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By J Stipcevich, N Patel, J Faithful5, S Narendranathan, L Tatnell4

ENGIE, the current owner and operator of the Hazelwood Open Cut coalmine, are in the process of rehabilitating the mine site in preparation for mine closure. Bucket wheel excavators (dredgers) used during coal mining operations are in the process of being demolished, which involves the controlled felling of dredger components using explosives. With the mine located in close proximity to the Morwell township and other critical public infrastructure, it is crucial that the use of explosives and the possible implications for mine stability is well understood. The felling of Large Mining Equipment (LME) will apply an impact load immediately to the underlying coal benches with the adjacent coal batters potentially at risk also of adverse slope stability impacts. This paper presents the 3D stability modelling methods employed to successfully assess the potentially adverse stability implications associated with LME collapse.

Jun 21, 2022

By T Takayama, M Matsumura, Y Konno

The steel industry accounts for 14 per cent of domestic CO2 emission in Japan, and iron ore sintering process occupies approximately three per cent. While Fe content in iron ore is gradually decreasing. So, the amount of concentrated iron ore will increase in the future. We have focused on magnetite concentrate as sinter materials, because magnetite can be easily magnetically beneficiated. However, it is experienced that blending magnetite ore resulted in increasing Fe2+ component in the iron ore sinter, which results in lower reducibility. Therefore, promoting the oxidation reaction from magnetite to hematite in the sintering process is countermeasure for reducibility. In addition, this promotion causes increase of oxidation heat, which results in high sinter strength and reduction of coke. It is assumed that the oxidation of magnetite tends to proceed in the cooling stage, where the oxygen partial pressure increases after the combustion of fine coke, but there are few studies on the effect of heat profile, especially cooling path. The purpose of this study is to design the effective sintering heat profile to promote oxidation of magnetite ore, especially, to investigate the effect of cooling path on sintered ore microstructure. In this study, magnetite ore and magnetite reagent were respectively mixed with calcium carbonate reagent. Then the mixed samples were pressed and formed into cylindrical tablets for simulating the adhesive layer of a pseudo particle. Through examining influence of maximum temperature and cooking rate on oxidation reaction of magnetite, we confirmed that the oxidation reaction of magnetite is suppressed at above 1350°C for maximum temperature, compared to 1300°C. Sintering at lower temperature is desirable because hematite is stable below 1350°C in the Fe2O3-CaO phase diagram.

Nov 8, 2021

By R Berry

This paper looks at two ways to estimate the bulk mineralogy of the rocks for assay intervals. The aim is to find an efficient indicator of the most common minerals in the rock. Phase (modal) analysis has traditionally been done using visual methods such as point counting and image analysis. A modern version of this process is the X-ray point counting routine using the SEM-EDS based software. These methods are too slow and expensive for routine analysis of bulk sample mineralogy at the normal assay spacing.Two sources of data were considered that provide information that can be used to determine the mineral abundance in assay samples. The most widely applied method is (semi-) quantitative X-ray diffraction (QXRD). The QXRD method is most applicable to major minerals and has limited application to minerals at low abundance. The nominal detection limit is 0.5 per cent. Values below five per cent have large errors. A second, less common, method is calculation of mineralogy from chemical assay data. Conversion of chemical analyses to mineralogical analyses depends on the unique chemical composition of each mineral. Elements only found in one mineral are easily accounted for, but many compositions are ambiguous. Deciding on the actual mineralogy is not simple. Recalculation of mineral mode from chemical analyses is more accurate than QXRD when the correct minerals, and mineral compositions, are known.Where only a few QXRD analyses are available they can be used to setup a protocol for calculation of mineralogy from assay data. Linear programming works well in this environment. The best results are obtained when both H2O and CO2 are directly measured. Loss-on-ignition (LOI) should be included if these are not available.Where both QXRD and chemical analysis are available for all samples, the best results are obtained using the least squared method to merge the data sets assuming QXRD has much higher analytical errors than chemical assays. The combined method provides more robust results because the high abundance minerals are controlled by the QXRD measurements while the chemical assays improve the precision for low abundance minerals

Sep 5, 2011

By T J. Laing, A B. Richards, A J. Moore

Blastholes fired in a pattern with a constant initiation delay create a frequency in the ground vibration similar to that from a percussion instrument, such as a drum, in the air. A constant firing delay generates a prime or forcing frequency into the ground motion. The forcing frequency may then be modified by ground transmission characteristics into subharmonics of the forcing frequency. The moving vibration source between blastholes also creates a frequency shift because of a Doppler effect. Other wave interactions may form beats. The effects are exacerbated by the accurate firing times of electronic detonators. This paper demonstrates how observations of wavetraces and frequency spectral analysis were used to recognise:Doppler effect and frequency ellipsoidssubharmonics (and sub-subharmonics) of the forcing frequencybeat formation that may double or triple peak particle velocity (PPV) levels.Recognition of beats permitted techniques to be used to control ground vibration from coal overburden blasting to limits deemed to cause no further instability in a slip failure. An understanding of the science involved has practical application elsewhere that has been successfully applied to initiation timings to reduce PPV and adverse human and structure response from other blasting operations.CITATION:Moore, A J, Richards, A B and Laing, T J, 2015. Blasting harmonics and controlling peak particle velocity, in Proceedings 11th International Symposium on Rock Fragmentation by Blasting, pp 527–532 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 24, 2015

By C Torrisi, J Andreatidis, M Duffy

BHPÆs Cannington process plant was commissioned in October 1997. The Cannington ore contains high grades of silver, lead and zinc but also contains high levels of fluorine which must be removed to produce a marketable concentrate. As a consequence the plant is more complex than the typical base metal concentrator. Some of the features of the Cannington operation include a single stage autogenous mill, multiple stages of flotation cleaning, two leach circuits, pressure filtration and a paste fill plant. The start-up and achievement of design performance for new lead/zinc operations has traditionally taken much longer than for gold or copper operation and is littered with many tales of woe with feasibility targets often not achieved (Agarwal, Brown and Katrak, 1984; Bulatovic and Wyslouzil, 1999; Leung, Andreatidis, Woodall and Alford, 1996; Sherman, 1999; Ward, 1998).

Jan 1, 2000

By D David

Geometallurgy is often a misunderstood and poorly defined concept. The first thing the paper will attempt is to provide a definition of geometallurgy. Ultimately this paper has been written to provide guidance to geologists, mining engineers and processing professionals as to what geometallurgy means in the crucial early phases of a potential mining project between the time of discovery and the time of commencing construction, should this occur. The paper covers the options available for conducting a geometallurgical study of a resource or orebody, appropriate to the level of definition required in the projectÆs development cycle. The paper will then describe how the geometallurgical information generated is subsequently used in calculations, planning and preparation of reports designed to inform and reassure stakeholders, such as the market. Ultimately in a successful project, appropriate options adopted in the development phase will form the basis of an ongoing geometallurgical program that links the major site disciplines for the good of the operation.CITATION:David, D, 2013. Geometallurgical guidelines for miners, geologists and process engineers - discovery to design, in Proceedings The Second AusIMM International Geometallurgy Conference (GeoMet) 2013 , pp 129-132 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 29, 2013

By G Lane, M Bueno

In a recent publication (Bueno and Lane, 2011) the authors presented the analysis of a consolidated dataset composed by 137 autogenous/semi-autogenous grinding (AG/SAG) mill pilot trials. By comparing the measured data against theoretical specific energy consumption, the analysis indicated which circuit configurations were more or less energy efficient. However, the analysis has also indicated that the energy efficiency of each of the types of circuits vary significantly.There are numerous factors that contribute to the variations of energy efficiency of AG/SAG mill-based circuits, such as feed size distribution, recycle ratios and ore characteristics. In view of this, the present work accesses these factors individually and discusses what may lead a particular circuit configuration to be more or less efficient in terms of energy and costs.CITATION:Bueno, M and Lane, G, 2012. Key drivers of energy and cost efficiency in autogenous/semi-autogenous grinding circuits, in Proceedings 11th AusIMM Mill OperatorsÆ Conference, pp 113-118 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Oct 29, 2012

By K Barbosa, G Wilkie, F Reyes, V Jokovic, C Evans

The idea behind Grade Engineering is to exploit the natural heterogeneity of an orebody (spatial, temporal) in order to divert low-value waste out of the mining value chain. Essentially, this involves rejecting material at relatively coarse particle sizes (10 mm to 200 mm). However, lack of knowledge about the inherent particle grade distributions in these coarse particle size ranges limits the opportunities for optimisation. Particle grade distributions are essential for quantifying and modelling gangue liberation and yield curves. These curves can then be used to predict the mass and value flows that will go towards the accept and the reject streams. Particle grade distribution information for particles coarser than 10 mm can be collected based on chemical assays of sufficient number of individual particles. However, for smaller particles (1 mm to 9 mm), a significantly larger number of particles is required for assays. Moreover, in some cases, the mass of individual particles is smaller than the minimum mass required for chemical assaying. Also, other quantification techniques such as automated mineralogy, eg Mineral Liberation Analysis (MLA), require extended measurement times to analyse statistically representative numbers of particles at these size ranges. This work investigates the use of 3D X-ray microtomography to fill this quantification gap at these size ranges (1 mm to 9 mm). In-house image processing algorithms are used to estimate the mineral/metal content in each particle. Particle grade distributions, as well as density distributions, are thus produced without a minimum mass requirement and with each scan providing information about tens to hundreds of particles at a time. Mineralogical data from MLA analysis, of finer size ranges, is used to inform X-ray microtomography, so a simpler 3D mineral map can be obtained using the image intensity. Chemical assay information of the scanned samples is used to validate and correct the mineral phase segmentation.

Aug 24, 2022

By T Isaksson, J Anderson

The procurement process for underground construction contracts, in particular those contacts involving tunnel boring machines (TBMs), is subject to many complex and inter-related variables, including national and local politics, public policy, community involvement and media attention û as well as strict environmental and legal requirements. Other restrictions include the time available to adequately investigate geotechnical conditions and viable technical options to determine the best construction methodologies û including selection of tunnel boring machine characteristics and, those construction means and methods suitable for the specific geotechnical and environmental conditions. The latter are, most often, quite imperfectly understood. æGetting it rightÆ implies that an optimal configuration û of machine type, characteristics and associated methodologies û can be found and successfully implemented for a particular project. æFrom the beginningÆ implies that the lack of time issue can be successfully resolved. Within an international context this paper highlights a number of issues of concern which relate to tunnel procurement systems and the ways in which certain key processes are managed during planning, design and construction. The authors argue that there is considerable room for improvement in the way tunnelling projects are undertaken and an approach is discussed which has the potential for substantial gains in cost and schedule and reduction of risk. Savings, however, may only be fully realised if the new methods can be fully implemented by all parties involved. This, we believe, will require the rejection of ætraditionalÆ forms of management and procurement with associated changes in the roles and responsibilities of owner, engineer and contractor. Additionally, risk identification, assessment and mitigation are essential cost and schedule control process which have, to this point, been underutilised by the underground construction industry.

Jan 1, 1999

By J E. Everett

An essential requirement of product quality control in the mining industry is to be able to reliably predict key quality properties of finished product from the data available before the extraction of the ore. From a production viewpoint, the unit of data collection is generally the input and output data set for each shift of crusher production, but could be any period where mine precrusher data can be reliably matched with product data.This paper demonstrates that linear regression models can be used to predict crush grades from blast grades, even where the crush material is blended from multiple sources or pits for each of which differing regression models might apply. The advantage of using increasingly complex regressions models to match the available data to give increasingly more powerful models is examined. The best model for any application will be a balance between required predictability, available data and the business’ tolerance for complex models.The regression modelling approach has several advantages over the more classic method of run-of-mine (ROM) crusher trials, which will be discussed.The models can use any predictor variable such as grade, geotype and in situ density provided the preextraction data set can be reliably matched with post-crusher data and is significant as a predictor. The models have been used extensively in the generation of the daily crusher plan with the aim of maintaining finished product grade. This approach has also been used associated with exploration drilling and long-term planning.It is acknowledged that there are inherent problems in fitting lump and fines grade to a linear model. However, these problems are minor when they are used for interpolation within the window spanned by the shift blend records used to produce the model. This paper discusses some of the issues limiting linear regression models in this application, and suggests methods enabling consistent models to be formulated

Sep 5, 2011

By F Rashidinejad

Iran has had an active mining sector for some 7000 years. Exceptional in terms of its mineral diversity, Iran produces 62 minerals, and is ranked among the world’s 15 most mineral-rich countries. Many people around the world know Iran as one of the major petroleum exporters. Oil and natural gas dominate Iran’s economy, and oil exports provide the principal source of income, contributing more than 80 per cent of foreign exchange earnings. Transformation of Iran from an oil exporter to an independent country to oil has been on the table for many years, even before the Islamic Revolution of 1979. Development of the Iran’s mineral industry is one of the major replacements for petroleum exports. In the last decade, Iran invested billion dollars in the mining and mineral industry sectors and to increase the added value, tried to export processed minerals instead of the raw materials. In accordance with the ‘20-year Perspective 2025’ that targeted by the Supreme Leader, Iran will be a country with the first rank in economy, science and technology in its region. The objectives over this perspective include briefly increasing annual production to 55 Mt of crude steel, 800 000 tonne of copper cathode, 1.5 Mt of aluminium, 200 Mt mineral products, 300 000 tonne of zinc and 5 000 kg of gold. These goals are achievable in normal circumstances, but concurrency of the 20-year Perspective 2025 with commencement of the UN Security Council sanctions against Iran, frustrated objectives of the perspective, at least the ones related to the mining and mineral industry sectors. This paper tries to elaborate the development programs and following challenges for the mining activities of Iran by 2025.

Nov 22, 2011

By S E. Wallah, D Hardjito, B V. Ran

The manufacture of Ordinary Portland Cement (OPC) is not only energy-intensive but also releases a significant volume of carbon dioxide (CO2) to the atmosphere. In addition, OPC in concrete often causes premature deterioration that affects the durability of concrete structures. This paper explores an alternative to OPC concrete called geopolymer concrete.The present research utilises low calcium (class F) fly ash as the source material to produce geopolymer concrete. Several factors that affect the mix design process such as mix proportion, curing time, and curing temperature have been studied. In addition, the long-term properties such as drying shrinkage, creep, and exposure to sulfate attack are also being investigated.The test data presented in this paper reveal that geopolymer concrete possesses high compressive strength, undergoes very little drying shrinkage and moderately low creep, and shows excellent resistance to sulfate attack. The result is extremely promising and demonstrates the sustainability of geopolymer concrete as a construction material for a sustainable future.

Jan 1, 2004

By H Kusumi, A Nishio, K D. Halim, Y Yun

In Japan, evaluation of rock mass is crucial in mountain tunnels that are constructed using the NATM (New Austrian Tunneling Method) to determine the support pattern that in turns determine the final support structure of the tunnel. The current evaluation method is highly dependent on the observations of on-site expert engineers that grades the rock mass in four levels across nine criteria: A. Condition of tunnel face. B. Condition of excavated surface. C. Compressive rock strength. D. Weathering. E. Spacing of discontinuity. F. Condition of discontinuity. G. Orientation of discontinuity. H. Spring water. I. Water degradation. However, in recent years, the number of said experts are decreasing rapidly due to labour shortage caused mainly by an aging population and declining birth rates. This is one of the biggest challenges that the construction sector currently faces, and this may affect the efficiency of tunnel construction projects in the future. Thus, this study proposes the implementation of a deep learning tool called the convolutional neural network (CNN) to quantitatively evaluate rock fractures on tunnel face. In addition, Gradient-weighted Class Activation Mapping (Grad-CAM) is applied to visualise CNN, as well as verify the applicability of CNN to the evaluation of rock fractures. In other words, by creating heat maps of tunnel face images, CNN is utilised to evaluate rock mass in categories that are associated with discontinuities. The CNN model is most accurate when six convolution layers, four pooling layers, and three dense layers are used. This yields an accuracy of 75.0~88.0 per cent. Thus, the CNN model is verified to be feasible method to evaluate rock fractures.

Nov 29, 2022

By P A. Montoya

La Colosa is a world-class porphyry Au project located in Colombia, currently undergoing prefeasibility analysis. As part of collaboration between AngloGold Ashanti and the AMIRA P843A GeMIII Project, the application of emerging geometallurgical characterisation testing and modelling tools has been incorporated in early stages of project development. The aim of the geometallurgical study is to map inherent comminution variability across the La Colosa deposit providing information critical for mine/mill design and optimisation. In this study, site-based data incorporating multi-element assays, quantitative analyse X-ray difraction QXRD bulk mineralogy measurements, EQUOtip rebound hardness data, and routine geological logging information from 59 diamond drill holes has been integrated with a range of geometallurgically specific comminution test (ie GeMCi, A × b, BMWi). The work in this paper demonstrates the integration techniques used at La Colosa to link routine data acquisition methods with comminution test results through the development of proxy support models. The integration incorporates a range of statistical techniques including principal component analysis and regression modelling. By creating proxy models, comminution index estimates can be propagated into the geological database enabling comminution processing domains to be defined. These domains provide the first spatial representation of comminution performance and variability at La Colosa and can be compared against traditional geological domains. This study provides the foundation for ongoing comminution characterisation as the La Colosa project evolves through project cycles into an operational mine.

Sep 5, 2011

By P McCarthy

The relatively new field of geo-metallurgy promises to improve the predictability of mill feed quality and enhance processing outcomes. However, it is subject to the same limitations as the prediction of grade using geostatistics and has additional limitations due to the spatial distribution of the variations being measured and the sample sizes required. Schedules based on geo-metallurgical models will, in turn, be subject to variations arising from geological control and practical mining constraints.This paper discusses the key drivers of variations in mill feed quality and quantity from a mining perspective. It concludes that geo-metallurgical modelling addresses only one aspect of the problem. A case study is provided to illustrate poor predictability of metallurgical performance even with very detailed geological data.

Aug 8, 2011

By Hein K. A A

The Mt Todd Gold Project is located 42 km northwest of the township of Katherine within the Northern Territory of Australia. It is situated in the southeastern portion of the Pine Creek Geosyncline. The Batman gold deposit, the largest of several deposits at Mt Todd, hosts an identified mineral resource of 92.9 million tonnes (Mt) grading 1.4 grams/tonne (g/t) as at 31 December 1993. Host rocks at Batman are assigned to the Early Proterozoic Burrell Creek Formation, comprising greywacke and siltstone interbedded with shale. Gold mineralisation is associated with a very broad zone of sheeted and stockwork quartz-sulphide veins that occupy a corridor of intense brittle fracture and faulting. A conceptual model of formation involves the dilation of joints and micro-faults within overlying sediments during sinistral movement along a basement shear zone. Synchronous granite intrusion generated convective circulation of crustal fluids through the sedimentary pile resulting in the formation of auriferous quartz veins within favourable structures. The Batman zone of mineralisation is not directly related to fold structures which typify several other major gold deposits within the Pine Creek Geosyncline.

Jan 1, 1994

By T D. H McGrath, G Wardell-Johnson, E A. Oraby, W Staunton, A R. Bax, J J. Eksteen

"Gold ores often show significant inter-domain variation with respect to the gravity recoverable gold (GRG) content and the leach behaviour of the non-GRG component. Liberation assessment is extremely difficult for gold due to its malleability and the high sampling errors and poor test reproducibility resulting from gold’s high specific gravity and the low metal concentrations that occur in most gold ores. The use of microscopic techniques for the liberation assessment of gold is also impractical due to the high number of sampling errors and high cost of analysis.Curtin University’s Gold Technology Group has developed an online carbon-in-pulp/carbon-in-leach (CIP/CIL) simulation model called SIMCIL, which has been used since 1999 to model and simulate industrial leach-adsorption circuits. Recently the model has been upgraded to include an integrated liberation-leach modelling (ILLM) approach, which can be used to evaluate the impact of various process parameters (such as grind size, bleed to gravity etc) and circuit configurations on leach-adsorption circuit behaviour and overall plant gold recovery. A new time-efficient ore characterisation methodology has been researched and developed to provide the required liberation-leach data used in the ILLM approach, which is implemented online for the modelling of gold operations. The ILLM characterisation methodology, test work data analysis, interpretation and application of the ILLM test work data are discussed.CITATION:Bax, A R, McGrath, T D H, Eksteen, J J, Staunton, W, Oraby, E A, and Wardell-Johnson, G, 2016. An Integrated Liberation-leach Model and Ore Characterisation Procedure for Gold Ores, in Proceedings The Third AusIMM International Geometallurgy Conference (GeoMet) 2016, pp 315–320 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Jun 15, 2016

By R Bradford, W Gift-Agbey, T Vorster, P Morgan, E Grobler

The Asanko Gold Mine in Ghana started processing ore from the Nkran pit in January 2016 at a production nameplate of 3 Mt/a. The flowsheet is a conventional SAG, ball mill and pebble crusher (SABC) with gravity-gold and carbon-in-leach (CIL) recovery. The nameplate production was comfortably achieved within 3 months, so much so, that it was clear the SABC circuit was capable of processing more than the downstream section of the plant. Consequently, a program of de-bottlenecking was initiated to rectify volumetric capacity constraints. This program was later referred to as ‘Project 5 Million’ (t/a) or P5M. Having completed the de-bottlenecking exercise, it became evident that the SABC circuit could not reach 5 Mt/a solely on hard rock from Nkran. The new challenge was therefore to increase the capacity of the milling circuit through a focused comminution initiative that would address the following: geometallurgical treatment plan; upfront fragmentation requirements; installation of feed and mill monitoring equipment; and integration of a knowledge-based control strategy. This paper takes the reader through the various measures implemented to increase the milling rates and to create a stable/ sustainable control philosophy. As a result of the implementation of advanced mill performance monitoring technology (MillSlicer) and the collaboration between a team of experts in comminution, control and operations, the Asanko Gold Mine process plant feed tonnage has successfully increased from 3 Mt/a to 5 Mt/a.CITATION:Bradford, R, Gift-Agbey, W, Grobler, E, Morgan, P and Vorster, T, 2018. Optimisation of Asanko’s Obotan SABC circuit to achieve ‘Project 5 Million’, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 477–484 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

By Y Wei, H-B Mnhlhaus

Particles are by far the easiest objects to simulate, because their dynamics is simple. Determining the motion of particles and their interaction, a wide variety of deformable structures can be constructed by connecting particles that have mass, position, and velocity, and that respond to forces. Starting from this simple idea we have derived what we call the particle-lattice method for the solutions of boundary value problems of deformation and fracture of solid mass. The problem of rock breaking by blasting operations as well as fracture and flow of rocks fragments involve momentum transfer between solid and fluid; gas flow and reactive mass transfer. In this paper we outline the method and describe briefly the salient features of the algorithm. We derive relationships between the contact properties for the discrete model and the properties of the underlying continuum and fluid flow coupling procedure. Finally we illustrate the potential of the method by means of example solutions related to the dynamic fracture and flow in jointed rock by blasting.

Jan 1, 1999

By K J. Riihioja, E Nozawa

SmartTag is a radio frequency identification (RFID) based technology designed to allow tracking of ore from its source through blasting, run-of-mine (ROM) pads, crushers, intermediate stockpiles and finally into the concentrator. This paper presents current developments and the future direction of the SmartTagÖ ore tracking system, as well as presenting some case studies. Successful applications of the SmartTag system have encouraged development to allow the system to be used in a wider variety of plants, in particular plants with finer crushing and screening stages. This presented Metso with a number of technological challenges, including RFID tag and antenna design. By reducing the traditional RFID tag diameter from 60 mm to 20 mm the RFID tags can now successfully pass through a secondary crusher. The new smaller RFID tags (referred to as mini RFID tags) have been used in some Process Integration and Optimisation projects with very promising results. The results indicate that the miniature RFID tags have a higher survivability to blasting and through secondary crushing stages. Extending ore tracking further through the process allows more reliable linking of spatial data with time based process performance. Metso is looking at developing even smaller micro RFID tags, and is also investigating other applications for the SmartTag system, including ore tracking from the original source to the final destination (ie from the mine, through the plant and ports to the customer).

Sep 26, 2011