New reconciliation model for gold industry

Reconciliation can be divided into stages, each stage representing the performance of a mining operation, such as: long-term estimation, short-term estimation, planning, mining and mineral processing. The gold industry includes another stage which is the budget, when the company informs the financial market of its annual production forecast. The division of reconciliation into stages increases the reliability of the annual budget informed by the mining companies, while also detecting and correcting the critical steps responsible for the overall estimation error by the optimization of sampling protocols and equipment. This paper develops and validates a new reconciliation model for the gold industry, which is based on correct sampling practices and the subdivision of reconciliation into stages, aiming for better grade estimates and more efficient control of the mining industry`s processes, from resource estimation to final production.

Metodologia para análise da confiabilidade estrutural de escavações em rocha.

A methodology for rock-excavation structural-reliability analysis that uses Distinct Element Method numerical models is presented. The methodology solves the problem of the conventional numerical models that supply only punctual results and use fixed input parameters, without considering its statistical errors. The analysis of rock-excavation stability must consider uncertainties from geological variability, from uncertainty in the choice of mechanical behaviour hypothesis, and from uncertainties in parameters adopted in numerical model construction. These uncertainties can be analyzed in simple deterministic models, but a new methodology was developed for numerical models with results of several natures. The methodology is based on Monte Carlo simulations and uses principles of Paraconsistent Logic. It will be presented in the analysis of a final slope of a large-dimensioned surface mine.

Estudo de variabilidade e otimização do circuito de moagem SAG da Usina do Sossego

Sossego was the first Vale SAG mill operation to process copper-gold ore. It is located in the State of Para, southeastern Amazon region of Brazil. In the first three years of continuous operation, Vale investigated different alternatives for improving the circuit`s performance by investigating operating conditions, mainly focusing on the SAG mill. It was decided to further assess the performance of the comminution circuit as a function of ore characteristics. A comprehensive ore characterization program was then conducted, together with the calibration of mathematical models on the basis of surveys carried out at the industrial circuit. The simulator was then used to predict the throughput associated to each ore type, as well as to establish the optimized circuit configuration and tailored operating conditions. This paper describes in detail the main aspects of optimizing the industrial circuit performance, as well as the successful method for predicting the production as a function of ore characteristics and circuit configuration.

Reconciliação pró-ativa em empreendimentos mineiros

The common practice of reconciliation is based on definition of the mine call factor (MCF) and its application to resource or grade control estimates. The MCF expresses the difference, a ratio or percentage, between the predicted grade and the grade reported by the plant. Therefore, its application allows to correct future estimates. This practice is named reactive reconciliation. However the use of generic factors that are applied across differing time scales and material types often disguises the causes of the error responsible for the discrepancy. The root causes of any given variance can only be identified by analyzing the information behind any variance and, then, making changes to methodologies and processes. This practice is named prognostication, or proactive reconciliation, an iterative process resulting in constant recalibration of the inputs and the calculations. The prognostication allows personnel to adjust processes so that results align within acceptable tolerance ranges, and not only to correct model estimates. This study analyses the reconciliation practices performed at a gold mine in Brazil and suggests a new sampling protocol, based on prognostication concepts.

Planejamento para o fechamento prematuro de minas

Several mining companies operating in Brazil have been preparing mine closure plans describing end of life actions to ensure long term physical stability, land rehabilitation and, to a certain extent, socioeconomic measures. Most Brazilian and international guidelines, however, skip early closure and only feature guidance to closure planning after reserve depletion. In this paper, two cases of early closure in Australia are reviewed, causes for early closure are explored, criteria to evaluate preparedness to early mine closure are proposed and tested in two mines. It concludes that, despite recent advances, planning for mine closure seldom take account of early closure risks.

Importância da hidrodinâmica na cinética de flotação de partículas grossas

The processes that govern the rate of particle recovery in a flotation cell include the following sub-processes: collision, attachment, and stability of the aggregate formed by particles and bubbles. Collision is controlled by bulk hydrodynamics inside the flotation cell, while attachment is largely dominated by variables that belong to the domain of surface chemistry (contact angle, induction time). As for the stability of the particle/bubble aggregate, its efficiency depends on both hydrodynamics plus surface chemistry variables of the system. The flotation recovery of coarse particles of apatite and glass spheres was measured by micro-flotation and batch flotation tests in which hydrodynamic parameters were evaluated, such as impeller rotational speed, diameter, and geometry, as well as particle size and density. Results revealed that a proper impeller rotational speed yielded turbulence levels, which enabled to keep particles fully suspended, this way optimizing the collision efficiency between particles and bubbles, without jeopardizing the stability of the particle-bubble aggregates.

Efeitos da alteração do limite de exposição ocupacional à sílica cristalina no processo de seleção de respiradores.

The purpose of this study was to investigate the respiratory protective device selection process and to identify changes in this process when an exposure limit value is updated. Two previous studies conducted in mining industries in the metropolitan area of Sao Paulo were put through the respiratory protective device selection process. The protection factors of the equipment provided by the companies were compared with the required protection factors and with the FUNDACENTRO`s respiratory protection program. The results showed that until 2005, some companies were providing inadequate protection, and after the change in crystalline silica exposure limit value in 2006, all the analyzed companies were providing inadequate respirators. This study suggests that there is an opportunity to create a web portal, where the selection process can be done by the companies with updated information.

Logística para agregados (brita e areia) em grandes centros urbanos

One of the human being`s basic needs is housing. In Brazil, the basic element for this is concrete, artificial stone, which demands a great amount of aggregates, such as sand and gravel. The sand and rocks are abundant in nature and gravel can be produced at low cost. However, transportation to the area of product utilization can be an incremental factor in the final cost logistics. Both sand and gravel have expressive price variations, which are not necessarily related to mining activities, but to logistic activities, mainly their distribution. Restrictive measures adopted in large urban centers, such as prohibition of hauling trucks in certain areas or during certain hours, alternate license plate end number system (even number plate ending can circulate on even-numbered days and visa versa), and axle-control, generate a need for a larger and more diversified fleet, not to mention more employees.

Influência da função distribuição de quebra na modelagem e simulação do circuito de moagem de Carajás - parte 2 - simulação

Using the previously described method for appearance function determination, described in Part I of this article, the breakage characterization of the main Carajas ore types was carried out. Based on such characteristics, the ball mill circuit performance was evaluated through simulations. The model described in the first part was used. The results were assessed by comparing ball mill products and cyclone overflow size distribution, as well as simulated recirculating loads. The simulations indicated the potential for processing such ore types at the Carajas grinding circuit, which until now was unknown.

Modelagem de dados de entrada para simulação estocástica de lavra

Mine simulation depends on data that is both coherent and representative of the mining operation. This paper describes a methodology for modeling operational data which has been developed for mine simulation. The methodology has been applied to a case study of an open-pit mine, where the cycle times of the truck fleet have been modeled for mine simulation purposes. The results obtained have shown that once the operational data has been treated using the proposed methodology, the system variables have proven to be adherent to theoretical distributions. The research indicated the need jar tracking the origin of data inconsistencies through the development of a process to manage inconsistent data from the mining operation.

Investigation of a method for predicting AUV derivatives

The paper addresses the problem of autonomous underwater vehicle (AUV) modelling and parameter estimation as a means to predict the dynamic performance of underwater vehicles and thus provide solid guidelines during their design phase. The use of analytical and semi-empirical (ASE) methods to estimate the hydrodynamic derivatives of a popular class of AUVs is discussed. A comparison is done with the results obtained by using computational fluid dynamics to evaluate the bare hull lift force distribution around a fully submerged body. An application is made to the estimation of the hydrodynamic derivatives of the MAYA AUV, an autonomous underwater vehicle developed under a joint Indian-Portuguese project. The estimates obtained were used to predict the turning diameter of the vehicle during sea trials. (C) 2008 Elsevier Ltd. All rights reserved.

A numerical investigation on the visco-plastic response of structures to different pulse loading shapes

The time varying intensity character of a load applied to a structure poses many difficulties in analysis. A remedy to this situation is to substitute a complex pulse shape by a rectangular equivalent one. It has been shown by others that this procedure works well for perfectly plastic elementary structures. This paper applies the concept of equivalent pulse to more complex structures. Special attention is given to the material behavior, which is allowed to be strain rate and strain hardening sensitive. Thanks to the explicit finite element solution, it is shown in this article that blast loads applied to complex structures made of real materials can be substituted by equivalent rectangular loads with both responses being practically the same. (c) 2007 Elsevier Ltd. All rights reserved.

Characterization of mixed waste of granite and LD slag

This study focuses on the technical feasibility of the utilization of waste from the cutting of granite to adjust the chemical composition of slag from steelworks LD, targeting the addition of clinker Portland cement. For this, chemical characterization of the waste, its mixture and fusion was performed, obtaining a CaO/SiO(2) relationship of around 0.9 to 1.2 for the steelworks slag. We selected samples of the waste, mixed, melted and cooled in water and in the oven. Samples cooled in water, after examining with X-ray difractrograms, had been predominantly amorphous. For samples cooled in the furnace, which had vitreous, there was the presence of mineralogical phases Akermanita and Gehlenita, which is considered as the ideal stage for the mineral water activity of the slag. The adjustment of the chemical composition of the slag from steel works by the addition of waste granite was efficient, transforming the waste into a product that is the same as blast furnace slag and can be used in the manufacture of cement.

Briquetting of steel grit recovered from the ornamental rocks cutting waste

This paper presents the results obtained with the production of briquettes from the steel grit found in the residue of ornamental rocks. The grit recovered by magnetic separation was characterized by titrimetric analysis, EDS (Electron Dispersive Spectroscopy) and X-ray diffraction for the analysis of iron concentration in the residue. The size and distribution of particles were obtained by the granulometric analysis method and scanning electron microscopy (SEM). The process resulted in a concentrate containing 93% metallic iron. The maximum load before fracture of the green briquettes was 1.02kN and of the dry briquettes was 3.59kN.

Characterization and application of the solid waste generated in the production of calcium carbonate precipitate as a corrective for the soil acidity

The calcium carbonate industry generates solid waste products which, because of their high alkaline content (CaO, CaCO(3) and Ca (OH)(2)), have a substantial impact on the environment. The objectives of this study are to characterize and classify the solid waste products, which are generated during the hydration process of the calcium carbonate industry, according to ABNT`s NBR 10.000 series, and to determine the potential and efficiency of using these solid residues to correct soil acidity. Initially, the studied residue was submitted to gross mass, leaching, solubility, pH. X-ray Diffractometry, Inductive Coupled Plasma - Atomic Emission Spectrometry (ICP-AES), granularity and humidity analyses. The potential and efficiency of the residue for correcting soil acidity was determined by analysis of the quality attributes for soil correctives (PN, PRNT, Ca and Mg contents, granularity). Consequently, the results show that the studied residue may be used as a soil acidity corrective, considering that a typical corrective compound is recommended for each different type of soil. Additionally, the product must be further treated (dried and ground) to suit the specific requirements of the consumer market.