Ana Carolina Chieregati

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.

Novo modelo de reconciliação para a indústria do ouro

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 industrys processes, from resource estimation to final production.

The application of sampling theory in bauxite protocols

The applications of Gys formula are appropriate for calculating variances of the fundamental sampling error (FSE) at any stage of the sampling protocol and before samples are collected as well. However, the formula can be inaccurate because general factors are used to estimate the ore characteristic. In order to allow the calculation of fundamental sampling error and the minimum representative sample masses without using Gys factors, there are experiments to calibrate the sampling parameters, namely: the heterogeneity test (HT); the sampling tree experiment (STE) and the segregation free analysis (SFA). The present work describes the experimental procedure for the three calibration methods using bauxite and shows the correlation between them.

Illusory reconciliation: the importance of sample representativeness

In the mining industry, reconciliation can be defined as the practice of comparing the tonnage and average grade of ore predicted by the geological model with the tonnage and grade generated by the processing or metallurgical plant. This practice has shown an increasing importance, since, when correctly executed, it increases short-term planning reliability and substantially reduces losses in the operation. However, the usefulness of reconciliation relies on the quality and reliability of the input data. Successful reconciliation can be illusory. In many cases, errors at one point of the process are offset by errors at other points, resulting in excellent reconciliation results. However, this fact can hide compensating errors in the system that may surface someday. Very often sampling errors can be masked and may lead to erroneous analysis of the reconciliation system, generating serious consequences to the operation, especially when mining reaches poorer or more heterogeneous areas of the deposit. Since good estimation is only possible with correct sampling practices, the reliability in the reconciliation results depends on the representativeness of the samples that generated them. This work analyzes the sampling practices carried out at Maraca Mine for reconciliation purposes. Results show that the apparently good reconciliation between the mine and the plant is in fact illusory, consequence of the compensation of many sampling errors generated by the collection of the primary samples at the mine.

Development of ball mill test for simulation of industrial circuit

The Bond method for ball mil designing has been used for 60 years. Based on the Work Index test, such method is applied mostly in traditional circuit configuration, which includes multi-staged crushing, followed by rod and ball milling. On the other hand, simulation is a widespread and used technique for comminution, classification modeling, and simulation. Even though both methods are complementary, there is no effective integration between them. This work shows a technique designed to integrate both energy and modeling approaches for estimating and improving ball mill grinding performance. The work is based on industrial data survey results, as well as on laboratory testing, the latter developed specifically for such a purpose. The technique was validated under an industrial environment for assessing the obtained results.

Validação de novo amostrador de furos de desmonte para fins de reconciliação

Mining operations around the world make extensive use of blasthole sampling for short-term planning, which has two undisputed advantages: (1) blastholes are closely spaced providing relatively high sampling density per ton, and (2) there is no additional cost since the blastholes must be drilled anyway. However, blasthole sampling usually presents poor sampling precision, and the inconstant sampling bias caused by particle size and density segregation is an even more serious problem, generally precluding representativeness. One of the main causes of this bias is a highly varying loss of fines, which can lead to both under- and over-estimation of grade depending on the ore type and the gangue. This study validates a new, modified sectorial sampler, designed to reduce the loss of fines and thereby increase sampling accuracy for narrow-diameter blasthole sampling. First results show a significantly improved estimation of gold grade as well as the minimization of the loss of fines.

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 FUNDACENTROs 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.