The continuous decline in ore grades has driven the mining industry to adopt innovative strategies to sustain and potentially increase production, particularly in response to the rising demand for strategic and critical minerals such as copper, which is essential for the energy transition. In underground mining, such as sublevel caving operations, ore passes are commonly used to transport ore between levels. Expanding and optimising the use of ore passes can improve operational efficiency, reduce energy consumption, and lower carbon emissions associated with hauling.
However, significant challenges arise in maintaining reliable gravitational flow within ore passes due to substantial vertical distances and increasing mining depths. To address these challenges, this study utilises a scaled physical model to investigate the flow behaviour of various particle types within an ore pass. The analysis considers multiple variables, including filling levels, particle size distributions, and particle properties. A total of 4160 flow experiments were conducted across 52 combinations of particle shapes and sizes to quantify the influence of these variables on material flow.
The highest number of hang-ups was observed for large triangular prismatic particles, with 125 events, followed by large spherical particles, which exhibited 96 hang-ups. In contrast, no hang-ups occurred for small spherical or octahedral particles. The hang-up frequency index decreased by 98.48 % when sphericity was reduced by 23.47 %, indicating a strong influence of particle shape on flow behaviour. For spherical particles, lower ore pass filling levels reduced the occurrence of hang-ups, whereas this effect was not observed in mixed prismatic particle shapes. This detailed analysis of hang-up events under varying conditions can help to identify critical scenarios affecting particle flow within ore passes. The findings provide essential insights into the parameters governing particle movement, thereby advancing the understanding of complex flow dynamics in ore pass operations.
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