Emerging Technologies

The Emerging Technology innovation element is looking to address issues requiring step-change approaches to mineral extraction or to fill gaps in existing extraction or processing elements. This includes but is not restricted to Explosive Free Rock Breakage which investigates several new means of extraction, Hoisting Technologies innovations including non-destructive testing of wire-rope and innovation in synthetic and semi-synthetic hoist rope alternatives and the Reclamation of Sludge underground and in open-pits. All of these initiatives are conducted under the management of research consortia.

Explosive-free Rock Breakage

Mechanical rock excavation has been applied in the metal mining industry. While there have been successes in specific explosive-free rock breakage (EFRB) applications in the past, they have not led to general use. EFRB has not been able to adequately advance in the higher range of rock strength and rock abrasivity. Most often, the equipment developed does not possess the flexibility of application given the variable nature of the rock, the geometry of mineralization and the accessway layout of an underground metal mine.

In spite of those limitations, possible breakthroughs in this technology have garnered serious interest by mining companies, who have already funded a number of large-scale EFRB projects. There are strategic drivers within the industry, such as an operational shift from open pit to underground mining, faster accessibility to orebodies and reduction in development costs, which are currently making EFRB an option that is being reconsidered by eight mining companies: Agnico-Eagle, AREVA, Barrick Gold, CAMECO, IAMGOLD, KGHM, Vale and Rio Tinto. They, along with Hydro-Quebec, the Societé de Recherche et Développement Minier (SOREDEM) and CanmetMINING are participating in a cooperative initiative to develop a toolbox of non-explosive rock breaking technologies that would be available for underground development at significantly higher advance rates than, but at cost of the same order of magnitude as, drill-and-blast. Ultimately, a matrix of technologies versus best applications would also be produced. In particular, the initiative will evaluate the field performance of selected technologies, compare selected technologies to drill-and-blast extraction performance through cost benefit analyses and identify potential equipment that would carry the selected technologies.

Throughout the initiative, key performance measures for EFRB technologies will be compared to conventional drill-and-blast techniques as a means of on-going benchmarking. Each selected area of research will be evaluated against rigorous success criteria meant to avoid pitfalls and unsatisfactory project results such as producing incomplete technology or technology of limited operational application. These performance measures will include, advancement rates, cost, energy consumption and ground control implications. The benchmarks and performance measures will also be important for assessing the operational benefits of the non-explosive rock-breaking technologies that are being assessed: a broad number of operational elements will be impacted and several points of integrated benefits need to be identified.

Five projects have been identified for Phase 1: current state-of-the-art, intellectual property related to current technologies and best ownership formulas for the EFRB participants, thermal fragmentation, ultrasonic rock breakdown, microwave rock weakening and thermal fragmentation. The latter two projects are designed to develop a technology to weaken the rock ahead of mechanical cutting.

Thermal fragmentation (certain ore bearing formations lend themselves particularly well to thermal fragmentation. This approach has been used to create and enlarge holes in rock masses, but not to extract ore directly. As such, the use of high temperature torches provides selective ore recovery and limits the waste being milled and deposited on surface as tailings; significant savings on grinding can be realized with recovered fragment sizes), ultrasonic rock breakdown (the concept of ultrasonic rock breakage has been tested historically by a number of research organizations around the world, mostly theoretical with very little direct mining application; breaking rock masses with ultrasonics requires too much power; the EFRB consortium has targeted this technology for assisting rock breakage carried out by mechanical cutting), and microwave rock weakening (thermal shock breakage is not only limited to direct heat application; microwaves, while selective as to the types of minerals affected, can impart sufficient thermal shock to imposed sufficient microfracturing to weaken rock considerably, >35%). The latter two projects are designed to develop technology to weaken the rock ahead of mechanical cutting.

Hoisting Technologies

Optimization of mine hoisting systems is becoming increasingly important as mines extend operations to ever-greater depths. Use of a hoisting cables monitoring system will increase hoisting capabilities for deep mines. This system will enable underground mining operations to achieve significant gains with regard to the capital cost for the initial construction of the hoisting infrastructures or for modification of them during operations, in order to increase hoisting capacity for economic reasons. In addition to allowing major savings for deep mines, such equipment could be used by all underground mining operations for continuous preventive monitoring of the condition of their hoisting cables.

Mechanized Dehydration

This novel technology, the mechanized dehydration system, effectively accelerates the decantation process enabling process water to be recirculated, facilitates sludge handling, minimizes the mine footprint and recovers valuable ore. This technology demonstration is directly inline with the Green Mining Initiative’s vision to increase productivity, reduce the mine footprint and protect ecosystems.