Lyntas/mining_domain_knowledge_reference_dataset huggingface dataset:
Area: Minning Maintenance Realibility
WARMAN 550 U-SHDU gland sealed pump.
Mill discharge application. Hard-metal pump casing and impeller; unlined. Duty: Q=5220m3/h, 37 m, Cw=72%
Drive: 1200 kW motor with Variable Frequency Speed Controller, direct coupled.
Area: Minning Maintenance Realibility
Diesel Electric Power Train in Hauling Trucks


Vibration Points Mining
Shovels
Motor Generator set
Hoist and swing transmission

Haulage trucks
Diesel engine 
Generator
Concentrator
SAG / Ball mills
Pumps
Conveyors
Area: Minning Maintenance Realibility
Shovel Vibration Monitoring 
There are a total of 13 electrically-powered shovels in operation at the mine, each with a 15 m3 bucket capacity.
These comprise; Bucyrus - Erie 295 B and 195 Bl, P&H 2100 BL and Marion 201 M. At present the shovel availability is approximately 65%. Vibration monitoring has played a major part in maintaining this high level, as just one year ago the availability was 45%. The main problems encountered are with the motor-generator (MG) Set which, at costs in the region of $250000 for replacement and $100000 for repair, represents a potentially considerable maintenance cost. 
The monitoring programme for the shovels covers the following items:
 Motor-Generator (MG) Set  unbalance and misalignment problems; 
Hoist and Swing Transmission -gear and bearing problems; 
Hoist Magnetorque® Drive - unbalance, bearing and operation problems.
Area: Minning Maintenance Realibility
Truck Vibration Monitoring 
The truck fleet at the mine consists of a total of 41 Wabco, Terex and Unit Rig diesel-electric trucks, each with a capacity of 170 tons. The trucks are powered by a 1600 BHP diesel engine driving a DC generator, which in turn drives an electric motor mounted on each of the rear wheel-sets. At a cost of approximately 1 million-$ each, these trucks represent a considerable investment.
Area: Minning Maintenance Realibility
Concentrator Vibration Monitoring
The Autogeneous Mill 
The autogeneous mills are 32 ft diameter cascade type grinding-mills, powered by two 3000 HP motors coupled by gearboxes, see Fig. 21. Because of their importance to the concentrator operation, they have number one priority in the plant. Vibration measurements at 16 measuring points are taken from the drive section of one mill at weekly intervals.
Area: Minning Maintenance Realibility
The most common types of problem encountered are due to installation misalignment, bearing failures and gearing problems.
Area: Minning Maintenance Realibility
Carbon-in-leach Process
The CIL (Carbon in Leach) circuit is an intermediate stage in the production of gold. The process involves dissolving the solid gold particles into solution using a process know as cyanidation.
The dissolved gold in solution is adsorbed onto activated carbon. When the carbon is loaded with enough gold it is removed from the circuit and sent to elution where the adsorption process is reversed and the gold is stripped off the carbon back into solution, electrowon and smelted into bars.
The remaining barren slurry reports to the tails thickener and is pumped to the tails dam.
The CIL circuit consists of two separate trains of tanks, with seven tanks in each train. In conventional CIL circuits, leaching takes place in the presence of carbon and therefore leaching and adsorption occur simultaneously. The CIL circuit at SDGM can be considered a hybrid circuit as the first tank of each train are purely leaching tanks (no carbon addition).
Area: Minning Maintenance Realibility
The Cyanidation Reaction
CIL technology is based on the fact that the gold dissolves readily in cyanide solutions in the presence of oxygen, and the resultant gold cyanide complex ion (molecule) is readily adsorbed onto activated carbon. The goal of leaching is to push the reaction to the right ie; consume the reactants to produce the gold complex in solution.
Therefore to leach the gold out of the ore and into solution, cyanide, and oxygen must be added to the slurry. Lime is added to the grinding circuit to modify the pH of the slurry to prevent the formation of deadly hydrogen cyanide gas. Cyanide is added in liquid form to the tanks and lime is added to the ore prior to milling. Oxygen is added in pure form, injected down the agitator shafts.
Area: Minning Maintenance Realibility
Factors Affecting the Rate of the Cyanidation Reaction
Size of Gold Particles
The gold must be in a fine particulate form (from the grinding circuit). The feed slurry must have an 80% passing size of 75um to achieve suitable gold recovery (refer to cyclone and grinding modules).
Free Cyanide Concentration
Increasing cyanide concentration drives the cyanidation reaction to the right. There must be sufficient free cyanide ions in solution to dissolve all the gold, otherwise it will be lost to tailings
Dissolved Oxygen
There must be sufficient entrained oxygen in the slurry. Increasing the oxygen concentration drives the reaction to the right
Slurry pH
PH modification is achieved by adding lime to the ore prior to milling which makes the slurry alkaline (high pH). The pH level in the tanks is monitored regularly by the process technician responsible for the CIL circuit. 
Residence Time
Residence time in the CIL circuit is the time taken for the slurry to flow through the tanks, and is an important operational consideration. The longer the gold particles are in contact with the cyanide in the slurry the more gold that will be leached.
Residence time is determined by the volume of the tanks (which is fixed), the slurry flowrate and the slurry density.

Agitation
Effective agitation allows the reactants to intimately mix and prevents the solids from settling out, bogging the tanks.

Temperature
Higher temperatures will increase the rate of gold dissolution, however it is not economical to heat the slurry. High temperatures also reduce the capacity of carbon to adsorb gold and lower the solubility of oxygen in the slurry
Area: Minning Maintenance Realibility
Carbon Adsorption Theory
After the leaching process is complete, the soluble gold must be concentrated and separated from the process slurry. The method of recovery of gold from the process slurry is by carbon adsorption.
Area: Minning Maintenance Realibility
Trash Screens
The overflow slurry stream from the cyclone nest feeds the CIL circuit via the leach feed thickener. Before entering the leaching circuit, all the wood fibre, cloth, plastic, rocks from cyclone blowouts and other trash material must be removed from the slurry. If trash is not removed it may block the CIL interstage screens causing tank overflows and also cause problems in the elution and carbon reactivation circuit.
The cyclone overflow is fed to three trash screens, the undersize reports to the leach feed thickener feed hopper and the oversize trash material is collected and discarded.
Area: Minning Maintenance Realibility
Leach Feed Thickener
Slurry from the trash screens flows into the thickener feed hopper. The slurry is pumped from the hopper to the thickener where the slurry is flocculated and thickened to a density of 50% solids. The thickener underflow reports to a hopper from which the slurry is then pumped to the leach feed splitter box.
Area: Minning Maintenance Realibility
CIL Tanks
The major component of the CIL circuit are the two, seven tank leaching trains. The eastern, first train of tanks (train no.1, tanks 1 to 7) were part of the original plant. The western, second train of tanks (train no.2, tanks 101 to 107) was commissioned as part of the stage three plant expansion, and is very similar in design and operation as the original train apart for a few minor differences. The first tank of each train is purely a leach tank (no carbon), the remaining six are leach and adsorption (CIL) tanks. Each tank has an effective volume of 761m3 each, and operate at a leach density of 50% solids, giving a residence time of approximately 4 hrs leach (first tank) and 22 hours CIL. Tanks 1 and 101 (the leach only tanks) are the slurry feed end of trains 1 and 2 respectively, and tanks 7 and 107 the tail end

The tanks are positioned in two staggered rows. In train 1 the tanks are interconnected with open launders and gate valves, in train 2 flow between tanks involves a system of pipes and dart valves. The flow through the tanks is such that any tank in the system may be bypassed, while the circuit continues to operate with reduced volume and residence time.
The slurry from the thickener underflow is pumped to a splitter box, which distributes the feed evenly between each train. Cyanide solution is added to the leach feed (thickener underflow) hopper, distribution box and also to the first three CIL tanks of each train (tanks 2, 3, 4, 102, 103 & 104). The tanks are agitated by twin impellers, with oxygen injected through lances down the hollow agitator shafts.
Tank 1 also incorporates a multi-mix unit and recirculation pump as another means of adding oxygen to the slurry. Slurry is pumped from the base of the tank and is discharged below the slurry line at the top of the tank. Within the pipe, immediately after the pump is the multimix unit which injects oxygen into the passing slurry stream. The oxygen is injected as a fine jet of bubbles which are sheared by the slurry flow, giving good oxygen dissolution within the slurry.
Slurry flows by gravity through each train, with the overflow launder from each tank being preceded by an intertank screen that prevents the advance of carbon with the slurry. Barren slurry from the final tank of each train flows to a carbon safety screen, which prevents the loss of carbon in the instance that the final intertank carbon screen is holed. The barren slurry underflow from the safety screen reports to the tails thickener feed hopper.
Reactivated carbon is added to the final tank (tanks 7/107) of each train and is moved counter currently to the flow of slurry by centrifugal carbon transfer pumps, finally being removed for stripping from the second tank (tanks 2/102) of each train.
Area: Minning Maintenance Realibility
Intertank Screens
Screens are fitted in each of the CIL tanks to retain the carbon in the tank, as the circuit operates with carbon being moved counter-current to slurry flow. The screens are cylindrical and are fitted just prior to the slurry exit launder. Wiper blades with a dedicated drive motor system are installed to keep the screen surfaces free from carbon build-up. If the wiper blades fail, then carbon is carried/forced onto the screen surface by the slurry flow. This impedes the flow of slurry and may cause the tank to overflow.
The screens may also become holed due to damage or deterioration. To check whether the screens are passing carbon, a sieve is dipped into the discharge launder and inspected. The screens will also become pegged with near sized carbon and other material such as small rocks and need to be removed and cleaned/replaced regularly to prevent tank overflows.
Area: Minning Maintenance Realibility
Carbon Forwarding Pumps
To facilitate the counter current movement of carbon, each CIL tank has a carbon-forwarding pump.
The pumps are run on a batch schedule as required to maintain the desired carbon concentrations in the tanks. The forwarding pump from tanks 2 and 102 pumps to the loaded carbon screen where the carbon is screened from the slurry and sent to the elution column. The slurry underflow from the loaded carbon screen is returned to either tank 2, 102, 4 or 104.
Area: Minning Maintenance Realibility
Carbon Safety Screens
Both of the CIL trains each have a carbon safety screen over which the tail slurry from tanks 7/107 is passed.
Carbon may be present in the tailings slurry due to either:
The carbon has abraded over time and is fine enough to pass the intertank screen.
The intertank screen is holed.
The seal between the launder and the screen has deteriorated or is not seated properly, allowing carbon to pass.
If the screen wasnt present this carbon would end up in the tailings dam resulting in gold and carbon losses. 
Generally the carbon on the safety screen is due to the screen being holed or the launder seal not sealing properly. This carbon is collected and put back into the circuit.
The slurry underflow from each of the carbon safety screens flows into separate tails thickener feed hoppers, from which the slurry is pumped to the tailings thickener feed box.
Area: Minning Maintenance Realibility
TAC Cyanide Analyser
The TAC analyser is an automatic titration unit that measures the cyanide concentration and pH of the slurry. A slurry sample from the splitter box is taken through a filtration sock and is sent by a peristaltic pump to the analyser unit. The filtered sample is titrated with silver nitrate to determine the free cyanide concentration. A probe measures the pH of the solution.
The cyanide concentration result as determined by the TAC is used in a control loop to automatically adjust the cyanide addition rate to the circuit.
Area: Minning Maintenance Realibility
Debex Carbon Meter
Each CIL tank is fitted with a Debex carbon meter. The meter measures the carbon concentration in the slurry. It works by sending an ultrasonic signal through the slurry, and from the loss of signal energy over the detection gap, determines the carbon concentration. The Debex system also incorporates a densiometer to account for variations in pulp density, which will alter the amount of energy absorbed from the ultrasonic pulse.
Area: Minning Maintenance Realibility
Leach Feed Slurry Autosampler
An autosampler intermittently takes a cut of the feed to the trash screens. The sample collects in a bucket that is removed daily by the laboratory technician.
Area: Minning Maintenance Realibility
Tailings Slurry Autosampler
An autosampler placed prior to each carbon safety screen takes a periodic cut of the tailings slurry from each train.
Area: Minning Maintenance Realibility
Waste Water Treatment
The systems treatment stages include: a
Sedimentation
Dissolved air flotation
Media filtration
Activated carbon filtration
Ultrafiltration
Reverse osmosis. 

In the sedimentation process, the suspended solids in the water are gravity settled. Then, through dissolved air flotation, various colloidal materials and dispersed particles are removed.

The water is then filtered to remove residual solids that may remain after the flotation stage. The removal of any dissolved organic material is completed with activated carbon filtration, followed by ultrafiltration. The latter step ensures that any residual suspended solids, colloidal and organic matter  including bacteria and viruses  are removed before the water is treated using reverse osmosis.
Removing as much sediment as possible is particularly important. It protects the infrastructure investment by making certain the membranes and other equipment used for reverse osmosis are neither fouled nor harmed by the water quality. Although this is important in any treatment process, water from mining in particular is full of sediment. The final polishing step in the water treatment process, reverse osmosis desalination, ensures that any dissolved salts and heavy metals are removed from the water before it is reused
Area: Minning Projects 
Grinding Mills
Part of the concentration plant, the grinding or tumbling mill is a large-scale grinding device (see Figure 2) used in mineral processing to grind large chunks of ore into a suitable size for the next step in the concentration process. A similar setup is used in the cement industry for crushing clinker.

There are several different types of grinding mills: ball, rod, autogenous and semi-autogenous grinding (SAG). In a ball mill, steel or stone balls are mixed with the ore and during rotation of the drum, the ore is ground by friction and compression into a suitable fineness. A rod mill uses a similar principle, but the steel or stone balls are replaced by rods to create the grinding action. In an autogenous mill, the ore itself is used in the grinding process. A SAG mill is a combination of a ball mill and an autogenous mill.
The main component of all mills is a horizontal rotating drum, typically with a rubber liner and regularly spaced lifter bars (see Figure 1). Generally, the ore is continuously fed into the drum in one end, then crushed and transported out in the other.

Figure 1: The drum interior at Garpenberg during a service stop clearly shows the rubber lifters. The rubber lifters are clearly visible.
In autogenous mills, a sufficient amount of bigger parts of ore inside the drum is critical to an effective grinding process. Maintaining particle size while minimizing equipment wear, downtime and power consumption is a challenge to production and maintenance engineers.
Area: Minning Projects 
Al Masane Al Kobra Mining Company is a precious metals and base metals developer focused on the completion and production of the 700,000 tpa copper, zinc and precious metals Al Masane Mine in Saudi Arabia. The Al Masane Project is fully funded and permitted. As of mid 2010, the surface facilities were completed and waiting for testing prior to delivery of ore. The contract to continue mine development has been awarded and pre-production development has commenced. 
 Production of copper concentrate, zinc concentrate, gold and silver bullion is scheduled for the 3rd quarter 2011. 
 The project is located in southwestern Saudi Arabia, approximately 640 km south east of Jeddah. It lies some 414 km by a newly paved road from the port of Gizan on the Red Sea. The mines copper and zinc concentrates will be trucked to the port of Gizan and shipped to smelters in Europe or the far east. 
 In addition to the known ore reserves that are being developed, exploration of gossans and geochemical anomalies in the greater Al Masane area has indicated that there is a high probability of discovering additional minable resources which will increase the life of mine.


Saudi Arabia Al Masane Cu & Zn Mining & Processing & Metallurgy EPC Project (700,000tpa)
EPC contractor BGRIMM in brief
BGRIMM, incorporated in China and directly under the Chinese central government (SASAC), is a leading institute providing innovative technology, diversfied products, and process-orientated engineering services in mineral and material industries worldwide. With ISO 9001 certificate and well established multi disciplinary organization, BGRIMM takes pride to be a complete solution provider integrating R&D, engineering and equipment manufacture tailored to customer requirments and serve the mineral industry with a full range of expertise from mining to mine closure.
Process consists of:
* Mining 2,000 tonnes of ore per day
* Crushing and grinding ore
* Floatation to produce copper and zinc concentrates
* Cyanidation of tailings to produce gold/silver Dore
Transportation of concentrates to the Port of Gizan on the Red Sea for export and dore for treatment in the gold/silver refining plant in Jeddah.
Area: Minning Projects 
Al Masane Geology and Mineralization
Three mineralized zones with massive sulfide mineable reserves have been discovered to date and outlined by 45,000 meters of diamond drilling from the surface and underground tunnels. The principal sulfide minerals in all the zones are pyrite, sphalerite, and chalcopyrite. The precious metals occur chiefly in tetrahedrite and as tellurides and electrum
INFRASTRUCTURE
 300-Man single status camp for employees
 Accommodation for expatriate and Saudi employees
 On-site medical facility
 Service building for 200 employees
 On-site diesel generation consisting of our 3.2 MW generators with three in operation, until connection to National Grid
 Potable water supply
 Sewage treatment plant
 assay laboratory
Area: Minning Projects 
Maaden Phosphate Development
Office: Al-Khobar, Melbourne, Beijing, Abu Dhabi  
Customer: Saudi Arabian Mining Company  
Location: Al-Jalamid and Raz Az Zawr, Saudi Arabia  
Timeframe: 2006 - ongoing  
The Maaden Phosphate Development located in Saudi Arabia is one of the worlds largest producers of di-ammonium phosphate, a fertilizer for use in grain and horticulture.
This $4.5 billion (direct capital cost) phosphate project being managed by WorleyParsons focuses on the economic development of the major phosphate resource rock located at Al Jalamid.  The full project development involves the design and construction of a beneficiation plant and associated infrastructure located at Al Jalamid, a major fertilizer complex and port facilities at Ras Az Zawr, a new 1400 km rail link between Al Jalamid and Ras Az Zawr for processing and a power generation plant.
The success of this world leading project is directly due to teamwork. WorleyParsons' commitment to supporting Maaden in maintaining their schedule and creating a multi-national workforce focused on safety, quality and cost has been invaluable in assisting Maaden to achieve their business objectives.
Area: Minning Projects 
Phosphate
Phosphate is one of the most significant products of Maaden as it is made naturally of phosphorus element. It is one of three main nutrition elements in the photosynthesis and is key element of the growth of agricultural crops.
According to the Food and Agriculture Organization (FAO) of the United Nations, the global food production needs to rise by 70%, and to be doubled in developing countries, so as to meet the anticipated needs of the world population, which will reach population of 9 billion people in 2050. Thus, there will still be a need to raise the productivity of phosphate fertilizers to meet this growing demand for food.
Maaden produces ammonium phosphate, which is recently widely used in agricultural field, Diammonium Phosphate (DAP), Monoammonium Phosphate (MAP). Maaden plans to introduce new phosphate compounds to become one of the leading suppliers of phosphate fertilizer companies in the world.
KSA is rich of all raw materials and other resources available to produce and supply phosphate fertilizers to the fastest growing countries in the world, all of which are close to the Kingdom.
Maaden continues its growth in the area of phosphate, based on two of the largest companies in the world, Ma'aden Phosphate Company, which was established in partnership with SABIC and Ma'aden Waad Al Shamal Phosphate, which was created in partnership with both SABIC and the US based Mosaic, which is one of the largest producer of phosphate fertilizer in the world.
Area: Minning Projects 
Ma'aden Phosphate Company (MPC)
With an investment of USD 5.5 Billion (SAR 21 Billion), MPC is a joint venture between Maaden and Saudi Basic Industries Corporation (SABIC), who share 70% and 30% respectively, with total production capacity of 3 Million TPA of DAP, MAP, and NP's. Each year, Maaden markets about 70% of its production from two major sites; Al-Jalamid, north of the Kingdom, where lies the phosphate mine in addition to an ore beneficiation plant; and Ras Al-Khair (RAK) site in the Eastern Province, which includes an integrated plant for the production of fertilizers and chemicals.

The mine produces about 11.6 Million TPA of phosphate ore, which undergoes the beneficiation process in the plant in order to produce nearly 5 Million TPA of beneficiated ore. MPC sought for investment in Al-Jalamid mine site, in terms of infrastructure, by constructing a power plant, potable water production and treatment facilities, a telecommunication network as well as a transportation network so as to facilitate exploration and production operations.
Phosphate concentrates are transported from Jalamid to RAK by rail for the production of phosphate fertilizers thru a number of facilities, including a phosphoric acid plant, a sulfuric acid plant, an ammonia plant, a Diammonium phosphate plant (DAP) and a desalination plant.
Based on the business relations of its founders (Maaden and SABIC), as well as the supply chain, markets and materials networks that cover the continents, MPC is growing as global company and playing an active role in this journey.