Search Documents

By K Jupp, T J. Howard

Cliffs Natural Resources Pty Ltd (CNR) operates iron ore mines in the Koolyanobbing region of Western Australia. Ore is mined from three locations, separated by many kilometres. The ore is stockpiled at these locations, according to an in-house ore classification system (based on grade and source) and then trucked to the crushing and screening plant at Koolyanobbing. Lump and fines products are railed to Esperance for ship loading and export to Asian customers. CNR prides itself on the relatively low inter-shipment grade variability of the products. The Koolyanobbing crusher is fed using a daily blend plan, generated to maintain lump and fines product grades within acceptable tolerance ranges around targets. Achieving low variability requires predicting lump and fines grades as accurately as practical from the estimated head grades of the ROM ores potentially going into the blend. The grade prediction model may be either a direct prediction of crushed lump and fines grades and lump percentage, or be split into two stages: the bias between blasthole estimated head grade and crusher head grade and then the lump-fines algorithm for splitting the head grade between lump and fines products. The lump-fines algorithm comprises the percentage of lump and the difference between the lump and fines grades. We describe a weighted least squares (WLS) regression model for predicting crusher grades and lump proportion from the estimated head grade for Fe, P, SiO2, Al2O3, Mn and S. The method is applied to CNR production data, where the regression model explains approximately 60 per cent of the variance in the crushed ore grade, for both lump and fines. A further small but significant improvement in prediction can be achieved by including the ore classification data in the model. The regression errors exhibit strong positive serial correlation, indicating trends in grade error across multiple blend records. To compensate for the longer-term error, an exponentially smoothed model was developed and applied to the daily grade blend errors. This gave an increase in the longer-term variance explained and therefore an improvement in grade prediction.

Jan 1, 2009

By A B. Jahed, Ö Aydan, T Ito

In this study, the authors compiled some case history data and present some typical examples of rock slope stability issues in Afghanistan with a special emphasis on Kandahar region and categorise rock slope failures according to the principles of modern rock slope engineering. The slopes considered involve rock-cut, natural rock slopes mainly. The effect of structural geology and discontinuous nature of rock mass on both slope-cuts and natural rock slopes is taken into account and some preliminary assessments on the stable and unstable rock slopes are presented. Furthermore, the seismic effect on their stability is also considered. It is also pointed out that similar issues could be observed in open pit mines, which may be exploited in years to come.

Nov 29, 2022

By D J. Bradshaw, E M. Wightman, C L. Evans, B Triffett

During the commissioning phase of Prominent Hill, periods of reduced recovery were experienced with higher-grade ore blends. This was unexpected and as part of the process to identify the cause, surveys were conducted in May 2009, with two different ore blends (copper grades: 1.94 per cent Cu (blend 1) and 2.49 per cent Cu (blend 2)). Metallurgical performance was assessed in terms of rougher recovery and grade with consideration of both pulp and froth effects. In addition, hydrodynamic measurements (gas hold up, bubble size, superficial gas velocity) as well as measurements of bubble load and top-of-froth grade were taken during the surveys and full mineralogical assessment of selected streams completed to characterise the nature of the differences. The metallurgical results showed that the lower performance was obtained with blend 2 which contained the higher amount of chalcocite and was higher-grade. Analysis of the survey data showed that for both ore blends more than half of the copper loss occurred in the +38 ¦m size fractions. Almost 30 per cent of the copper in the +38 ¦m fractions that reported to the rougher tails during processing of blend 2 was liberated compared to less than five per cent for blend 1. Additionally almost 60 per cent of the copper in the +38 ¦m fraction of blend 2 was chalcocite compared with approximately 20 per cent in blend 1. This paper discusses the sensitivity of the chalcocite-to-surface chemistry effects causing marked reductions in recovery either through reduced pulp recovery or froth phase (detachment) effects. The reagent suite and operating conditions were subsequently changed and the recoveries increased substantially and the sensitivity to ore changes eliminated. It should be noted that subsequent optimisation work, which focused on recovery improvement, has led to copper recoveries of over 90 per cent being achieved.CITATION:Bradshaw, D J, Wightman, E M, Evans, C L and Triffett, B, 2012. Characterising the reasons for the difference in performance of two ore blends in early processing at OZ Minerals Prominent Hill Operation, in Proceedings 11th AusIMM Mill OperatorsÆ Conference, pp 273-278 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Oct 29, 2012

By W B. Edgar, S C. Dominy

High-nugget effect vein-gold systems are generally considered to be one of the most challenging of deposit types to evaluate and exploit. To potential investors and mining companies, they are viewed as high risk because of the associated uncertainties in the grade estimate and general paucity of Ore Reserves at production start-up. However, despite the well-known risks, these deposits often have a grade upside that makes them potentially attractive. The reporting of resource grade is of importance and perhaps even more so is the reporting of the associated uncertainty attached to the grade estimate. The use of the grade estimate supported by a grade range is recommended to achieve more complete and useful disclosure. The definition of the grade range can be somewhat subjective, ranging from opinion based estimates through to data-based estimates and geostatistical conditional simulation. Whichever method used, the over-riding issue must be the provision of enough data of appropriate quality and full disclosure to the public of relevant uncertainties.CITATION:Dominy, S C and Edgar, W B, 2012. Approaches to reporting grade uncertainty in high-nugget gold vein projects, in Proceedings Project Evaluation 2012 , pp 95-108 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 24, 2012

By E Asakpo, S Chaffer, A Heath

Newmont has had continuous production at their Ahafo operations, Ghana, since 2006. In 2013, Ahafo initiated an efficiency programme to improve mill performance and reduce energy consumption. Following this assessment, a Turbo Pulp Lifter (TPLTM) was installed in the Ahafo SAG mill in April 2015 to replace the existing radial pulp lifters. Plant operational data showed delivery of a power saving of 10 per cent, an improvement in throughput of 3.3 per cent, with no loss of grind size. Pulp lifter life was also doubled from 11 to 22 months.However, during subsequent relines when the grates were removed it was found that one in four of the outer pulp lifters were wearing at a faster rate than the remainder. This was investigated by Discrete Element Method (DEM) modelling, which predicted some overtopping and internal recycle within the pulp lifter. Significantly, the model predicted that the recycled material would pass back down every fourth outer pulp lifter, matching the field observations. Subsequently, the DEM investigation was continued and became an R&D project to improve the TPL design. The results are summarised here, leading to the development of the next generation Spiral TPLTM.CITATION:Heath, A, Chaffer, S and Asakpo, E, 2018. The development of optimised pulp lifter design for the Ahafo SAG mill using discrete element method modelling, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 585–594 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

By C N. Hatton, K Ward

Tailings operations are inherently reactive as operations personnel continuously contend with a concentrator reject feed (tailings) transient in physical and engineering properties, which places a constant constraint on capital and operational spending. It requires a unique skill set to manage the prescribed distribution of tailings under unenviable conditions. Enter the tailings operator, an oftenundervalued commodity and untapped resource that can provide benefits beyond the rigors of dayto- day operational support. Experience consistently demonstrates that skilled and committed operators can serve a vital function in the safe construction of a tailings storage facility. It takes a village to raise a tailings dam. An important part of this process is establishing a culture of operational accountability and ownership. Operator development training is nothing new. However, we find that many of the intrinsic operator skills are left unexploited, and an operator's experiential knowledge base and creativity are commonly overlooked and underutilized. With proper training and guidance, these skills can be harnessed, contributing to safe dam operations. Operator engagement, when properly facilitated, provides tangible benefits ranging from improved tailings engineering properties to reduced closure costs. One important benefit is helping transitioning tailings management from reactive to proactive. There are many processes involved in the reactive to proactive transition process. One element of that process includes engaging operators in the tailings management process and facilitating legacy ownership. The core of operational legacy ownership is measured and described using five-stage operator engagement rubrics. Levels of operator engagement are presented with a description of the incremental benefits of each stage. An important part of legacy engagement is providing the tools to operators necessary for managing the tailings. Therefore, the approach identifies specific methods used by operations personnel to control tailings distribution and in-place properties. The end goal of leveraging operator engagement is to facilitate committed ownership and transition tailings management from an inefficient, reactive process to an improved, cost-effective, proactive practice.

Jul 1, 2021

By S R. Pecover

AustraliaÆs opal and sapphire mining industry has fallen from its peak in the 1980s and 1990s into a significant low today. This is not due to exhaustion of the resource, but instead an over-reliance of the Australian miner on achieving a fair price for the gemstone product from offshore middlemen dealers. Gemstone and geological research is also at a low as Federal higher education expenditure has fallen with research institutions relying increasingly on private funding in an environment of restricted autonomy and flexibility for researchers. What little remaining research skills the universities have is being bled into the private sector as a result of the mining boom and encouraged by lower than average academic salaries. Nevertheless, some highly innovative research has been taking place, often by self-funded individuals and retired academics simply with a desire to advance the understanding of the particular branch of science in which they are interested. New models for the formation of sapphire and opal are now beginning to be applied to the exploration for these gemstone commodities. This research, together with well thought out plans for managing the gemstone product through its value-adding steps to the jewellery retail level, has the potential to bring about a resurgence in the Australian gemstone industry.

Jan 1, 2008

By R Ibarra, H Solis, G Teowee, B E. Papillon

The authors have previously described a piezoelectric-based system to measure the dynamic pressure during actual detonation in the field. This technique is used in a water hammer test set-up where a donor detonator is fired first, with the pressure sensor and an acceptor electronic detonator placed underwater in a water tank, and maintained at a fixed distance away from the donor detonator. The functioning and timing of the acceptor detonator are captured using a customised microcontroller board called the water hammer timer. Using such water hammer testing, the effect of dynamic pressure was studied as a function of the magnitude of pressure during the electronic timing countdown. Data obtained indicate there is no significant impact in the timing of the electronic detonators in contrast to what has been reported in non-electric detonators.CITATION:Teowee, G, Solis, H, Papillon, B E and Ibarra, R, 2015. Effect of dynamic pressure on electronic detonator timing, in Proceedings 11th International Symposium on Rock Fragmentation by Blasting, pp 575–578 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 24, 2015

By Fradd WP

South Australia pioneered metal mining in Australia and was the main source of copper for several decades. Gold discoveries and mining also contributed significantly to the development of the Colony. Across the State can be seen the holes, the mullock heaps and, in some instances, the remnants of machinery of the past era. In this, the centenary year of the discovery of the Teetulpa goldfield, considered by some to he the most significant discovery of gold in the State, it is appropriate that we should present a paper on the history of gold mining in South Australia. South Australia has not been a major producer of gold with recorded production a little in excess of 15 million grams (15 t). This represents about 0.25 per cent of the Australian total and ranks last of the States of the Commonwealth. The outstand- ing feature of gold production in South Australia has been the succession of short periods of rela- tively high production immediately following a discovery, with payable dirt being quickly exhausted, a fact clearly illustrated by the graph of South Australian gold production (Figure 1).

Jan 1, 1987

Currently all engineering schools face a common problem, an ever expanding technological base which must be presented to students within a fixed time period. Traditionally the programmes of study taken by engineering students destined for employment within the mineral industry include formal instruction in aspects of management to an extent greater than that presented in other engineering disciplines. Providing an adequate coverage of an expanding technological base within a fixed time span can lead to a reduction in the time available for 'non-technical' subjects, such as 'management'. This situation calls for periodic review of course contents and allocations of time. Following consultation with an Advisory Committee representing the mineral industry, mining research establishments, and kindred teaching institutions, the University of Melbourne has revised its mining programme. This programme is offered as an example of how aspects of management such as communications, economics, labor

Jan 1, 1980

By S France

The Waterview Connection will complete a strategic Auckland motorway route linking the south, west and north. The project will comprise 2.5 km of ‘undrained’ driven tunnels and 900 m of drained cut-and-cover tunnel and portals.The project is aligned beneath a stream valley of Oakley Creek incised through alluvium and in places overlain by landfill, between Mt Albert volcano and a ridge formed in alternating sandstones and siltstones. The hydrogeology of the area is complex with perched aquifers in compressible soils, cascading water levels in fractured rock aquifers, and discontinuous higher permeability units resulting in artesian water levels and groundwater springs.Numerical groundwater modelling was undertaken to assess the potential effects of tunnel construction and long-term operation on the groundwater system; the magnitude and extent of changes in groundwater level and the resulting potential for settlement, buoyancy effects, contaminant migration and adverse effects on creek base flow. Modelling also provides inputs to tunnel design such as groundwater seepage volumes and water pressures.The driven tunnel will be ‘undrained’ long-term so potential effects on the groundwater system are limited to short-term dewatering during construction. Significant project time and cost savings can be made if the portal areas are permanently ‘drained’, but this means potential effects are greatest in the long term condition.This paper summarises the investigations, implications of the complex hydrogeological setting on tunnel design and environmental assessments, and groundwater modelling undertaken during the planning stage of this project. The groundwater modelling has been used to incorporate mitigation options in tunnel design and construction sequencing; a comprehensive monitoring program will be used to trigger appropriate responses should effects differ from those predicted.

Mar 8, 2011

By W D. Rech, K W. Keskimaki

As an integral part of the conversion from rail haulage to conveyor haulage at Henderson, over six kilometres of drifting and several large complex openings were mined. The deepest of these areas was nearly two kilometres beneath the surface, bringing all of the challenges of rock stress and heat that come with mining at these depths. Though many mines operate at these depths, the development of the infrastructure necessary to support a 36 000 tonne per day caving operation brought some unique challenges to the development mining activity. The issues handled include: finding experienced staff for a æfast trackÆ development program; rock bursts and ground conditions; inflow of 50 degree centigrade water; acceleration of the project completion; large diameter raise boring and difficult muck handling.

Jan 1, 2000

By Hoppe AJ

Drilling and shooting techniques at Moura open-cut have evolved over a period of 16 years and are the result of hard earned experience combined with established practices and consul- tation with professional services. The wide range of overburden types encoun- ted in the field requires varying methods to achieve the best results at all times. Safe working conditions for the employees and protection of mining equipment is of para- mount importance and close liaison is maintain- ed with the Department of Mines Queensland to keep abreast with changing legislation. Drill patterns, charging profiles, types of explosives and ultimate results are des- cribed in detail along with a resume of equip- ment. Costs of drilling, labour and explosives are also analysed with a total of approximately 20c per cubic metre of shot ground. Future developments and improvements to facilities are also outlined.

Jan 1, 1978

The problems of the as-built water supply system are discussed. Recent modifications to the collection dams and the water cleaning station using wedge wire screens to resolve these problems are outlined.

Jan 1, 1978

By A Horn

Mineral processing is characterised by a constant adaptation to changing raw materials and market conditions. It is the link between the mined raw material and a marketable product. As a lot of high-grade reserves are exploited, a steady deterioration of raw material quality can be observed. At the same time, the customer’s requirement for product purity and consistent quality increases.Over recent years beneficiation techniques for iron ore fines have become more important in order to achieve a maximised utilisation of ore resources and to produce competitive products according to international standards.Many high capacity iron ore beneficiation plants that target the production of fines focus on gravity separation processes using fluidised bed classifiers and spirals or wet high intensity magnetic separators as an alternative. This paper demonstrates the suitability of utilising the allflux® two-stage fluidised bed classifiers to treat iron ore particles up to 2 mm in size as well as showing how the high capacity gaustec® wet high intensity magnetic separation (WHIMS) technology offers several advantages compared to other WHIMS technology.The combination of the allflux® and gaustec® technologies offer the following benefits:The two-stage fluidised bed classification extracts a significant amount of concentrate from the feed. This in turn reduces the feed capacity required for the gaustec® WHIMS located downstream.The second classification stage produces a -0.5 + 0.1 mm product and a -0.1 mm product. The efficiency of the magnetic separation on these classifi ed products is high due to optimised settings for each size fraction.

Jul 11, 2011

By D Brereton, C J. Moran

In this era of rising focus on the social and environmental costs and benefits of mining operations, the valuation methodologies used to assess such impacts become increasingly important. Within an industry dominated by an engineering culture that places emphasis on net present value (NPV) calculations using high discount rates, difficulties often arise when attempting to justify projects with longer-term, harder to quantify benefits. This is particularly so when these benefits fall in the social and environmental domains and involve other stakeholders. In this paper, we summarise the results of a recent literature review on this subject, which focused on the valuation of æBeyond ComplianceÆ initiatives in the mining sector. We discuss a range of approaches including the quantification of hidden internal costs, financial methods of incorporating risk into calculations, the integration of quantitative and qualitative information, and also the valuation of æexternalitiesÆ or costs and benefits borne by others. We then use a series of examples relating to the management of water in the minerals industry to illustrate how some of these approaches could be applied. There are high-level commitments from both individual companies and groups such as the ICMM to incorporate sustainable development criteria into decision-making processes within the industry. We conclude the paper by arguing that, to meet these commitments, there is a need for the industry to adopt a broader range of valuation methodologies than appears to be the case at present.

Jan 1, 2006

By M T. Grigoleit, M S. Schneider

The iron ore industry in Australia has, in recent years, experienced an unprecedented growth phase. But now that major expansions are moving into the operation phase, new challenges have emerged. Whereas initial planning may involve a few modelling studies, ongoing performance monitoring and improvement requires a different, more intense approach. This is especially important in the face of changing factors such as commodity prices, exchange rates and labour markets. Response time is key. As a mining operation proceeds from initial planning to daily operations, the time window for analysis shortens, going from months to weeks to days as the business matures.Simulation models and analysis tools are typically built and run by specialists in the planning phase, but then what? The investment has been made, but realised only once. What if further analysis could be carried out in-house, re-using existing models using up-to-the-minute data? Can we create virtual mines that run in parallel to live operations that allow computers to identify areas of a value creation or operational improvement? These questions can be answered by the innovative application of big data, simulation and predictive analytics. The future will be having this all integrated into one platform that offers, for the first time, an opportunity for non-experts to apply existing modelling and analysis assets – combined with live data – to deliver support for continuous improvement, and the ability to respond quickly to external changes in the best possible way, before they become big problems. These techniques will represent a step change in the ability for operations to maximise efficiency and will underpin the intelligent operations of the future. These issues are addressed in this paper.CITATION:Schneider, M S and Grigoleit, M T, 2015. Maximising productivity through big data, simulation and predictive analytics, in Proceedings Iron Ore 2015, pp 475–480 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

By C Fricke, R Wood, P Velletri

"In a climate characterised by an ever increasing focus on cost reduction and maximising the utilisation of existing assets and infrastructure, understanding the uncertainty associated with alternative investment and operational choices becomes paramount to minimising the risk of making an ineffective decision. To assist in this process, TSG Consulting has developed an analytic framework to capture the underlying complexity of a mineral supply chain, and then quantify the impact of the uncertainty associated with the key drivers of business productivity. The technical basis of this approach follows three distinct steps: analyse the current system and identify the major factors that drive value build detailed models that can measure the response of the system to potential changes in the factors identified quantify the sensitivity of financial and capacity forecasts to these factors.Each of the above steps draws on a different area from the field of applied analytics, namely: data analytics dynamic modelling and designed experimentation meta-modelling and optimisation.Following the three-step approach described above ensures a rigorous modelling and analysis process is executed to support strategic mine planning decisions. The approach is equally applicable to the analysis of fully integrated system supply chains (pit-to-port), the evaluation of incremental capital investments to targeted areas of a supply chain, or when considering revisions to the operating philosophy of a system in the short term. The basis of each of the three analytic steps is explored in detail in this paper. The result is the definition of a structured mechanism for a business to actively manage risk and drive productivity as a component of the strategic mine planning process.CITATION:Fricke, C, Velletri, P and Wood, R, 2014. Enhancing risk management in strategic mine planning through uncertainty analysis, in Proceedings Orebody Modelling and Strategic Mine Planning Symposium 2014, pp 275–280 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Nov 24, 2014

By A B. Bayooke, A C. Robertson

In terms of underground tunnelling in metres advance per capita, Australasia compares well with the best world performers. This is because of the large number of metalliferous mines, coalmines and civil tunnelling projects, with the Australian tunnel advance for civil and mining projects exceeding 625?km/a. In terms of hard rock quarry extraction, Australia produces approximately 200?Mt/a of aggregates, roadbase, fill material and specialist rock products from its quarries, which equates to approximately 8?t/capita. Australian mining and tunnelling contractors are also of world standard and are used to excavating in a variable range of ground conditions in a competitive environment. One author has been involved in tunnel and underground space planning and quarrying in Australia for the past 25 years and predicts that, over the next 20 years, there will be a major swing towards underground space for commercial uses. This paper identifies the potential uses of underground commercial excavation and the planning and geotechnical challenges for the future. Underground quarrying creates new opportunities to extend existing quarries within their urban footprint with minimum impact on the surrounding community. Investigations by the authors reveal that there are very few cities in the world that actually incorporate underground space planning in their city plans. However, cities such as Helsinki have been planned in detail to utilise the rock resources beneath them. Brisbane is used as a case study for a practical application of commercial underground space and underground quarrying in Australia.CITATION:Bayooke, A B and Robertson, A C, 2014. Geotechnical challenges for underground commercial space and quarrying in Australia, in Proceedings AusRock 2014: Third Australasian Ground Control in Mining Conference , pp 317–322 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 5, 2014

By P Holtham, K Duffy, B, W Valery, E Tabosa, rade

Pre-concentration has potential to significantly improve Mineral Resource efficiency by removing gangue early in the process, before energy intensive and expensive comminution and fine processing. However, there are numerous options for pre-concentration and the performance and benefits of these are very case specific. To determine the best option for a particular deposit and to successfully integrate it into the overall mining and processing operations requires comprehensive evaluation. This needs to consider orebody suitability, technology capability and economic viability. The in-situ variability of a deposit and how it is influenced by mining methods and the liberation size of gangue are key factors which are generally not well understood. Geostatistical methods provide an insight into orebody variability, and the overall selection of any pre-concentration solution must be an integrated approach between geology, mining and processing. Many pre-concentration evaluations investigate the potential of just one option. Technology selection should start wide and may include: selective mining, pre-screening (with or without selective blasting), sorting (bulk and or particle), coarse gravity separation (e.g. jigging, DMS), coarse particle flotation, magnetic separation, etc. The upgrade performance of these processes is very ore specific and should be determined from testing, with detailed multi-component modelling used to determine the overall process performance. Many of these pre-concentration processes require significant ancillary equipment, feed preparation and materials handling. It is important to realistically estimate all costs to understand overall economics and select the best option. Some examples showing evaluation and comparison of pre-concentration options are presented in this paper. These include assessments of in-situ variability using geostatistical tools, process modelling of pre-concentration options and overall performance, preliminary layouts and cost estimates, and economic evaluations.

Nov 10, 2020