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By M M. Hilden, M S. Powell, B Foggiatto

In an environment of decreasing ore grade, increasing costs and uncertainty with respect to commodity prices, the industry could benefit from evaluating alternative technologies and innovative circuit configurations. The flexible circuit approach suggests that the design of grinding circuits can be adapted to changes in feed properties and economic conditions. Advances in modelling and simulation are enabling metallurgists to predict the performance of more complex circuit configurations with increased confidence. Ore variability information and processing costs may be used as modelling inputs to determine the optimum processing conditions at a given time. A case study has been completed demonstrating the value of combining a flexible circuit with a model-based optimisation of the process. Ore properties and equipment performance data obtained in operating plants have been used to model and simulate flexible circuit configurations.This paper explores strategies to introduce flexibility to existing circuit configurations when processing ores with high variability. Multicomponent models incorporated in the model developers’ kit (MDK) allow the simulation of more complex and flexible circuits. This capability enables demonstration of the potential to enhance metal production through adapting processing routes according to the ore type being processed. The simulation of different flow sheet configurations allowed the definition of the best option for maintaining the metal production when treating lower grade ores, highlighting the advantages of flexible circuit configurations compared with a one-process-fits-all approach.CITATION:Foggiatto, B, Hilden, M M and Powell, M S, 2014. Advances in the simulation of flexible circuits, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 391–398 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

By G King, Q Shu, W Cao, F Gyakwaa, H Singh, S Wang, M Huttula, T Fabritius

Metallurgical slag, such as refining slag, is essential to enhance or promote steel cleanliness. The CaO–MgO–Al2O3–SiO2 system is the primary source of oxides-based inclusions. It plays a vital role in applications in various pyrometallurgical processes. Numerous thermodynamic databases and physicochemical properties of slag studies mainly focus on quenched samples and measurements at room temperature. Consequently, the present study explored the physicochemical, structural properties and crystallisation evolution for CaO–MgO–Al2O3–SiO2 glassy slags via in situ hightemperature Raman spectroscopy and synchrotron X-ray diffraction. The study was carried out by synthesising CaO–MgO–Al2O3–SiO2 slag with varying Al2O3/SiO2 ratios. The results from the in situ high-temperature measurement demonstrated a pattern showing a transformation of a broad peak from the glassy matrix to crystalline peaks. The study showed crystallisation of dominant phases such as Ca2SiO4, Ca2Al2SiO7 and CaAl2O4 that correspond and are attributable to changes of structural units during in situ high-temperature measurements. The results further showed a correlation between an increase and transformation in crystalline phases observed from the spectra obtained from non-isothermal heating of the samples.

Jun 19, 2024

BHP Steel International's Newcastle blast. furnaces have operated since their caimissioning on cake based on local low rank coals. In the early 1960's Newcastle coke was believed to be the weakest in the world. Newcastle coke now supports a blast furnace operation with a productivity of 2.1 t/d.rn IV, a fuel rate of 490 kg/t and a coke rate of 415 kg/t. This coke is nuudv from blonds of lcxni and southern Sydney basin coals with blend Ro nex in the range 0.94 - 1.01. Blast furnace performance in periods of differing coal blends is conjured. The relationship between coal aril coke quality indices and blast. fin-mice perforrnarcc.e is discussed as well as the relevance of conventional coke tests. New BHP coke tests are referred to.

Jan 1, 1987

Woodlawn Mines began underground operations in 1986. At the time of going underground it was envisaged that there would be no 'contract' payment to the underground employees. This was a relatively unique step to make, especially as most major underground mines in Australia relied heavily on the contract system to motivate their workforce. (Obviously with varying degrees of success.) Woodlawn faced the task of motivating their employees through a multi-skilled system with a great emphasis on leadership and a genuine care for their employees. The 'proof of the pudding' is that Woodlawn has not lost any time over industrial issues since beginning underground operations in 1986. To achieve success in any operation the organisation must not only be advanced in its management principles but also be prepared to be innovative in the way it deals with physical problems, ie ground control, equipment selection and maintenance. Difficult ground conditions at Woodlawn have necessitated the deployment of two Cabolt Jumbos and the construction of cost-effective shotcrete systems. The shotcrete system now being built has been tested in a prototype form and is proving to be a safe and simple way to manage weak, low stress friable ground. Although the ground at Woodlawn has low stress component by virtue of the fact the ore can have a density of 4.5dm3, cable dowelling has become a necessity. The two cable dowel jumbos install high quality reinforced cables. The pressure of 'production' means that these machines must be consistently available for use and the training of maintenance personnel and operators ensures that a maximum of cable dowels can be installed over any given time span. In any modem mine ventilation is a primary concern and the major area of concern comes from the vehicles themselves. In our recent replacement for the standard 'Toro' loader, three engine options were considered. A relative newcomer to underground mining was accepted. The Detroit 60 series (DDEC) engine came with a great reputation and has lived up to this. The engine has an electronic management system that reduces particulates to a hardly visible minimum, provides great amounts of engine power and reduces fuel consumption by approximately 45 per cent. The operational benefits of such an engine are worth sharing through this conference.

Jan 1, 1995

By Mance G

Today there are many different techniques of soil remediation used in Australia and throughout the world. This paper considers the thermal desorption remediation technique and, in particular, the application of high temperature filtration to the process. The thermal desorption technique involves the treatment of hydrocarbon (oil, petrol, etc) contaminated soil. The process involves heating the soil in a retort or kiln to drive off the volatile organic contaminants. The exit gas stream from the retort is subsequently passed through an after burner to thermally oxidise the hydrocarbons. This technique produces soil and combustion gas streams which are free of hydrocarbons. Due to the heating and agitation of the soil within the retort, soil particles become entrained in the hot gas stream. To avoid the blockage and fouling of the system's interim ductwork and the afterburner, high temperature filtration technology has been applied to remove these soil particulates without cooling the gas Stream.

Jan 1, 1995

By Nidagal V

This paper discusses the dewatering strategy adopted and the considerations and procedures required to incorporate a dewaterinq scheme into the Mt Whaleback mining operation. It concludes that in pit pre-dewaterinq has successfully allowed mining to progress below the standing water level with the minimum of disruption or radical change to the mining method. It is recognised however, that dewatering is not a static activity and there is a requirement for ongoing investigations and development. Pre-dewatering commenced in October, 1984. Purpose designed pumping trailers have been employed to minimise the loss of pump availability resulting from the frequent. need to remove and reinstall pumps when close vicinity blasts occur. To July, 1986, some 0.5 Mm' of groundwater had been pumped from the unconfined orebody aquifer. Mining has progressed to some 20 m below the standing water level without. any undue water associated problems. Ultimately, it is ,cheduled to extend some 300 in below the original water level in the West Pit. With the development of an increasing area of the mine below the standing water level, the influence of seasonal high intensity rainfall events, which had previously caused little concern, now need to be addressed. Pumping equipment has been designed to evacuate storm water at a rate consistent with mine production Considerations.

Jan 1, 1986

Recent work on computerised mineral resource databases at the Institute of Geological and Nuclear Sciences Limited has concentrated on the development of the GERM, REGCHEM, and MINLIT databases, and their integration in a Geographic Information System using MapInfo software on an IBM-compatible microcomputer local area network. GERM (GEological Resource Map) is a mineral deposit inventory with national coverage and more than 10 300 entries. REGCHEM (REGional Exploration GeoCHEMistry) is a database of stream sediment analyses from open-file mining company reports, containing more than 14 000 sample sites from the Coromandel and west Nelson regions. MINLIT (MINeral LITerature bibliography) is an annotated bibliography of literature on topics relating to the exploration and geology of mineral deposits in New Zealand, and includes more than 5000 entries for published books and papers, and unpublished mining company reports, university theses, and government reports. Master sets of GERM and MINLIT continue to be maintained on a VAX mainframe network but REGCHEM is operated only in the PC environment using the Microsoft ACCESS database management system software.

Jan 1, 1993

By Watson DF

Calculation of the amount of metal in an ore deposit or mining block should be approached by multiplication and integration of appropriate numerical manifolds describing the spatial distribution of the relevant variables, viz. grade, specific gravity and also thickness for bivariate data. Construction of a numerical manifold necessarily involves some form of interpolation but detailed characteristics of this are often not specified in various automatic methods, some of which even provide manifolds with discontinuities. A manifold used in calculations should describe in a geologically plausible way the spatial distribution of the variable of interest. Different approaches to the problem are discussed and compared. Particular computational inconsistencies emerge when "accumulation" is used as a variable in calculations of average grade. If an ore deposit is variable in relation to its sampling and especially if selection of mining blocks according to grade cut-off is a necessary operational decision, the biases introduced by accumulation methods can bring about serious problems of over-evaluation. Modern computational techniques make unnecessary the use of accumulations; because of potential inconsistencies it would seem unwise to use them in any ore reserve computation.

Jan 1, 1987

By Esaki M, Nishimura K

This paper describes the results of the field application tests at Miike Colliery on the integrated automatization of the longwall mining system for medium thick coal seam. The purpose of the research is to develop an automatic longwall mining system which can be controlled accurately from outside of the face, and the ultimate goal is an eliminate of men from the face. Presently, the field test is being conducted in Yotsuyama mine following to a success in the performance test on surface. Remote Batch Control System for shield supports has been adapted to operate all supports from the control panel located at the entrance of the face. Remote monitoring and control system of the drum shearer has also been tested. The system makes it possible to operate the shearer either at the main gate or full automatic. Productivity and safety will be substantially improved as those systems enable to eliminate all workers from the face under the severe working conditions with high ground pressure and hot and humid atmosphere due to increasing mining depth. So far, we have been satisfied with the results of the field test and those system will be an effective countermeasure to operate the face with a high risk of rock-burst.

Jan 1, 1987

By Aspinall T. O, Just G. D

Computer software systems have been developed to assist in a wide range of specific mine planning and scheduling applications. In selecting appropriate systems for any mining operation it is apparent that certain features have particular advantages for each mine site. The ideal solution to this problem is to select a range of systems which best relate to sections of each mining operation. This approach raises potential data linking difficulties where output from one system is incompatible with input requirements for other systems. A study at the University of Queensland investigated the problems related to the integration of a number of mine planning and scheduling software systems. The project used data from large scale coal strip mining operations in Central Queensland. Two major computer packages used extensively in the study were the SURPAC mine planning and XPAC mine scheduling systems. Dragline and truck and shovel operations were analysed in the project. Results of the work have been directly applied at the mine site to assist current strip design by effectively automating the design procedure. This enabled sensitivity studies to determine the effects of changing dragline working levels and varying pit dimensions. Coal blending studies and procedures to optimise operations have been investigated using linear programming within a spreadsheet software application. Output from the SURPAC and XPAC programs was directly linked to the linear program for this analysis. The simulation program GPSS/PC was also used in a similar manner to assess optimisation parameters.

Jan 1, 1992

By A Yame, P J. Pollard, E Atase, J Garu, M Tangwari, D R. Hastings, R W. Smillie

"An EXTENDED ABSTRACT is available for download. A full-length paper was not prepared for this presentation. The Townsville prospect is situated approximately 4 km north of the Ok Tedi copper-gold mine in Western Province, Papua New Guinea. Drilling in the 1990s delineated a resource of >1 Moz of gold within shallow, skarn breccia-hosted mineralisation associated with quartz-carbonate infill, together with pyrite, chalcopyrite, pyrrhotite, sphalerite, galena, tennantite-tetrahedrite, arsenopyrite, marcasite, and a variety of Au-, Ag- and Bi-telluride minerals. The deepest of these historical holes (TVL034) also intersected copper-gold-silver mineralisation more than 100 m below the gold-rich zone that is associated with calc-silicate skarn breccia. Although copper-gold-silver mineralisation in DDHTVL034 is associated with clinopyroxene-rich skarn, it was also noted that garnet in the skarn breccia became progressively darker in colour with depth, ranging from green at shallow levels to dark red-brown at depth. This indicated that the skarn breccia is zoned, with more proximal garnet skarn at depth possibly indicating an association with porphyry-style copper-gold mineralisation.Based on this skarn zonation model, recent drilling at the Titan prospect, located approximately 500 m south of TVL034, was targeted at potential copper-gold silver mineralisation beneath shallow skarn breccia-hosted gold mineralisation. DDHTVL 081 intersected 46 m at 6.36 g/t Au from 68 m and 80.7 m and 1.67 per cent Cu, 1.27 g/t Au and 20.32 g/t Ag from 184 m. Exploration is now attempting to define the extent of copper-gold-silver mineralisation by defining structural controls on the skarn breccia together with paragenetic and mineral zoning data.CITATION:Smillie, R W, Pollard, P J, Hastings, D R, Yame, A, Tangwari, M, Garu, J and Atase, E, 2015. Exploration of the Townsville Cu-Au-Ag skarn, western province, Papua New Guinea – preliminary observations of paragenesis and zoning, in Proceedings PACRIM 2015 Congress, pp 593–600 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Mar 18, 2015

The results expected from a longwall face can best be estimated from the ideal production rate, determined by the capacity of the equipment and the conditions in which it is installed, the effective operating hours, and the utilisation.The effective operating hours are determined by a number of scheduling factors which include the proportion of manned time to calendar time, the effective shift factor (effective time to manned time) and the move times.Analysis of the results achieved on the last 121 completed longwall panels in Australia (1984 onwards) shows a significant trend between 'actual tonnes/manned hour' and 'ideal production rate' (the measure of the capacity of the installation).Using 1982 'state of the art' longwall equipment, (the average in use in the seven year period), it should be possible to produce around 2.7M tonne/year ROM from a mine with one longwall. Few mines are achieving this.A review of production scheduling factors and general natural hazards affecting some mines suggests three things.1. Whilst some increase in average effective hours has followed the CIT decision, further improvement is possible at many installations.2. Many mines subject to general natural hazards, such as high gas make and high general stress, have found effective solutions and achieve the same utilisation as the overall average.3. A small number of faces within such mines have been severely affected, some less so. The most severe effects of natural hazards appear to be very site specific. This emphasises the need for detailed investigation of the causes, and development of means of predicting their presence. Only then can either satisfactory technical solutions be found to overcome the problems or prior decisions be chosen not to mine badly affected panels.

Jan 1, 1991

By Campbell Brown G A

IN 1904-5 diamond drilling operations in the Mount Morgan mine proved the presence of some millions of tons of rich copper-gold ore, averaging about 45%to 50%silica and 22%Fe as sulphide. To smelt this ore in blast furnaces, without previous concentration, large quantities of basic flux were required. Unlimited quantities of cheap limestone were available at Marmor, on the GladstoneRockhampton railway, 50 miles from Mount Morgan, but the supply of iron flux was a more difficult problem. Smelting Operations started with one furnace in January, 1906, using as flux low-grade sulphide ore from the mine, containing very little silica. When the second furnace was blown in this was supplemented by ironstone from small deposits in the immediate district. It was recognized that these sources of supply would be insufficient to keep the full plant going after the third furnace had been blown in. Accordingly, the deposits at Kabra and Mount Etna were opened, neither of which proved capable of supplying the quantity required-viz., 1000 tons per week. Negotiations were meanwhile being conducted with the Marble Island Iron and Limestone Co. to obtain the right to mine at Iron Island, where a sufficiently large deposit was known to exist. Shipments from this source commenced in January, 1907, and ceased at the end of July of this year, when the metallic flux from...

Jan 1, 1911

In the general planning of this area, provision was made for the distribution over the whole area as required of the following services:(a) Power and lighting from the substation distribution boards 'located in the winder house.(b) Miscellaneous electrical indicating, control and signalling systems.(c) Telephone lines from the main internal automatic exchange located in the changehouse, the town exchange to the automatic exchange and also direct lines from the town exchange to selected offices.(d) Compressed air from the incoming 16-in. air main. (e) Water, both unfiltered and filtered; and the disposal of the following effluents:(f) Sewage from the area to the town sewage system.(g) Changehouse shower water to the regeneration area.(h) Storm water to the general mine surface drainage system leading out to the naturally drained area north of the No. 8 Shaft.

Jan 1, 1957

Since I first enrolled to study Mining Engineering, the idea of working with big machinery and explosives has always appealed to me. After a few courses at uni, combined with vacation work and a number of presentations at the New LeadersÆ Conferences I had attended, I began to realise that the explosives side seemed to have more appeal than the others. As I look back on the past two and a half years that I have spent with Orica Australia Pty Ltd as part of their graduate program, I would have never imagined the dynamics of explosives in mining. This I put down to the ever changing and rapid development in technology converting blasting techniques into a defined predictable science. The opportunities I have been given have delivered all the appeals from when I first started my study. As a result of my entry into a profession that uses explosives to deliver broken rock in a range of mining and construction projects, through the use of advanced blasting technology and products, my experiences have been wide and varied. These experiences have included the use of OricaÆs i-konÖ detonator technology and blast design software to allow for blasting operations to occur in a range of environmentally sensitive quarrying and construction projects throughout New Zealand, to the implementation of various Orica blast based services aimed at improving dragline dig performance and reducing coal loss thus improve overall mine sustainability in the coal mines of Central Queensland, to the advanced utilisation of Orica explosive products and technology in a number of the worlds largest copper mines in Chile. I have witnessed first hand the blasting technology available within Orica Mining Services to both deliver fundamental changes in mining results and in turn kick off my career with a bang.

Jan 1, 2009

By L M. Foster, J R. Kellett, G A. McMah

The Great Artesian Basin (GAB) contains one of the largest reserves of fresh water in the world. The volume in storage is enormous, being estimated at nearly 65 000 million megalitres (ML). Development of this resource, dominantly for the pastoral industry, began in the late-1800s and quickly accelerated. With exploitation of the resource, artesian pressures declined almost as rapidly. This loss of head is a result of the total discharge from the basin and much of this discharge is waste of water. The waste through uncontrolled bores and inefficient distribution systems still amounts to about 75 per cent of all discharge. However, the volume in storage has hardly been depleted. The major concern is the effect of withdrawal on artesian pressures. Due to the size of the Basin, the relatively flat gradients and low permeability, the movement of water through the aquifers is extremely slow and independent of recharge. Hence, the normal concepts of sustainable yield (ie discharge should equal recharge) cannot be applied to the Basin as a whole as travel times do not allow for the effect of recharge to be seen away from the outcrop areas within management timeframes. The large volume in storage, though, can provide an extensive buffer to the impacts of temporary water needs. This effect should be considered when assessing the acceptability of fixed life projects such as mines and the extracted volumes from their operations. Identifying a sustainable yield involves balancing the acceptability of the economic, environmental and social costs with the associated discharge and fall in head, to arrive at an acceptable balance.

Jan 1, 2003

The Porphyry Gold Mine (150km NE of Kalgoorlie) was reopened in November 1983 with production commencing in April 1984. Original reserves quoted for the open pit were 822000 tonnes at 5.2 g/t Au based on wide spaced diamond drill holes. Close spaced grade control drilling has revealed some loss of tonnage and a significantly lower grade. In the area of the pit mined to 30 June 1985 this grade control reserve estimate contained 67% of the gold in the original ore reserve with the grade being 19% lower. It is anticipated that the final grade control reserve estimate will contain around 80-85% of the gold contained in the original reserve. There has been close agreement between the Mill Head grade (4.19 g/t Au) and the grade control predicted grade (4.2 g/t Au) confirming that dilution is not a major problem. After initial poor agreement (attributed to "lock-up" in the circuit) the bullion calculated head grade steadied out at 93% of the grade control prediction. This difference is considered to represent the geostatistical bias in the drill hole/crushed rock sampling. Gold recovery has been in the range 93-95% (compared with bullion calculated grade). The net result is that the recovered grade of ore mined to 30 June 1985 is 70% of the original ore reserve grade.

Jan 1, 1986

By M Wortley, A Cantarutti, T Ozkocak

The estimation of the grinding mill charge weight is vital to ensure its efficient performance. Mill underloading or overloading can cause losses through decreased production or unplanned down time. Metso Minerals Process Technology Asia Pacific and South America (MMPT) has developed two systems for measuring mill load. The first is an acoustic system (SmartEarÖ) and the second is an online model-based charge estimation system. The aim of both systems is to facilitate better operation of grinding mills. SmartEarÖ performs analysis on an audio signal from the mill and allows each different frequency component to be viewed, analysed and used in process control for load estimation. By isolating different frequencies, SmartEarÖ can give an estimate of mill load. The online dynamic mill model uses measurable mill parameters (such as power) to predict the current total load. Kalman filtering can also be utilised to further increase the accuracy of the model. Both of MetsoÆs systems have been installed at BHP BillitonÆs Cannington mine to measure the load within their autogenous (AG) mill. In this paper, the methods of mill load estimation are reviewed and compared to the bearing pressure reading, which is the current method used by Cannington to control mill load. The redundant estimates of mill load provide increased confidence and consequently more robust grinding operation under a wide range of conditions.

Jan 1, 2008

Traditionally, the predominant drilling method in open pit mining has been large hole rotary drilling using cumbersome, inflexible equipment offering merely limited scope for improvements in pit design and overall costs. By contrast, the recent development of comparatively light high-pressure down-the-hole hammer crawlers has paved the way for new ideas and trends. High penetration rates coupled with superior mobility and fast set-ups contributing to substantial productivity gains have resulted in a renascence for this drilling method in open pits. The ability to cover a wide range of hole diameters and angles gives designers unique drill pattern possibilities especially when establishing steep and stable pit slopes. As pre-split holes, buffer holes and production holes all can be drilled by using the same equipment, there are, there are obvious advantages in production scheduling as well as in materials handling and service. This paper presents some case stories, which will demonstrate the benefits and improvements that the introduction of new drilling methods and equipment has brought to open pit mining operations.

Jan 1, 2003

The gossan developed from the Whim Creek Cu-Zn-Pb-Ag sulphide deposit, in the Pilbara region of Western Australia, occurs near the top of a ridge in a dissected plateau 01 moderate relief. The gossan is characterized by the abundance of secondary ore minerals which indicates that it is relatively immature, due to climatic conditions and erosional stripping.The abundant presence of secondary carbonates indicates that the low pH generally resulting from sulphide oxidation has been neutralized, probably by the buffering effect of carbonatcs and silicates. Fe, Cu, Pb, 'Ag and Sn have been enriched in the gossan relative to the primary ore, and Mn, Ti, Co and Ni have been strongly depleted; other elements have remained substantially unchanged. The gossan has a strong gcochemical signature characterized by high Cu, Zn, Pb, As, Sb, Sn, Ag and Mo coutents. Boxwork textures are poorly developed, bu't the gossan has other diagnostic mineralogical features including sulphide inclusions in quartz and the presence of residual cassiterite.

Jan 1, 1982