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By L D. Redden, M G. Nelson

Mechanical flotation machine design is typically based on hydrodynamic analysis, with scale-up calculated by geometric proportionality. End users often specify and purchase machines on the basis of retention time, characterised by the æ$/m3Æ approach; they may also consider the manufacturerÆs installed base. In some applications, end users also consider specific energy and the impact of energy consumption on operational costs. In other cases, a decision may be based on machine type (forced-air versus self-aspirating) and perceived metallurgical or operational advantages of one machine type over the other. With regard to metallurgical performance efficient bubble-particle contact is very important and is primarily influenced by two factors:the concentration and size distribution of bubbles in the machineÆs contact zone (the volume enclosed by the disperser); and the number of times that slurry is pumped through the contact zone. The second factor is a function of the machineÆs pumping rate and its retention time. Field data show that pumping efficiency is independent of aeration rate. In this paper, a new dimensionless number for the characterisation of flotation efficiency is presented. The contact frequency number (CFN) is defined as the number of times a given volume of slurry passes through a machineÆs active contact region, and is given by: CFN Qp/Qf, where:Qpis the pumping rate through the contact regionQfis the volumetric feed rate to the machine

Jan 1, 2005

By N Voller, A Ishmurzin, G Hackl, M Wu, A Kharicha, M Chintinne, C M. G Rodrigues, A Ludwig

Slag fuming (SF) is a critical process for recycling zinc-containing slags, but the corrosive nature of molten slag poses challenges to the reactor durability. The freeze-lining (FL) technique offers a solution by forming a protective layer on the reactor wall. It requires intensive cooling using watercooled jackets, which can stabilise the FL while compromising the energy efficiency of the process. This study presents a computational fluid dynamic (CFD)-based model to optimise the SF process by considering FL formation and its impact on heat transfer and reactor wall temperature. A volumeof- fluid (VOF) model is coupled with a mixture continuum (MC) solidification model to capture the intricate multiphase flow dynamics within the SF furnace. Two FL types are considered: FL solidifying on the reactor wall in the slag bath region; and FL solidifying on the reactor wall in the freeboard region. The FL of the first type forms when the slag temperature drops below liquidus temperature. The FL of the second type only forms when a splash-induced slag droplet collides with the freeboard wall and solidifies. A series of splashing events are necessary to coat the freeboard wall. The simulation was run until a global energy balance was reached. This means that the heat losses from the water-cooled jacket, bottom wall, outlet and fuming balance the heat gains from the hot gas injected through the submerged plasma torches. The increase in FL thickness, due to its low thermal conductivity, reduces the heat losses through the reactor walls. The calculated FL thickness and heat fluxes were in good agreement with industrial data, validating the model’s credibility. The simulation results provided valuable insights into the fuming process, including slag bath temperature evolution, slag splashing dynamics, FL formation patterns, local heat fluxes through the reactor wall and overall energy balance. These findings can inform process optimisation strategies to enhance the energy efficiency and sustainability of SF operations. The authors have built a prior version of the model framework and applied it to simulate FL formation in an electric smelting furnace (ESF). The results from both the ESF and the current SF highlight the applicability of such model framework to a range of industrial processes involving FL formation. This model framework can ultimately contribute to more energy-efficient and sustainable industrial operations.

Aug 21, 2024

By A Guillen, J-P ChilFs

Most 3D geological modelling tools were designed for the needs of the oil industry or detailed mine planning and are not suited to the variety of situations encountered in other application domains. Moreover, the usual modelling tools are not able to quantify the uncertainty of the geometric models generated. The potential field method was designed to build 3D geological models from data available in geology and mineral exploration, namely the geological map and a digital terrain model (DTM), structural data, borehole data and interpretations of the geologist. This method considers a geological interface as a particular isosurface of a scalar field defined in the 3D space, called a potential field. The interpolation of that field, based on cokriging, provides surfaces that honour all the data. The 3D model and its parts are always consistent with the observations. New developments allow the covariance of the potential field to be identified from the structural data. This makes it possible to associate sensible cokriging standard deviations to the potential field estimates and to express the uncertainty of the geometric model. It also, for the first time, gives a statistically optimal, geologically sound way of interpolating geology, other than directly joining the dots as you do with CAD. Practical implementation issues for producing 3D geological models are presented: how to handle faults, how to honour borehole ends, how to take relationships between several interfaces into account, how to model thin beds over many kilometres, how to optimise lithological properties and how to integrate gravimetric and magnetic data. We describe all geology surfaces and volumes using implicit functions. These are then rendered onto the required sections, plans, etc. The estimation of orebody grades and tonnes, using an unbiased and optimal geostatistical technique, makes use of the stratigraphically bound 3D geology model. An application to the geological modelling of the Hamersley iron ore district, Australia, is briefly presented.

Jan 1, 2009

By B T. Qin, C Zhu, Y W. Jia, Y Lu, F L. Li, Q L. Shi

Air leakage through rock fractures in coal mining is a major cause of coal spontaneous combustion. In order to overcome the deficiency of the existing fire control technology and prevent coal spontaneous combustion by isolating coal from oxygen, the article proposes a novel technology of inorganic solidified foam (ISF) with high expansion to fill fractures effectively. ISF consists of fly ash, cement, setting accelerator, redispersible polymer powder, water and aqueous foam. For preparing homogeneous and stable ISF, a preparation system with a pore type foam generator, a mixer device installed with a hollow shaft and helical blades, air compressor, slush pump and monitoring instruments was developed, and the working principles of key devices were elucidated. Based on a series of experiments on the different ratios of each component material and technological parameters of the preparation system, ISF with a foam expansion ratio of 8~10 and dry density of 250–400 kg/m3 was prepared. The relationship between elastic compressive strength, modulus of elasticity and density was summarised. Based on the injection experiment for fracture of loose coal pile with high temperature, the characteristics of sealing air leakage, compressive strength, thermal insulation, flow and cooling of ISF in the fresh state were investigated, indicating that ISF can effectively cut off the air leakage and cover the coal sample to reduce the temperature in the earlier stage, and ISF can remain stable and not crack. The ISF was applied to Luwa coalmine to seal small coal pillar pressure fractures and loose coal fractures in goaf. After press-casting the ISF in Luwa coalmine, the pressure-difference of inner-outer increased, meaning the effect of external conditions on the pressure-difference decreased, showing that it could plug the air leakage effectively.CITATION:Qin, B T, Shi, Q L, Lu, Y, Zhu, C, Li, F L and Jia, Y W, 2015. The novel technology of inorganic solidified foam with high expansion for preventing coal spontaneous combustion, in Proceedings The Australian Mine Ventilation Conference, pp 121–126 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 31, 2015

By L Cain, C Every, S Mirlatifi, J Ashley

This paper presents a geographic information system (GIS) based method for the prediction of ground movement and the associated impact on existing buildings and structures due to tunnelling in the North West Rail Link (NWRL) project. The NWRL is a priority rail infrastructure project for the New South Wales (NSW) Government and includes 15 km of twin tunnels between Bella Vista and Epping, which will be Australia’s longest rail tunnels. The NWRL tunnels will be constructed in an urban environment where the prediction of ground movements induced by tunnelling and the associated impacts to existing structures must be assessed in the early design stages of the project. An assessment process was developed using GIS able to respond to design changes.An iterative GIS analysis methodology was developed to generate ground settlement contours and identify impacted buildings and structures in response to multiple changes in tunnel alignment during design development stages. The GIS analysis undertook to rapidly provide detailed and accurate parameter information including tunnel depth from surface, tunnel separation, diameter and sample point proximity to the tunnel and assess ground movement contours along the project alignment. Determination of the ground surface settlements were based on empirical methods proposed by Peck (1969) and Mair (1993). The control parameters and the relationship between damage categories and risk classifications for impact assessment were based on Burland, Broms and de Mello (1977), Rankin (1988) and Boscardin and Cording (1989) methods.The GIS-based ground movement impact assessment approach adopted for the NWRL project demonstrates an efficient, iterative and robust approach and could provide an initial framework for other similar tunnelling projects where rapid design changes and early understanding of tunnelling impacts are required to bring greatest benefit to all stakeholders.CITATION:Mirlatifi, S, Cain, L, Ashley, J and Every, C, 2014. An iterative geographic information system based approach for the assessment of tunnelling impact to existing buildings and structures, in Proceedings 15th Australasian Tunnelling Conference 2014 , pp 647–652 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 17, 2014

By A Bennett, A Peck

BHP has recently constructed a Hot Briquetted Iron Plant at Port Hedland in the Pilbara region of Western Australia. Supply of iron ore fines to the plant is by conveyor from the companyÆs existing Nelson Point stockyards. The conveyor passes under Port Hedland harbour in a concrete segmentally lined tunnel, approximately 1030 m long and with a 5.1 m external diameter. The tunnel was constructed by a Tunnel Boring Machine (TBM) which both excavated the ground and erected the tunnel lining. The tunnel was bored between cut and cover in situ concrete portal structures, the TBM being launched from the Finucane Island side towards Port Hedland town. The alignment required lengthy gradients of 1:6 on either side of the harbourÆs dredged channel, under which the tunnel is bored with a minimum clearance of 8 m.The tunnel is fitted-out with:1800 mm belt conveyor capable of 10 000 tph;walkway along which a specially designed inspection/ maintenance vehicle can run; andtunnel services including power, light, fire detection and suppression communications, water mains for wash down and sumps and pumps for drainage.This paper gives a general overview of the design and construct contract, important aspects of the design and the construction process itself.

Jan 1, 1999

By A Markham

Stream diversions are a common feature of mine sites worldwide. From an operational perspective, a fundamental requirement of a stream diversion is that it should convey water flows between two points in a safe, controlled and predictable manner. On the other hand, rivers and waterways are naturally dynamic systems, and many of their natural values are achieved through their ability to alter their forms and processes over time in response to flow events - often in a potentially unsafe, uncontrolled and unpredictable manner. In order to ensure that diverted river reaches achieve the dual objectives of short-term operational stability and longer term physical equilibrium with surrounding landscapes, alteration of form and process must somehow be understood and incorporated into the design process. However, performance targets for waterways are not always easy to define and assessing what is good and bad in such variable systems can be difficult. This paper discusses the role of the stream diversion from the operational, environmental and regulatory/relinquishment perspectives, and how stream diversions must achieve physical stability in the short-term, but dynamic equilibrium in the long-term.CITATION:Markham, A, 2012. Mine site stream diversions - A balance of competing objectives, in Proceedings Life-of-Mine 2012 , pp 215-218 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 10, 2012

By Y Peng, D Wannas

In the fine particle flotation technologies being developed today the fine hydrophilic (gangue) particles are usually well dispersed. These highly dispersed fine particles can be recovered into the flotation froth product by mechanical entrainment. Flocculation of hydrophilic particles caused by polymer depressants could potentially reduce the mechanical entrainment of these particles. This paper reports testwork completed on fine particles of several solids, iron oxide, hydroxylapatite, galena and sphalerite, as well as on a relatively coarse quartz sample (-75+38 ¦m). Dodecylamine was used as a collector for the quartz, and several dispersants and polymer depressants, including sodium silicate, sodium metaphosphate, zinc sulfate, potassium dichromate, corn starch, corn dextrin and carboxymethyl celluloses (with molecular weights of both 700 000 and 80 000) were used as flotation modifiers. The major part of the testwork involved flotation tests in a 200 ml flotation column. Both water and solid recoveries were recorded. The degree of flocculation and dispersion was determined by settling tests in 250 ml graduated cylinders. It was observed that flocculation of the fine hydrophilic particles significantly reduced their mechanical entrainment, while dispersion severely aggravated it. Thus, in the flotation separation of artificial mixtures of the -75+38 ¦m quartz and fine iron oxide or hydroxylapatite, polymer depressants that caused flocculation were found to perform better than the ones that did not cause flocculation.

Jan 1, 2005

By J S. Kuszmaul, T O. Aspinall

The applicability of environmental geotechnics for erosion management is increasing in importance worldwide. The environmental impact of mining and evolving environmental legislation has been receiving increased attention worldwide in the last two decades (Bradfield, Shultz and Stone, 1996). The potential impacts associated with unstable spoil dumps from mine operations is the focus of concern both by the mining industry, environmental legislative agencies and members of the public. This is because of the need to increase the reliability of erosion prediction and in the minimisation of costs for spoil dump design. Engineered slopes of mine spoils may be stable at the end of construction, but they can deteriorate over time. Engineering design of mine spoil dumps seeks to reduce the potential for such erosion damage through correct selection of an initial stable landform scheme (Goh, 1997). The design of mine spoil dumps must also conform to the specifications of evolving legislation. The Queensland Environmental Management Overview Strategy (EMOS) states that, for minimised degradation of the surface area due to erosion during the development of a project, the erosion rates should be between 12 - 40 tonnes/hectare/year and that the depths of rills and gullies be limited to less than 30 cm (QDPI, 1988). The aim of engineering design is to ensure the long-term stability of the spoil dumps. The implementation of effective planning and operating procedures through recontouring and grading assists in the reshaping of spoil dumps to a safe, stable and non-erodible environment.

Jan 1, 1998

By A Cranley, A Giblett, S Thacker

The Newmont Tanami Operations are located in the Northern Territory, approximately 550 km north-west of Alice Springs. The Granites process plant commenced operations in 1986 as a 300?000 t/a ball mill / carbon-in-leach (CIL) plant and has undergone numerous expansions between that time and the current day, with project-to-date gold production exceeding 6.5 Moz. Annual plant throughput has exceeded 2.8 Mt/a while processing a blend of open pit material and ore from the Callie Deeps underground mine, with annual gold production exceeding 400 koz. In 2013 the operation processed 1.8 Mt of underground ore for the production of 323 koz of gold.This paper reviews the operation and expansion of The Granites process plant since the mid to late 1980s with particular focus on the gravity gold recovery circuit. The Tanami ores contain significant levels of free gold, and gravity recovery has long been an integral component of the metal recovery process at the Granites plant. The results of ten years of gravity circuit performance analysis and optimisation are presented.CITATION:Giblett, A, Cranley, A and Thacker, S, 2014. Three decades of gold production at the Newmont Tanami operations, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 209–216 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

Attempt has been made to determine the nature of charge on activated carbon surface by studying the electro-kinetic properties of the carbon in the presence of cations, anions and aurocyanide solutions. The zeta-potential measurements were made in the presence of individual ions and also in combinations. The cations and anions chosen were those commonly associated with gold bearing ores in Kalgoorlie area. It was found that the iso-electric point of Norit Carbon was at pH 4.45; below this pH the charge was positive, while above, it was negative. In the absence of gold cyanide solutions and in the presence of individual cations the i.e.p. shifted to the alkaline range (pH 7.2-8.5) while in the presence of anions the i.e.p. was shifted to less than pH 3.5. In the presence of aurocyanide solutions, the iso-electric point was still in the acid region irrespective of whether anions or cations were present. The probable mechanism for such a behaviour has been attempted after measuring the specific conductivities of solutions before and after gold adsorption, by studies using the electron- probe-mirco-analyser, and S.E.M. on the carbon surface.

Jan 1, 1982

By G Byrne, A Bowden

There is often a difference in opinion about the allocation of risk in the establishment of mine closure bonds or financial assurances. From the State’s perspective, protection is needed to ensure that the broader community is not left with the liability of properly closing a mine in the event of a default by the mine operator. Such a default might occur where an operator decides to abandon a site, perform incomplete rehabilitation, becomes insolvent or claims limited liability. On the other hand, mine operators who can demonstrate a strong financial position plus a record of social and environmental commitment and performance, argue that there should be some recognition of this in setting a bond that is less than the full cost of early closure. They argue that a mine rehabilitation bond based on the full cost of early closure is overly conservative and ignores the actual risk of the operator being in default. This paper examines an approach that incorporates the risk of default into the establishment of mine closure and rehabilitation bonds. CITATION:Bowden, A and Byrne, G, 2018. Mine closure bonds (financial assurances) – the ‘how much?’ conundrum, in Proceedings Life-of-Mine 2018, pp 32–34 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 25, 2018

By Phillips RN

Semi-confined, trachy-andesite sills which overlie the German Creek Seam, within the critical tensile strain zone, form major groundwater hazards to longwall mining at the German Creek underground mines. The water contained in these aquifers is normally neutral, but highly saline. Techniques used to detect aquifers include routine air-lift pumping in exploratory drill holes, downhole geophysical and geological logging and upstage packer testing. Hydraulic constants are calculated from pump-out and pump-in test results. Hydraulic parameters for the calculation of mine inflow rates are determined from pump-out test results because these tests appear to be more representative of aquifer drainage during goat dewatering than pump- in testing. During mining of the first longwall block at Central Colliery, caving fractures intersected overlying aquifers after the longwall had retreated 40m, and mine water inflow rate rapidly increased from less than one litre/sec to 25 litres/sec. The amount of water pumped out of the mine during first panel extraction was 140 megalitres with drawdown occurring over an area of 168 hectares. In the Southern Colliery area approximately 324 megalitres of highly saline water which is actively stored in the Aquila Sill area will be pre-drained from six well points prior to longwall mining. With effective pre-drainage from surface drill holes, maximum inflow rate into the mine during initial goafing can be reduced from 165 litres/sec to about 45 litres/sec.

Jan 1, 1988

The first step in the mining and processing of nearly any mineral ore is comminution. Since the oil embargo of 1979, the mining companies have been striving to reduce energy consumption and costs. The first serious step was the introduction of in-pit crushing in the early 1980s. With in-pit crushing accepted as a standard design mode, the energy saving emphasis turned to comminution practices. A great deal of attention has been focused on blasting and grinding. The one step that has not been addressed is the primary crusher. This paper will address the opportunities for comminution improvement through optimisation of the primary crusher.

Jan 1, 2004

By R Ahola, M D. Henschel, M A. McParland

With the introduction in recent years of third-generation interferometric synthetic aperture radar (InSAR) techniques, monitoring of mine slopes, benches and surrounding areas has benefitted from increased accuracy and coverage. Fundamental research into point and distributed scattering techniques has pushed the use of InSAR to provide higher spatial and height resolution. In this paper we discuss the operationalisation of third-generation InSAR techniques and show its application to active mining operations.This paper will discuss the use of multiple independent measurements of ground movement obtained from operationally-derived InSAR products over a wide variety of deformation areas within an active open pit mining operation (ie pit slopes, dewatering depressions, tailings containment and waste dumps). A technique that shortens the time between observations (increased observation frequency) and provides ongoing estimates of measurement accuracy will be described. The methodology exploits available satellite data by using multiple satellites and multiple beams. The paper will also examine factors in the design of a mine survey with third-generation InSAR and illustrate some of the necessary engineering trade-offs to efficiently monitor a mine from space.Overall, this paper aims to demonstrate the capabilities and advantages of operational third-generation InSAR techniques for ground movement monitoring of mining operations and provide a framework for proper design of a mine InSAR survey.CITATION:Henschel, M D, Sato, S, Ahola, R and McParland, M A, 2014. Designing interferometric synthetic aperture radar surveys for mine monitoring with accuracy assessment, in Proceedings AusRock 2014: Third Australasian Ground Control in Mining Conference , pp 233–238 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 5, 2014

By Wood CJ, Davis JJ, Askew H

A dynamic model of a dense medium circuit has been developed and tested against plant data. The model shows the response of the circuit to both controlled (changes in specific gravity set point or changes in circuit coal feed rate) and uncontrolled changes (changes in raw coal moisture, loss of raw coal feed) in operating conditions. The model is built up from dynamic models of the individual sumps, pumps, pipes, splitters, magnetic separators and automatic controllers in the circuit. The model can be used for design of automatic control loops and for investigation of possible process modifications such as changes in water addition points. This paper describes the model construction, the testing of the model against actual plant data and gives some examples of its use in investigating plant response to changes in operating conditions.

Jan 1, 1978

By D R Quick

The Goodall gold mine is located 30 km east of Adelaide River, within the Pine Creek 1:250 000 map sheet, at 8 525 000 mN: 750 000 mE, on the AMG grid. The first gold was poured in April 1988 and the mine closed in September 1993, having produced 228 400 ounces of gold from 4.095 million tons of ore, at a head grade of 1.99 g/t. Oxide and primary ore was mined from one large open cut and low grade oxide ore from three smaller pits. The gold mineralisation was discovered in 1981 by means of a helicopter borne rock chip sampling survey, which delineated 13 discrete anomalies. Systematic grid sampling of rock chips outlined an area of 1300 m by 300 m within the 2.0 g/t contour. Over 7500 m of costeaning was used to delineate the A and B-Pod mineralised areas. Geochemical soil sampling played only a minor role in the discovery and geophysics none at all. By the end of 1984, 40 diamond drill holes had been completed and a resource of 3.63 million tonnes at 3.0 g/t calculated. In January 1985, Western Mining Corporation Ltd became a joint venture partner and funded exploration to cam a 60 per cent interest. Additional drilling led to a feasibility study in 1987, based on a Measured and Indicated resource of 4.25 million tonnes at a grade of 2.35 g/t. The host rocks are quartzo-feldspathic wacke and interbedded phyllitic siltstone, of the Proterozoic Burrell Creek formation. The main zone of gold mineralisation, A-Pod, occurs in a sub-vertical vein array, up to 50 m wide and 800 m in length, of quartz and sulphide veins (5-20 mm wide), It is parallel to and on the east limb of an upright, north plunging anticline. Five types of veining have been recognised, with the bulk of the gold mineralisation associated with quartz-pyrite-arsenopyrite and chlorite-quartz-pyrite veins. The gold occurs as particles, from 1-20 micron, as inclusions and along fractures in pyrite and arsenopyrite and to a limited extent in chlorite. The mineralisation is epigenetic and structurally controlled by fractures developed during an earlier folding event. The gold is assumed to have been derived from the underlying sediments of the Koolpin Formation by hydrothermal fluids emanating from the deep seated northern margin of the Cullen Batholith. Precipitation of gold may have been controlled by variations in temperature and pressure.

Jan 1, 1994

By Maiman R

One method of forecasting prices of metals is based on analysis of historic relationships between prices, inventories and consumption. The first, but generally overlooked step in this analysis should be to remove from the inventory and consumption figures the effects of seasonal variations. The next step is to construct diagrams which show prices plotted against ratios of inventories to consumption. These diagrams indicate that, when inventories are high, prices show little response to changes in inventories. Below a critical level of inventories, however, the psychology of the market changes and small changes in inventories lead to large moves in prices. The critical level of inventories is termed the "pinch-point"; the diagram which shows prices in relation to ratios of inventories and consumption may be called a "pinch-point diagram".

Jan 1, 1990

By Y, Li Jianxiong, Hu Hua, Gu Desheng

After having briefed the technical and economical advantages of continuous mass mining in underground metal mines, the authors discuss the four stages of research and development of continuous mass mining in China. The four stages are: vibrating ore drawing in a stope, continuous mass mining in a stope continuous mass mining without rib pillars in an area and continuous mass mining in whole mine. The authors briefly review the research achievements of the first and the second stage; Combining the key national research project of the æNinth Five Year PlanÆ ù æThe experiment and research of continuous mass mining without rib pillarÆ, the authors introduce in detail the technological condition of mining, the design ideas of continuous mass mining, the design scheme of mining, the technology of mining. the equipment of mass mining, the chief research achievements and so on. The success of research of continuous mass mining without rib pillar indicates the arrival of the third stage of research. The introduction of continuous mass mining will promote the technology revolution of mining in China remarkably. The authors also point out that the development direction of continuous mass mining of the 21 century is continuous mass mining in whole mine, which is the fourth stage of research.

Jan 1, 2000

By A Radici, M Attwill

The Dampier Port Upgrade Project (DPU) involves an upgrade to Hamersley IronÆs Parker Point iron ore port facility at Dampier, Western Australia. The $US700 million DPU Project will increase Hamersley IronÆs shipping capacity at Dampier from 72 million tonnes per annum (Mtpa) to 116 Mtpa. The DPU Project comprises a new car dumper facility and rail spur, an upgrade to the existing stockyard and conveying system, a new screen-house and a 450 m wharf extension with two new shipping berths and a new ship-loader. This paper discusses the innovative design and construction of the new car dumper facility, which is capable of automatically unloading 240 car iron ore trains at a rate of 10 000 t/h. The facility design is unique compared to more conventional designs currently in operation, and greatly improves operation and maintenance functions.

Jan 1, 2005