Institute for Occupational Safety and Health (NIOSH) developed the Determination of Sound Exposures (DOSES) software and implementation guide for use by mine management and safety personnel. This paper describes the development, functions and basic operation of the initial-release version of DOSES. A revised version is being developed to incorporate additional user-suggested functions, and its development and implementation to assess noise control solutions will be described in a future article. The software relies on a time-motion study that profiles the worker’s daily activities. Observations about the worker’s location and tasks or other activities are recorded along with the start and end time, to determine the duration of the tasks so they can later be matched up with the noise data. The software gives the user the option of assessing dose relative to the MSHA PEL, the action level or the NIOSH recommended exposure limit. The software generates a variety of interactive on-screen displays showing where, when and how the worker’s noise dose accumulated. It also can generate customizable printed reports. These outputs can be used to highlight the tasks, locations and times that are associated with the greatest amount of a worker’s noise exposure. DOSES simplifies and streamlines the record keeping and analysis associated with time-motion studies and worker noise exposures, so mine management can make engineering noise control or administrative control decisions to limit the noise overexposure of their workers.

Jan 1, 2011

By Noel C. Joughin, Orrie Fenn, Brian E. Protheroe

Work has shown that the use of high-pressure water jets enhances the performance of mechanical cutting in very hard rock. To assess the potential of this approach for use in conjunction with free rolling cutters, a series of tests has been conducted using both disc and button type cutters, to determine the relative effects, on cutter performance, of variations in relevant jet and cutting parameters. In these tests it was found that water jet assistance can result in reductions in the forces on a free rolling cutter typically of the order of 40%.

Jan 1, 1985

By B. W. Cavender

Innovative mining and metallurgical operating techniques and processes can be identified and developed by analyzing changes as they occurs within the mine, plant, technology or industry. Sources of change to be monitored for innovative opportunities include unexpected successes or failures, incongruities between perceived and actual events, process needs, changes in perceptions and the development of new knowledge. Innovation can be organized, practiced and managed. The perception of change as an opportunity rather than a threat is mandatory, as is the systematic measurement of innovative performance. Innovation is enhanced by specifically designed policies regarding organizational structure and staffing, daily management practices and compensation and incentives.

Jan 1, 1996

By Erie F. Wolstenholme

The purpose of this paper is to describe work undertaken, within the System Dynamics Research Group at Bradford Management Centre, into the development and application of a System Dynamics model of an international mineral industry; aimed at providing a basis for analysis of the interrelationship of supply, consumption and price over time, under different production and stocking policies. A review is presented of some of the major characteristics and problems associated with such industries. This is followed by an outline description of the model and the way it has been applied to examine various supply responses, in the light of changing consumption patterns. Demonstration results deal with model validation and with analysis of international buffer stocks and conflicting supply policies on the historic situation in the copper industry.

Jan 1, 1979

By C. L. Glorioso

As an introduction and credentials for our talk, let me take a moment to introduce you to Wimpey Worldwide and specifically to Wimpey Minerals, USA, Inc.

Jan 1, 1995

By J. J. Gusek

Several final pits in the Seneca No. 1 Surface Coal Mine were abandoned in the 1960's without being reclaimed. In addition, a progressive landslide aggravated by the abandoned mine land conditions was threatening a county road and private property. An AML-funded project to stabilize the landslide and reclaim the final pits was completed in 1986 for the Colorado Division of Mines and Geology (formerly Colorado Mine Land Reclamation Division). The site was visited after ten growing seasons. The land is stable and the vegetation re-establishment is strong. Volunteer native plant species are now invading the reclaimed sites.

Jan 1, 1997

The need for an integrated approach to optimization of unit operations in both the pit and the mill has long been recognized, but the complexity and nature of the overall problem has up to now resisted solution. This paper reports on a modeling methodology which couples symbolic and numeric computing to unify operations in both the pit and mill. The ultimate goal of this work is to optimize all operations that are influenced by blasting. Blasting plays a key role in all facets of operations. Obviously, drilling and blasting costs are determined by blast design, but the down-stream costs that are closely related to blasting results are often treated as separate functions: loading, hauling, cleanup, and crushing and grinding are all heavily influenced. Diggablilty and bucket fill factor are a function of fragmentation, the condition of the floor and uniformity in the shape of the muck pile. Likewise, cycle times and loading delays partially determine haul cycles, while fragmentation distribution and size determines the efficiency of truck loading. Removal and breakage of oversize causes loading delays and increases cleanup costs. The influence of blasting doesn't stop at the crusher. Mill productivity, power consumption, and maintenance are a function of the feed. Even at the SAG mill a reduction of a critical particle size during blasting can increase throughput. Thus, a bottle-neck for production far removed from unit operations in the pit can be alleviated by a modification in blast design. The question is: how do we optimize blasting with respect not only to itself but to al\ related mining and milling operations? For that matter, how do we even model blasting so that we can control the results of a blast?

Jan 1, 1991

By John K. Adams

Phosphorus may be incorporated into sedimentary rocks in at least four different ways: (1) by the accumulation of detrital mineral fragments, (2) by the accumulation of phosphatic organic debris, (3) by diagenesis and (4) perhaps by the primary precipitation of calcium phosphate. Based-on the petrographic examination of Cretaceous and Tertiary sediments from the northern and central parts of the Atlantic Coastal Plain, Diagenesis is the most important of these mechanisms. Both syndiagenesis and epidiagenesis are required to explain the origin of all the diagenetic phosphate mineral species which occur in the northern and central parts of the coastal plain. Syndiagenesis produced much of the coastal plain's apatite. It was operative below the sediment-water interface while the substrate was being compacted. Compaction forced pore waters, which were enriched in phosphate by the decomposition of organic matter, upward through calcareous sediments. The PO43- radicle replaced the CO23- and calcareous nodules, pellets and shell fragments were converted to apatite. Epidiagenetic reactions occurred in the subaerial environment where downward percolating meteoric waters carried phosphate in solution to cites where cation activity was sufficiently high to form new minerals. Vivianite may form where ferrous iron is available and wavellite and variscite may form in the presence of aluminum rich minerals. Textural evidence suggests that many of the reactions were repeated. The present day appearance of apatite, vivianite, wavellite and variscite in the coastal plain may represent several generations of diagenesis.

Jan 1, 1972