Mining trends in the gold sector indicate a growing imbalance in global supply and demand chains, especially in light of accelerated efforts towards industrial electrification and automation. As such, it is important that research and development continue to focus on processing options for more complex and refractory ores. Unlike conventional (i.e., free-milling) ore feeds, refractory gold is not amenable to standard cyanidation, and requires additional pretreatment prior to leaching and recovery. With recent technological advancements, such as sensor-based ore sorting, there is opportunity to advance the development of smaller untapped refractory resources with marginal economics, particularly those in proximity to processing infrastructure within major gold districts. However, it will be critical that the necessary tools are developed to capture the potential system-wide effects caused by varied ore feeds and improve related decision-making processes earlier in the value chain. Discrete event simulation (DES) is a powerful computational technique that can be used to monitor the interactions between important processes and parameters in response to random natural variations; the approach is thus suitable for the modelling of complex mining systems that deal with significant geological uncertainty. This work implements an integrated artificial neural network (ANN) and DES framework for the regional coordination of conventional and preconcentrated refractory gold ores to be processed at a centralized plant. Sample calculations are presented that are based on a generated dataset reflective of sediment-hosted refractory gold systems.

Interdisciplinary barriers separating data scientists and geometallurgists have complicated systematic attempts to incorporate machine-learning into mine production management; however, experiences in excavating a vein-hosted gold deposit within the Alhué region of Chile have led to methodological advances, which is the subject of the current paper. These deposits are subject to several challenges, from increasing orebody complexity and decreasing gold grades to the significant geological uncertainty that is intrinsic to these systems. These challenges then translate to mineral processing, which is already dealing with increased environmental and technological constraints. Geological uncertainty causes stockout risks that can be mitigated by the approach that is developed within this paper, which features alternate operational modes and related control strategies. A digital twin framework based on discrete event simulation (DES) and a customized machine-learning (ML) model is proposed to incorporate geological variation into decision-making processes, including the setting of trigger point that induces mode changes. Sample calculations that were based on a simulated processing plant that was subject to mineralogical feed changes demonstrated that the framework is a valuable tool to evaluate and mitigate the potential risks to gold mineral processing performance.

Sensors and process control systems are essential for process automation and optimization. Many sectors have adapted to the Industry 4.0 paradigm, but copper smelters remain hesitant to implement these technologies without appropriate justification, as many critical functions remain subject to ground operator experience. Recent experiments and industrial trials using radiometric optoelectronic data acquisition, coupled with advanced quantitative methods and expert systems, have successfully distinguished between mineral species in reactive vessels with high classification rates. These experiments demonstrate the increasing potential for the online monitoring of the state of a charge in pyrometallurgical furnaces, allowing data-driven adjustments to critical operational parameters. However, the justification to implement an innovative control system requires a quantitative framework that is conducive to multiphase engineering projects. This paper presents a unified quantitative framework for copper and nickel-copper smelters, which integrates thermochemical modeling into discrete event simulation and is, indeed, able to simulate smelters, with and without a proposed set of sensors, thus quantifying the benefit of these sensors. Sample computations are presented, which are based on the authors’ experiences in smelter reengineering projects.

Digital technologies are continually gaining traction in the mining and mineral processing industries. Several studies have shown the benefits of their application to help improve various aspects of the mineral value chain. Nevertheless, quantitatively assessing new technologies using a holistic approach is vital to evaluate whether the potential localized benefits ultimately translate to an overall increase in project net present value (NPV). This study develops an integrated system-wide methodology for open-pit mines, supporting the technoeconomic assessment of implementing new technology that impacts strategic and operational timeframes. The first part of the framework relies on a state-of-the-art mine plan optimization algorithm that incorporates geological uncertainty. The resulting outputs are then fed into the discrete event simulation portion of the framework (second part) to maximize plant throughput using alternate modes of operation (blending strategy) and operational stockpiles to deal with unexpected changes in ore feed attributes. Sample calculations loosely based on a gold deposit located in the Maricunga belt, Chile, are presented in the context of evaluating different intelligent ore sorting technology options.

Oil remains a major contributor to global primary energy supply and is, thus, fundamental to the continued functioning of modern society and related industries. Conventional oil and gas reserves are finite and are being depleted at a relatively rapid pace. With alternative fuels and technologies still unable to fill the gap, research and development of unconventional petroleum resources have accelerated markedly in the past 20 years. With some of the largest bitumen deposits in the world, Canada has an active oil mining and refining industry. Bitumen deposits, also called oil sands, are formed in complex geological environments and subject to a host of syn- and post-depositional processes. As a result, some ores are heterogeneous, at both individual reservoir and regional scales, which poses significant problems in terms of extractive processing. Moreover, with increased environmental awareness and enhanced governmental regulations and industry best practices, it is critical for oil sands producers to improve process efficiencies across the spectrum. Discrete event simulation (DES) is a computational paradigm to develop dynamic digital twins, including the interactions of critical variables and processes. In the case of mining systems, the digital twin includes aspects of geological uncertainty. The resulting simulations include alternate operational modes that are characterized by separate operational policies and tactics. The current DES framework has been customized to integrate predictive modelling data, generated via partial least squares (PLS) regression, in order to evaluate system-wide response to geological uncertainty. Sample computations that are based on data from Canada’s oil sands are presented, showing the framework to be a powerful tool to assess and attenuate operational risk factors in the extractive processing of bitumen deposits. Specifically, this work addresses blending control strategies prior to bitumen extraction and provides a pathway to incorporate geological variation into decision-making processes throughout the value chain.

The Alhué deposit (Melipilla, Chile) is an example of a hydrothermal Au-Ag-Zn(-Pb) vein system hosted within the volcanic rocks of the Las Chilcas Formation. The dominant ore minerals observed are free electrum and native gold associated with silver sulfosalts, and with magnetite and base metal sulphides, including pyrite +/− sphalerite-galena-chalcopyrite. The alteration assemblage in the veins mainly consists of quartz epidote-chlorite-actinolite with lesser smectite, amphibole, and calcite-kaolinite-garnet. Mineralized veins also contain variable amounts of base metals, some of which (e.g., copper and iron) are considered harmful to the extraction of precious metals. Iron and especially copper minerals are known cyanide consumers; ore type classification schemes that do not consider the detrimental effects of such mineralogy or process elements can ultimately result in metal losses from ore feed restrictions, as well as spikes in cyanide consumption and higher operating costs. Mineralogical and geological variation can nonetheless be managed by applying alternating modes of operation as demonstrated in this paper; the decision to switch between modes is governed by current and forecasted stockpile levels feeding into the process. Simulations based on experiences at the Alhué deposit are provided that demonstrate the importance of standardized operational modes and their potential impact on cyanide consumption control.