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Performance Optimization in Underground Mining Combining Strategic Development and Wireless Technologies
Performance Optimization in Underground Mining Combining Strategic Development and Wireless Technologies
VOL. 72 NO. 10
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18
OCTOBER 2020
VOL. 72 NO. 10
Feature Articles 28
18
Performance optimization in underground mining combining
strategic development and wireless technologies
Klaus Pacheco Hague and Víctor O. Tenorio
28
Dump planning optimization with environmental
constraints
J. Dufayard, R.E. Vivas and C. Goldsmith
32
Regulatory training-needs assessment: survey
highlights industry trends and best practices
Lori Guasta, Hugh Miller and Michelle Reiher
®
Senior Editor
Georgene Renner
OFFICIAL PUBLICATION OF SME renner@smenet.org
www.miningengineeringmagazine.com
Associate Editor
Margo Ellis
OCTOBER 2020 ellis@smenet.org
VOL. 72 NO. 10
Managing Technical Editor
Chee Theng
theng@smenet.org
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Politics of Mining
ROCKTECHNOLOGY.SANDVIK /AUTOMINE-FOR-TRUCKS
Industry Newswatch
smenet.org
Industry Newswatch
WIRELESS DATA
HOSTING SYSTEM
SCAN ME
C urrently there is a
trend to maximize the
productivity of underground
Figure 1
Typical sublevel stoping layout. Source: Atlas Copco (now
operations by implementing Epiroc).
diverse technologies.
However, differences between
manufacturers and the purpose
of their functions become a
major challenge for smooth
integration. At the same time,
the design of excavations may
need modifications when the
demand for production increases
and changes in development
are required. The combination
of strategic design and the
utilization of new wireless
technologies may represent a
significant improvement in the
effort of optimizing the overall
performance. A proposed
solution for implementing a mine
plan that includes near-real-time
performance measurements,
workstation design with tracking
systems, the integration of
diverse production areas and
analysis of results is presented
to obtain measurable outcomes
and help reduce operational
delays while increasing safety for
operators.
Mining companies are
constantly trying to improve productivity performing adequate decision making. This
through the optimization of production action should focus as much as possible on
cycles by reducing operational delays, preventive actions and corrective actions as
reducing costs and well.
controlling workforce The present work is an approximation
Klaus Pacheco Hague and Víctor
and equipment risks. of the design of a mining operations control
O. Tenorio are mining engineer/
The advance of current system considering all aspects included
graduate student in mining
technologies allows in the process. Interacting disciplines are
and geological engineering and
a company to use its geology, engineering, planning, operations,
professor of practice, Mine Intel-
benefits to create a safety and geomechanics, among others.
ligence Research Group, respec-
communication and All of them can be integrated through
tively, Department of Mining and
control system that interconnection using a monitoring and
Geological Engineering at the
unifies the information control system with the use of new wireless
University of Arizona in Tucson,
and centralizes it with communication technologies. This is based
AZ, email kpacheco@email.
the idea of helping with on an underground mining operation with
arizona.edu.
the analysis of data and the mining method of sublevel stoping with
Fletcher values what their customers say. Since 1937, Fletcher has been answering some of
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Underground
Figure 4
Scheme of system distribution in vertical section.
sublevels for drilling and blasting at fixed in the sublevel stoping mining method.
intervals in ascending and descending form,
with main levels and ramps for mineral Network type selection
extraction. This type of method is considered The selection of the type of network and
a massive method of underground its design depends on many factors such as:
exploitation that generates large tonnages
of fractured ore and therefore large volumes • The status of operations, determining
resulting from swelling. To decide on the use the location of the network
of this mining method, a series of studies depending on where it would be
must be carried out. located if this is an exploration area,
The selection of massive methods faces production, mine development,
the challenge of planning and for this we auxiliary services, pumping chambers,
must take into account the following criteria: electric stations, main ventilation
circuits, backfilling plants and
• Geometry of the deposit. electrical substations.
• Distribution of the mineral and its • Time of permanence of the
grades. communication network, depending
• Geotechnical properties of mineral on what phase the installation zone
and rock. is in. For example, is it new work, is
• Technical and economic aspects. it in constant production, is it in the
• The dip must be greater than 40º. culmination stage, mine-filling area,
• Boxing rocks must be competent and etc.? In this case, the installation of
resistant. wireless systems reduces the cost of
• The mineral must be competent and permanent installations and allows
with good stability. the equipment to be reinstalled in
• The limits of the deposits must be adjacent areas.
wide and regular. • The purpose of the installation.
That is, if it is required for control,
Figure 1 shows a vertical section with the monitoring, data storage, video
typical layout and infrastructure distribution surveillance, tracking or emergency
radio signals, video images and alert of installing a control and monitoring
messages will be transmitted and collected system is analyzed. The entry of the current
centrally. This information can also be fed communication is through the main
to the operational network of areas related access ramp, which is 9.05 km (5.62 miles)
to the mine such as the plant, workshops, long with an average negative gradient
warehouses, etc. or provided to other users. of 8-10 percent. The mine is planning to
A scheme of a control room and its scope increase another 4 km (2.4 miles) more
is shown in Fig. 2. in explorations and about 30 km (18.6
By using this system, mine operators miles) in production areas. The operation
have a complete overview of the mine at involves ore production zone, areas under
all times and can determine who else can development and preparation, auxiliary
receive the information. The application service areas, mine filling system, pumping
of a multifunctional open system is an systems, and energy circuits.
essential element in the design of a Figure 3 shows a production area
control room. When using the Ethernet section with the layout and infrastructure
and TCP/IP protocol, all installed devices distribution.
are compatible, and the distance does It is proposed to establish a system
not cause major problems. The system of communication and control of
separates the process control from the the operation by integrating all the
management level, guaranteeing a stable participatory elements in the process by
and safe function. Figures can be displayed installing systems recommended by the
in full screen or in a diminished window manufacturers. According to information
or can be transferred to a large-screen from suppliers, the installation cost of a
monitor. Operators decide who can access conventional system on average varies
the data, who will have active access rights in the range of $15-$20 per linear meter
and who will be assigned read-only rights. compared to a wireless system, which can
The data can be saved as HTML files, vary in the range of $25-$30 per linear
which can then be retrieved through a web meter.
browser. Installing a central control station The idea of the process optimization
can reduce costs through: and remote control of the processes
is to install data collection systems in
• Optimization of the workforce since the equipment so that the information
the control room only requires two is obtained by receiving equipment
or three people per shift, so workers with wireless technology and telemetry
can be assigned to other areas. along the road and work areas. This
• Reduction of maintenance as equipment consists of ore passes, dumps,
problems are recognized before hydraulic hoppers, fans and ventilation
they can cause serious damage. In circuits, mechanized drilling and support
other words, the preventive process equipment, material hauling and transport
is made easier with a control room. equipment, pumping systems, mine filling
• Reduction of delay in the processes systems and electrical substations. A
due to the fact that the documents schematic of the distribution of the system
and reports are issued automatically, is shown in a vertical section (Fig. 4) and a
reaching the end users and being horizontal section (Fig. 5) for a production
processed simultaneously with the area and the control elements to be
operative process. considered. n
Once the ore is mined from the pit, the Usage industry 2006 2016 2020 (est.)
material is sent to the high-pressure acid Lithium-ion batteries 20 percent 51 percent 62 percent
leach (HPAL) for recovery of nickel. HPAL
Super alloys 24 percent 20 percent 16 percent
is a process in which nickel and cobalt are
extracted using elevated temperatures and Hard metals 12 percent 8 percent 6 percent
pressures in order to separate the metals from Ceramics & pigments 10 percent 8 percent 6 percent
their ore. This process is beneficial because of
its ability to process ore quickly and efficiently. Other 34 percent 13 percent 10 percent
In our current industrial setting, both nickel
and cobalt are sought after and heavily used. order to maintain the balance and meet the
Nickel is resistant to corrosion even at blend for the final product. The first step in this
high temperature and is used to plate other process is restraining the amount of material
metals to protect them. The primary industrial that is allowed into the mineral processing
use is for alloys, specifically in the creation plant. This can be done through application
of stainless steel. Nickel alloys are also used of constraints and restrictions that allow for
in desalination plants, and boat/turbine a reasonable processing of all the desired ore.
propellers. Outside of alloys, nickel is also used Sequential planning of the waste dumps and
in nickel-cadmium and nickel-metal hybrid how they connect into the haulage plan is very
batteries, as well as coins and currency pieces. important in the life-of-mine plan.
Cobalt is a major component of lithium-ion
batteries, which is a developing industry Pushback and slope design — with
due to the rise of the electric car industry. constraints for mill. Over the course of
Other industries include superalloys, material their lives, these mines may have different
strengtheners, and the ceramics and pigments pushbacks and extraction points used to
industry. Table 1 details predictions of cobalt excavate the area and produce the resources.
usage by industry. A detailed plan is required in order to meet
In addition to using cobalt in these all the constraints, both production and
batteries, newer lithium-ion batteries are using environmental. The initial design of these
nickel manganese in their production. With pushbacks and associated dumping locations is
electric cars, and lithium batteries becoming what drives and limits the production schedule
more common, these metals will only become as the pit is excavated and backfilled. There
more sought after. The New Caledonian mines may have to be several designs created and
are contributing to the production of green manipulated in order to meet the variety of
technologies. restrictions that are in place. Even once an
initial plan is developed, it will have to be
Dump planning optimization revisited and altered as the mine develops
The mines of New Caledonia are subject in order to clearly understand the future
to the highest environmental standards and workings to proceed.
regulations. One example is the restriction
of disturbance limits. The disturbance area
is restricted to the ultimate pit limits, and
all mining activity must stay in this confined Figure 2
area. This imposes a series of limitations and Pit with highlighted mining direction.
challenges, including a limitation on the space
available for waste dumps. So, throughout
these projects it may be necessary to backfill
the pit with waste material. However, opening
the space on the pit floor to accommodate the
waste can be tricky. In addition to the opening
of the pit floor, the blending of grades is
important, which makes planning of the mine
pushbacks and of the dump sequencing a
difficult task. These deposits contain both
manganese and magnesium, which need to
be controlled to meet the plant technical
requirements. This poses a significant
challenge in mine planning as the excavation
requires precise removal of material types in
www.miningengineeringmagazine.com Mınıng engıneerıng OCTOber 2020 29
Dump Planning Optimization
Figure 3
Pit design parameters.
environmentally or from a
production standpoint. Taking
all of this into consideration
creates a difficult task when
designing the excavation
sequencing, furthering the
need for attention to detail.
In addition to the material
constraints and slope designs,
the pit boundary limits and
dump design heavily impact
the design process.
Conclusions
In the coming years new developments and
plans will continue to improve the quality of
mining, and the recovery of desired minerals.
It is important to minimize the impact of
mining on local ecosystems and preserve the
landscape that minerals are extracted from.
By backfilling the waste material, the impact
of the mine site on the local environment can
be reduced and reclamation efforts can begin
faster. Mine plans may have rigid restrictions
that need to be met, but manipulating the
constraints that are available allows for a Figure 6
plan that is both precise, and achievable. Continuing the backfilling process.
Finding the best location for backfilling the
dump sequence can be an iterative problem
as it depends on the space available as the pit
opens up. The space available in the pit for
backfilling may in turn be a function of the
grade and blending requirements that dictate
how the pit opens up and limits the space
available for the in-pit dumps. n
References
Garcia, J. and Vivas, R.E. (2015) “Reconciling mine
plans with mine operations at Freeport-McMoRan
Sierrita,” Englewood, CO. Society for Mining, Metallurgy,
and Exploration Inc. (SME), Preprint 15-119. Figure 7
Haynes, W. M. (2017). CRC Handbook of chemistry
and physics: A ready-reference book of chemical and
Finalizing the backfill dumps.
physical data. (97th ed.). Boca Raton, FL: CRC Press. doi:
978-1-4987-5429-3
Villa, J. A., Vivas, R. E., & Reyna, P. (2017, February).
Peña Colorada iron ore project Coeur ready for gold,
silver’s return USGS’ iron ore production report. Mining
Engineering:
Peña Colorada Iron Ore Project Coeur Ready for
Gold, Silver’s Return USGS’ Iron Ore Production Report,
69(2), 14–19.
Zozaya, L. and Vivas, R.E. (2016) “Pursuing
Operational Excellence at Cobre del Mayo,” Tucson, AZ.
Hexagon Mining.
Key takeaways
• MSHA-required training is needed among
a variety of direct and indirect mining
industry jobs.
• While work in the metal/nonmetal sector
was represented more than coal or
construction, overlap exists in trainees
T he Colorado School of Mines’ (CSM) Energy,
Mining and Construction Industry Safety
(EMCIS) program has been providing U.S. Mine
serving both surface and underground
mining.
Safety and Health Administration (MSHA)- • Companies with fewer than 100
required training to students, individuals and employees are more likely to use external
companies throughout the United States for more trainers for MSHA-required training.
than 20 years. This training has been possible • Instructional methods most commonly
through NIOSH support under a U60 cooperative used in MSHA-required training include:
agreement. The program is particularly critical lecture provided by main trainers (84
for underserviced populations working on mine percent), PowerPoint presentations (78
sites, including contractors, suppliers, consultants, percent) and videos (DVDs, YouTube,
equipment manufacturers and small mine etc.) (65 percent). Approximately 19
operators. In this new decade of 2020, the EMCIS percent of participants reported that
program is working to support current and future online delivery was used.
efforts to increase the quality, availability and • A need exists to use instructional
delivery of MSHA-required training. Effective methods and facilitation that encourage
regulatory training, strategic partnerships and participation and interaction among
outreach and research efforts to support this trainees.
work are important to ensure the competencies of • Qualitative insights from narrative
mining professionals. These activities also serve to comments collected include: 1) value
promote compliance and best practices to ensure a of interactive instructional methods;
safe and healthy workforce in the mining industry. 2) value of games to encourage active
In January 2020, a training-needs assessment participation; 3) value of experienced
survey was conducted to solicit feedback regarding and knowledgeable trainers; 4) specific
MSHA-required training. The results from this training content matters; 5) value of real-
survey will be used as a life stories to communicate safety; and
continuous-improvement 6) importance of training content being
The authors are principal inves- mechanism to ensure that current and relevant.
tigators and staff at the Energy, training and other services
Mining and Construction Safety provided through EMCIS Description of the sample
Program at the Colorado School are meeting the needs of the The majority of respondents were affiliated
of Mines in Golden, CO, email industry and prospective with a mining company (36 percent) or identified
emcis@mines.edu. trainees. themselves as a consultant (31 percent).
A convenience sample Figure 1 shows a range of direct and indirect
Figure 3 Figure 4
Respondents’ commodity affiliation. Respondents’ mining sector affiliation.
Dredging, 7%
Instructional methods
When asked to note which instructional
methods are used in respondents’ experience
with regulatory training, several common
methods were identified. Nearly 84 percent of all
respondents indicated that a lecture provided by
main trainers was used, followed by PowerPoint
presentations (78 percent) and videos (DVDs
and YouTube) (65 percent). Nearly 53 percent of
34 OCTOber 2020 Mınıng engıneerıng www.miningengineeringmagazine.com
Regulatory Training
Figure 8
Instructional methods used in respondents’ past MSHA-required training.
respondents reported that interactive exercises type agreement scale of 1 to 5 with 5 indicating
or games (small or large group activities) and the most favorable response of “strongly agree.”
hands-on techniques were used, followed by Based on Kirkpatrick’s (1994) model of training
quizzes or tests (43 percent), live demonstrations evaluation, Level 1 or reaction data collected were
(32 percent) and special guest presentations (29 overwhelmingly positive (either a 4 or 5) for each
percent). Approximately 19 percent of participants of the items. Figure 9 shows the percentage of the
reported that online delivery was used. This aligns sample that disagreed, were neutral or agreed
with narrative data collected that reveal the with the item statements regarding: 1) clearly
potential for increased use of more interactive communicated training objectives (88 percent
instructional methods, compared to traditional favorable); 2) training content being organized
lecture, PowerPoint presentations and videos and easy to follow (90 percent favorable); 3)
(Fig. 8). the facilitator being knowledgeable about the
content (85 percent favorable); 4) the facilitator
Training effectiveness being well-prepared (82 percent favorable); 5)
Seven survey items were used to measure participation and interaction being encouraged
respondents’ perception of training effectiveness. (76 percent favorable); 6) topics considered
Responses collected were based on a Likert- relevant (81 percent favorable); and 7) the
Figure 9
Respondents’ perception of past MSHA-required training effectiveness.
*MME is abstracted and indexed in Web of Science, Current Contents, Science Citation Index Expanded, Scopus, Google Scholar, EBSCO, ProQuest and many more.
Chair of Mining Engineering and Mineral Economics, Department Mineral Resources Engineering, Montanuniversität Leoben, Leoben, Austria
2
Full-text paper:
Mining, Metallurgy & Exploration, https://doi.org/10.1007/s42461-020-00262-1
To read the full text of this paper (free for SME members), see the beginning of this section for step-by-step instructions.
Innovation plays a critical role in the mining industry not involved and current trends. The digital transformation pro-
only as a tool to improve the efficiency of its processes and cess that the industry is going through is analyzed, along with
to reduce costs but also to meet the increasing social and en- other relevant trends that are likely to shape the mining of the
vironmental concerns among communities and authorities. future. Additionally, a case study is presented to illustrate the
Technological progress has also been crucial to allow the ex- technical and economic implications of developing a disrup-
ploitation of new deposits in more complex scenarios, such as tive innovation project.
lower ore grades, extreme weather conditions, deeper deposits,
harder rock mass and high-stress environments. Background
This paper discusses the importance of innovation for the Natural factors such as decreasing ore grades, deeper de-
mining industry and describes the mechanisms by which it posits and harder rock mass, combined with increasing envi-
is carried out. It includes a review of the drivers and actors ronmental and social awareness, have spurred the industry
www.miningengineeringmagazine.com Mınıng engıneerıng OCTOBER 2020 37
MME Technical-Paper Abstracts
to constantly work to enhance its processes along the whole cy, resulting in higher degrees of vertical disintegration [1].
value chain. In this, innovation plays a crucial role by provid- Companies would focus on their core businesses while rely-
ing suitable solutions to surpass these difficulties, ensuring the ing on suppliers for the development of technological solu-
continuity and sustainability of the mining activity. tions, therefore avoiding the risks associated with the large
This article aims to characterize the innovation environ- investments involved.
ment in the mining industry, specifically: This outsourcing trend has also allowed the creation
of collaborative alliances between mining companies, local
• Importance of innovation for the mining industry: suppliers, and governmental and academic institutions for
relation between labor productivity and innovation. the development of technological solutions.
• Dynamics of innovation in the industry: drivers and
actors. Current trends and mining in the future
• Current trends and future of the mining industry. Defining a future view for an industry is not a simple
task. Nevertheless, in the case of the mining industry, it is
Innovation in the mining industry possible to identify certain trends that can be of help to out-
A first approach to understanding the relevance of inno- line this future scenario. First and most evident is the ma-
vation within the industry can be made through the analysis jor technological shift occurring across all industries: the
of labor productivity. so-called Fourth Industrial Revolution, as the transition to
Technological advances usually have an impact on the the digital era. Then, social and environmental concerns are
output, allowing higher production rates while maintaining a already compelling mining to look for safer, more efficient
similar workforce, or directly reducing the needed personnel and sustainable ways of conducting business.
by the automation of processes. Several authors have ana- In this section, the process of digital transformation is
lyzed these processes, and while in periods of labor produc- analyzed, along with some of the key technologies in the
tivity growth it has been possible to isolate the positive effect digital mine (Fig. 1), and the main challenges that companies
of innovation, during declining cycles this task turns more must face for successful digitization. Additionally, three im-
complicated. However, the fall in these periods is attributed portant trends are reviewed and discussed: electromobility,
mainly to natural and economic factors. For example, in a invisible zero-waste mining and continuous mining.
high-price mineral commodities scenario, it is profitable for
companies to compromise their costs, in order to increase Case study: A continuous mining system for caving
production. In other words, while declining labor produc- operations
tivity may be inevitable during certain periods of time, the The Continuous Mining System (CMS) was an innova-
development and adoption of new technologies, along with tion project developed by Codelco, in Chile, that intended to
innovation at a managerial level, are essential to maintain create a continuous material handling system for block and
mining’s competitiveness through the different cycles. panel caving operations. After almost 20 years of research
Whereas in the past mining companies would have tend- and testing, the project was finally dismissed as a conse-
ed to develop technology solutions in-house, over the last quence of difficulties faced in the construction phase for its
decades of the 20th century outsourcing became a tenden- industrial validation [4].
From Codelco’s experience in the process validation of
the CMS project, several key elements can be identified, and
lessons can be learned:
Full-text paper:
Mining, Metallurgy & Exploration, https://doi.org/10.1007/s42461-020-00261-2
To read the full text of this paper (free for SME members), see the beginning of this section for step-by-step instructions.
The Quick-Erect Stopping System (QESS) offers a new tial for mine rescue operations. Now, the QESS is well-suited
way of reducing the radon exposure of miners in Germany, for small-scale mining. The QESS can be used to both protect
especially during remediation work in old mines. The QESS miners from radon exposure and to support mine rescue op-
is a lightweight, modular and reusable construction kit of in- erations. Moreover, the QESS was also successfully used in
terlocking telescopic aluminum tubes, radon-proof foil and ventilation experiments.
expanding foam. It is designed to seal off radon-rich parts of
galleries within minutes. Originally, the QESS was developed Background
to protect miners against radon exposure. Then, the QESS Mining in the Ore Mountains (Erzgebirge) and Vogtland
found the attention of several mine rescue teams at a Ger- mountains began in the 12th century and continues to this
man mining conference. Some mine rescue drills by The Stu- day. Both mountains are low-mountain ranges in the East
dent Mine Rescue of the Technical University Bergakademie German state of Saxony. The mining has left numerous gal-
Freiberg, Wismut Mine Rescue and Front Range Mine Res- leries and shafts that cause occasional surface damage. To
cue helped to improve the system and highlighted its poten- protect people, buildings and infrastructure, around 250
miners from eight companies are permanently engaged in equipped with tips made of hard plastic at both ends. The
remediation work at up to 40 smaller and frequently chang- tube tips can be inserted into the slots of other tubes. One
ing construction sites in an average year. of the two tips of a tube is equipped with a spring. There-
The high radon potential in the two mountain ranges is fore, the telescopic tubes can be pulled out and stretched to
significant for radiation protection of miners during reme- brace radon-proof foil in a gallery. The telescopic tubes can
diation work. It is not unusual to find radon activity concen- either be inserted in other telescopic tubes or braced inde-
trations of 100,000 Bq/m3 in mine air currents under natural pendently. They do not have to assume a radial form but can
ventilation. The most important radiation protection mea- be braced freely, adapting to any imaginable form of a mine
sures are ventilation with mobile mine fans and pipes, tem- opening. If necessary, the telescopic tubes can be extended
porarily sealing off galleries with the help of mine stoppings, out of the cross section to brace the foil in front of or behind
and rotating miners after they have worked at construction the cross section. Under conditions of high pressure in the
sites with high radon activity concentrations [1]. Miners are gallery, it is possible to support the QESS from the front with
monitored with personal radon dosimetry [2]. telescopic tubes against the floor, walls and ceiling by using
Miners usually erect mine stoppings with the help of front openings in the tubes. Finally, the erected structure is
wood, foil and expanding foam. Erecting such stoppings is sealed with expanding foam (Figs. 1 and 2).
time-consuming. On average, two miners need four hours to Setting up the QESS takes two miners 15 to 30 minutes.
build one stopping. First, miners need to carry material and The QESS can be dismantled in less than five minutes. It is
tools by hand from the mine opening through narrow and reusable except for the foil and the foam. To erect the QESS,
twisted galleries to the construction site. The distance they no tools or electricity are required. There is no need to mea-
have to cover can amount to several hundred meters. Then, sure the gallery to be sealed off. Moreover, the reflecting foil
they have to construct the stoppings to a perfect fit with of the color-coding can be clearly seen in the light of miners’
the wood on site. To do so, they have to measure the mine lamps.
openings meticulously. In the end, the stoppings are sealed The full-text paper shows examples using the QESS for
with expanding foam. Stoppings need to be dismantled be- radiation protection, mine rescue and ventilation experi-
fore and re-erected after all blasting operations. As a result, ments and includes a discussion on the costs of the QESS
miners have to endure radon-containing mine air for many compared with other stoppings.
hours.
The goal of this project was to develop a new reusable Discussion and conclusion
stopping with a quick assembly time to reduce the working The QESS protects miners from radon, smoke and dust.
time of miners in mine air currents with high radon activity Compared with conventional stoppings, the QESS reduces
concentrations. the radon exposure of miners due to its significantly shorter
assembly time.
Quick-Erect Stopping System (QESS) The QESS is not designed to be cheaper than other sys-
The QESS is a lightweight, modular and reusable con- tems. It is also not intended to replace systems that are built
struction kit consisting of interlocking telescopic aluminum stationary for permanent use. Mull et al. calculated the con-
tubes, radon-proof foil and expanding foam able to seal off struction costs for a small stopping with five materials and
radon-rich parts of galleries of any width within minutes. The three transportation distances for the Reiche Zeche Mine
QESS comes boxed for transport over ground and includes in Freiberg, Germany [4]. With a 16-time assembly, the cost
two bags for transportation underground. The QESS can be of the reusable QESS is around the same as that for wooden
extended by more kits [3]. stoppings.
Each construction kit contains 15 two-piece, extend- The QESS is a new system. The full-text paper outlines
able telescopic tubes in four different lengths, which are the current state of development. Many questions about the
color-coded with reflecting foil. All tubes have regularly application of the QESS remain unanswered. A first assess-
placed slots from top to bottom on both sides. The tubes are ment of the QESS comes from Yildirim [5]. ■
Full-text paper:
Mining, Metallurgy & Exploration (2020) 37:955–963, https://doi.org/10.1007/s42461-020-00233-6
To read the full text of this paper (free for SME members), see the beginning of this section for step-by-step instructions.
The alkaline hydrothermal processing of K-feldspar material: that is, the CASH mixture. This paper investigates
rocks in an autoclave can be a pathway to synthesize a po- the change in mineralogy and elemental release as a func-
tassium fertilizer for tropical soils that is potentially cheaper tion of the hydrothermal processing time and temperature.
and more efficient than traditional potash (KCl). When K-
feldspar undergoes hydrothermal alteration in the presence of Method
calcium oxide (CaO), it generates a complex mixture of calci- In this study, a sample of K-feldspar rock (ultrapotassic
um-aluminum-silicate-hydrate (CASH) minerals that incor- syenite) of Brazilian origin was used. The X-ray diffraction
porate K atoms stochastically in their structure. These atoms (XRD) analysis showed a 79.5 weight percent of K-feldspar,
are subsequently released, as shown in a test-tube leaching followed by Na-feldspar (12.7 weight percent) and pyrox-
test, indicating a possible uptake by crops. The relationship ene (6.6 weight percent). The XRF analysis showed the SiO2,
between the processing temperature and time in the autoclave Al2O3 and K2O contents as 63.4, 17.1 and 13.4 weight per-
for the hydrothermal reaction and the resulting mineralogy cent, respectively. CaO (reagent grade; Sigma-Aldrich) was
and elemental release are only partially understood and are used as received. The mixture used as feed for the autoclave
investigated in this study. Elucidating that relationship is the process was obtained by milling jointly 849.3 g of the rock
key requisite for subsequent techno-economic analysis, and and 150.8 g of CaO. For each of the hydrothermal synthe-
ultimately for the development of a fertilizer that can be con- ses corresponding to a specific set of temperature and time,
sidered as a feasible alternative to KCl. the feed mixture, freshly prepared, and water were loaded in
an autoclave (Parr Instruments, 7.6 L, Ti with stainless steel
Background liner, 4843 Parr controller) at a weight ratio of 1:4. Process-
Soluble potash is mined in a few areas of the world and is ing was carried out at temperatures of 200, 220 and 230 °C
generally expensive or unavailable for farmers in the tropi- and times from 0.5 to 3.0 hours. For each of the conditions,
cal region of the world. Conversely, alternative K-bearing a new batch of feed mixture was processed for a total of 18
minerals such as K-feldspar are distributed worldwide but batches, each of 1 kg. Following the reaction in the autoclave,
are considered insoluble by farmers and therefore ineffec- the hydrothermal slurry was poured in a pan and dried over-
tive as a fertilizer. Hydrothermal processing of K-feldspar night at 120 °C. After drying, the solid cake was ground with
powder in an autoclave in the presence of CaO generates a a pestle in a mortar to obtain a powder renamed as hydro-
mixture of CASH minerals with a K release rate that is en- thermal material.
hanced with respect to that of unprocessed K-feldspar. How- The hydrothermal materials were characterized by XRD
ever, little is known of how the processing conditions, par- and also analyzed by laser-diffraction particle size distribu-
ticularly temperature and time in the autoclave, influence tion (PSD), scanning electron microscopy (SEM), electron
the overall mineralogy and K release rate of the processed probe micro analyzer (EPMA) and elemental release via
Full-text paper:
Mining, Metallurgy & Exploration (2020) 37:1339–1347, https://doi.org/10.1007/s42461-020-00237-2
Keywords: Zijinshan gold-copper mine, Practical experience, Hydrometallurgy, Engineering design, Heap (bio)leaching
To read the full text of this paper (free for SME members), see the beginning of this section for step-by-step instructions.
The Zijinshan gold-copper mine, located in Shanghang China, which can be attributed to the successful application
County, China, is a porphyry-type, low-grade ore deposit with of hydrometallurgy as well as proper engineering design. A
a geological profile of upper gold and lower copper. Despite large-scale, open-air cyanide heap leach has been success-
its low-grade nature, it has become one of the largest in pro- fully implemented to recover gold under the humid and rainy
duction scale and most profitable nonferrous metal mines in weather conditions of southern China. Furthermore, accord-
42 OCTOBER 2020 Mınıng engıneerıng www.miningengineeringmagazine.com
MME Technical-Paper Abstracts
ing to the gold ore characteristics, a combination of gravity
separation, carbon-in-leach and heap leaching processes was
developed to improve gold recovery. In terms of copper ex-
traction, copper ore of a grade higher than 0.25 percent is fed
to the flotation plants to produce copper concentrate (gold is
also enriched here), while copper ore of a grade lower than
0.25 percent undergoes heap bioleaching followed by solvent
extraction and electrowinning to produce cathode copper. Ad-
ditionally, a unique bioleaching system has been established
at the Zijinshan Mine: low operating pH (0.8~1.0), high con-
centration of total soluble iron (~50 g/L), high temperatures
(45~60 °C) and low activity of microorganism (~104/mL) in
the pregnant leach solution (PLS). This review paper sum-
marizes the practical experience acquired in developing the
Zijinshan gold-copper mine and could be of use in other gold Fig. 1 Flowsheet of the combination of gravity separation,
and/or copper plants. carbon-in-leach and heap leaching processes.
Introduction
Exploitation of the Zijinshan gold and copper ores be-
gan in 1993 and 2002, respectively. The proven reserves are (~50 g/L), high temperatures (45~60 °C) and low activity of
318 t of gold and 2.42 Gt of copper at cut-off grades of 0.15 microorganism (~104/mL) in PLS [1]. A high content of py-
g/t and 0.15 percent. By the end of 2018, the cumulative pro- rite in the copper ore causes the production of excess acid
ductions of gold and copper were about 213 t and 0.41 Gt and iron. Additionally, heat is generated when the inorganic
(not including copper sulfide concentrate), respectively, gen- sulfide minerals are oxidized. The temperature of the PLS is
erating an economic benefit of $327 billion. maintained at 45~60 °C throughout the year. Because of the
A large-scale, open-air cyanide heap leach was first suc- low pH, high concentration of iron and high temperature,
cessfully implemented to recover gold in humid and rainy growth of an iron-oxidizing microorganism, Leptospirillum,
weather conditions. At present, the grade of gold ore fed to is largely inhibited. Therefore, the oxidation-reduction po-
the heap has been lowered to 0.27 g/t. Nonetheless, the treat- tential (Eh ) fluctuates between 700 and 740 mV versus SHE
ment cost per tonne of gold ore is only about $4.20. Differ- (standard hydrogen electrode). The total number of microor-
ent from other copper bioleaching plants, a unique bioleach- ganisms in the leaching solution significantly decreases from
ing system with characteristics including low pH, high iron 106/mL (start-up state) to 104/mL (steady state). The dissolu-
concentration, high temperature and low microorganism tion of copper minerals could be promoted at high tempera-
activity has been established at the Zijinshan Mine. Copper ture but is minimally affected by Eh at 60 °C. On the other
recovery of approximately 80 percent can be reached. The hand, the dissolution rate of pyrite is strongly correlated
average operational costs for copper ore and cathode cop- with Eh, and there is a limited influence of temperature on
per are about $9.43/t and $1.10/lb, respectively. pyrite dissolution at low Eh. Therefore, the selective leach-
ing of copper minerals is achieved under the conditions of
Technological innovations high temperature (45~60 °C) and low Eh (700~740 mV ver-
The Zijinshan gold ore has high mud content, which sus SHE). Furthermore, the balance of excessive iron ions is
causes poor permeability and diffusion of leaching solu- realized through the in situ formation of jarosite at high tem-
tion in the heap. In addition, the free coarse gold could not perature in the heap. Under the above unique operational
be completely dissolved during the residence time of 60 to conditions, a copper recovery of approximately 80 percent
70 days. These factors make for relatively low gold recov- could be achieved in the Zijinshan bioleaching system.
ery. Therefore, a combined flowsheet of crushing, washing
and screening, gravity separation, carbon-in-leach and heap Conclusion
leaching was developed (Fig. 1). First, the gold ore is washed The successful application of hydrometallurgy as well as
by spray on a vibrating screen after crushing. Product that proper use of engineering design are the key factors in the
is smaller than 6 mm undergoes gravity separation before large-scale development of the Zijinshan gold-copper mine.
entering the next screening. Of particular note is that a Most aspects of the production processes, such as mining,
Knelson gravity separator is used to recover the coarse gold. beneficiation, ore stacking, heap (bio)leaching, carbon-in-
After screening, the undersized part (200 mesh) is subject- leach, solvent extraction, electrowinning, and wastewater
ed to carbon-in-leach treatment, by which the influence of and tailing treatments are summarized in the full-text paper.
mud on the permeability and diffusion of leaching solution This practical experience could help promote the develop-
is avoided. Additionally, the oversized ore enters the heap ment of hydrometallurgy and serve as a model for other gold
leaching system. By adopting this combination of processes, and/or copper plants around the world. ■
gold recovery is increased to 82 percent as compared to 68
percent obtained by single heap leaching. Selected reference
The Zijinshan copper bioleaching system runs stably 1. Ruan RM, Liu XY, Zou G, Chen JH, Wen JK, Wang DZ (2011) Industrial practice
of a distinct bioleaching system operated at low pH, high ferric concentration,
under its unique operational conditions, including low op- elevated temperature and low redox potential for secondary copper sulfide.
erating pH (0.8~1.0), high concentration of total iron ions Hydrometallurgy 108:130-135
Full-text paper:
Mining, Metallurgy & Exploration, https://doi.org/10.1007/s42461-020-00259-w
Keywords: Mine worker fatigue, Fatigue, Emerging technologies, Miner health and safety
To read the full text of this paper (free for SME members), see the beginning of this section for step-by-step instructions.
Fatigue is a relatively well-investigated topic in the surface • Fatigue is “temporally tied to the workday,” empha-
transportation industry with a research focus on sleep depri- sizing the relationship between time of day at work
vation and disruption. This paper examines fatigue in min- and fatigue.
ing operations. While mine operators are using or currently
introducing technology to monitor fatigue, there is little work In addition, this research used an extended version of
that focuses on the operators’ experience of fatigue and the a conceptual model of fatigue developed by Matthews that
acceptance of fatigue-monitoring technology. Focus groups distinguishes between distal and proximal factors [2]. On the
were conducted to investigate these topics. The results of this right side of Fig. 1 are listed the proximal factors, and on
research suggest that current fatigue-monitoring systems lack the left are the distal factors affecting sleep history. Distal
validity, reliability and user acceptance. Overall, these results factors include sleep efficiency, clinical condition, life events
emphasize the importance of a socio-technical systems per- and stressors that impact the quality and amount of sleep,
spective to guide interventions aiming at improving miner personality factors that are affecting the proximal factor of
health and safety. fatigue state (with impact on psychological, behavioral, cog-
nitive and physiological parameters) and the time duration
Background of the previous shift.
The goal of this research was to explore the experience Current technology-based fatigue management ap-
of fatigue of haulage operators in the mining industry by proaches use a range of physiological and behavioral re-
conducting focus groups examining fatigue experience, fa- sponses to assess operator fatigue. The monitoring approach-
tigue management, and operator’s experience with current es of fatigue levels in mining include camera-based mea-
fatigue-monitoring technologies. The basis for this research surements, such as percentage of eye closure (PERCLOS),
is the three-factor model [1] of fatigue with the following electroencephalography (EEG) and other physiological
facets: or behavioral measures to estimate fatigue. Unfortunately,
most of these systems are only able to measure fatigue at the
• Fatigue involves both “extreme tiredness” and “re- point at which it occurs but are not able to predict fatigue
duced functional capacity.” levels of an operator.
• Fatigue is experienced physically, mentally and/or
emotionally. Method
Focus groups were conducted at two mining sites in the
Rocky Mountain region of the United States, with a total of
eight focus groups (four groups at each site). Overall, 42 par-
ticipants, ranging from five to seven per group, participated.
All participants worked as haul truck operators and vol-
unteered to participate in this Institutional Review Board-
approved study. All focus group discussions were audio-
recorded for later transcription and analysis. Focus groups
discussed up to 12 questions covering the following topics:
Full-text paper:
Mining, Metallurgy & Exploration (2020) 37:1093–1103, https://doi.org/10.1007/s42461-020-00236-3
Keywords: Green mining; Ecological mining, Sustainable mining, Evaluation index system, Fuzzy evaluation
To read the full text of this paper (free for SME members), see the beginning of this section for step-by-step instructions.
Green mining is the latest technological advancement to re- evaluation system for surface mining. We defined its connota-
duce mining’s environmental impact with minimal energy and tion and developed an evaluation index system based on the
resource consumption. Green mining — aimed at protecting theory of green grades. As the indicators are selected based on
nature and providing socio-economic benefits — is a multi- extensive research, they express the advantages and disadvan-
faceted network of its connotations and key indicators. China tages of various aspects of a mine. The index is composed of
has not yet defined its connotation and formed an effective three attributes (safety, efficiency and environment), nine crite-
Conclusion
Green surface mining must ensure that all available re-
sources are optimally utilized, adverse impacts on the eco-
logical environment, economic environment and social envi-
ronment are prevented or minimized, and safe and efficient
production is ensured. For these reasons, the industry must
strive to achieve the concept of green mining to make min-
ing coexist with nature successfully. When assessing the cur-
rent situation of green surface mining in China, it was found
that the environment is the most critical aspect of green
surface mining, followed by efficiency and safety. In order
to strengthen the adoption of green mining, we recommend
paying attention to research into engineering technology, the
study of economic and industrial policies, focus on the regu-
latory system, environmental management, socio-economic
impact evaluation and technology transfer. ■
SME Fellows
John F. Abel Jr. Arthur F. Colombo Ronald O. Harma Ta M. Li Timothy G. O'Neil Ponisseril Somasundaran
Dan Alexander Harry M. Conger Leonard Harris Raymond L. Lowrie Bhupendra K. Parekh Stanley C. Suboleski
Corby G. Anderson Kadri Dagdelen Raymond Henn Gerald H. Luttrell William G. Pariseau David A. Summers
Mark A. Anderson Edward C. Dowling Jr. J. Brent Hiskey George W. Luxbacher Ronald L. Parratt Patrick R. Taylor
Frank F. Aplan Joseph M. Driscoll Steven C. Holmes Deepak Malhotra Syd S. Peng Jack E. Thompson
Barbara J. Arnold James R. Dunn Rick Q. Honaker David R. Maneval Mary M. Poulton Michael A. Trevits
James R. Arnold C. Dale Elifrits James D. Humphrey John G. Mansanti Raja V. Ramani Nikhil C. Trivedi
Timothy D. Arnold Mark E. Emerson G. Frank Joklik John O. Marsden Donald E. Ranta John L. Uhrie
George S. Austin Ted H. Eyde Leonard R. Judd Francis Martino Ramana G. Reddy William A. Warfield
Leonard G. Austin Barbara A. Filas Daniel W. Kappes Michael K. McCarter Jean-Michel M. Rendu John D. Wiebmer
Sukumar Bandopadhyay William G. Fischer Michael Karmis Gene E. McClelland Lee W. Saperstein Ronald L. Wiegel
James M. Barker Robert C. Freas S. Komar Kawatra Drew A. Meyer Robert W. Schafer William H. Wilkinson
William J. Beck Edward S. Frohling Jon J. Kellar Hugh B. Miller William Joseph Schlitt Kelvin K. Wu
Rodney L. Bleifuss John E. Frost Jessica Elzea Kogel Jan D. Miller Arthur A. Schweizer Roe-Hoan Yoon
James W. Boyd Douglas W. Fuerstenau Jeffery L. Kohler Brij M. Moudgil Rohini P. Sharma Courtney Young
Jürgen F. Brune J. Stephen Gardner Michael C. Korb John N. Murphy William M. Shepard Joseph C. Zelanko
Charles H. Bucknam Richard E. Gray Robert P. Kudlawiec Robert E. Murray Samuel J. Shoemaker Jr.
Richard L. Bullock Thomas A. Gray Martin C. Kuhn Jan M. Mutmansky Douglas B. Silver
Alan A. Campoli R. Larry Grayson Ihor A. Kunasz D.R. Nagaraj Madan M. Singh
William Carr Kenneth N. Han K. Marc Le Vier Michael G. Nelson Raj K. Singhal
Yoginder (Paul) Chugh Bill A. Hancock Joseph W. Leonard III Thomas J. O’Neil Erik Spiller
www.miningengineeringmagazine.com Mınıng engineering october 2020 47
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