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By G McSpadden

At September 2001 the beneficiation plant at BHP Billiton Iron OreÆs Mt Whaleback mine is set to treat 9.5 million tonnes per annum (Mtpa) of iron ore, 40 per cent better than original design. This paper describes the steps, decision-making processes and innovations used to increase capacity at minimum cost. The plant was designed in 1979 to operate at 1133 t/h for 6000 hours per annum, treating 6.8 Mtpa. Sufficient suitable contact ore was unavailable and feed was finer than planned. The plant was designed with minimum surge capacity between multiple process units. It had never reached design capacity. In 1993 a study by Fluor Daniel to treat increased tonnage resulted in modifications to improve plant operations. Efforts to expand production by increasing reliability did not achieve the desired capacity. NJ Morrow (Pty) Ltd (NJM) conducted a technical audit in 1996 with process evaluation by Mineral Processors. Replacement of operator interface and PLC logic in 1997 made plant operation and diagnosis easier. Involving operators in logic development enhanced their plant knowledge. Fluor Daniel Simulation developed a simulation model of the process. Mineral Processors and NJM reviewed the model findings, recommended metallurgical improvements and developed preliminary designs and costs. BHP Engineering produced a detailed design with a cost estimate of $A34 million. After analysis and revision of the design, a $A10.4 million upgrade to 8.5 Mtpa was carried out. Detailed modifications to the process units, particularly the HM drum plant, allowed significantly higher capacities and improved metallurgical performance. The target capacity was achieved in June 2001. Further modifications are progressing to treat lower-grade ores.

Jan 1, 2002

By R West

The Olympic Dam smelter facility processes copper concentrate feed using direct-to-blister smelting technology to support the current site production rate of 225 000 t/a copper. The metallurgical control of the Olympic Dam smelter is largely managed from a single central control room. Control room operation and management is therefore a key function in ensuring safe and reliable operation of the smelter, including identifying and initiating control of abnormal events. As part of a consolidated smelter reliability improvement program, a team consisting of process and control system engineers was formed. The teamÆs charter was to address and resolve the alarm flooding issues being faced by the control room technicians and the lack of an up-to-date base of supporting functional documentation. The project was successfully resourced with WorleyParsons metallurgists, Citect PLC technicians and the on-site technical team. Implementation was conducted over a 12 month period with the goal of achieving best practice alarm levels. The goal was achieved through a systematic process of alarm design review that analysed every configured alarm versus best practice design standards. Innovative concepts such as group-based alarms, first-up interlock displays, graphic only alarming, alarm help and alarm shelving were developed and implemented in conjunction with improved alarm masking. Total configured alarms were reduced from 20 000 to 5000 while the alarm rates were reduced from in excess of 200 alarms per hour per controlling technician to best practice levels of less than 12 alarms per hour per controlling technician. Completion of this program has provided a firm foundation for implementing further control optimisation and was a key activity in supporting sustained smelter reliability levels.

Jan 1, 2005

By Wall J, Platell R, Knight P

The Argyle diamond mine is located in the East Kimberley area of Western Australia, some 100 km south of the town of Kununurra. The diamondiferous Argyle olivine-lamproite diatreme was discovered in August 1979. Production began in December 1985 at a planned throughput of 3 Mtpa to recover 25 million carats of diamonds. Presently, Argyle is the world's largest producer of natural diamonds and produced over 40 million carats in 1993 from seven million tonnes of lamproite ore treated. Two phases of evaluation have been carried out. The first in 1981-82 was designed to prove around 60 million tonnes of ore to justify the establishment of a mine with a minimum life of 20 years. The second phase, in 1989-90 involved drilling the orebody to greater depths to provide data on which to plan the final pit design. The final pit contained 120 million tonnes of ore at 5.3 carats per tonne (ct/t) grade. Mining of the planned pit will extend the mine life to around the year 2004, following which it is possible that a further cut-back could be mined. There is also the potential for future underground mining. A substantial amount of geotechnical work has been undertaken due to the fact that the pit will be nearly 500 m deep and is located in a mobile zone causing abnormally high residual stresses to occur in the pit walls. The occurrence of low strength rocks at depth in the pit walls further complicated the situation. Hydrogeological investigations were done to determine pit dewatering requirements and to assess the effect of dewatering on pit wall stability.

Jan 1, 1994

By H Kurth

Oyu Tolgoi copper and gold mine in the southern Mongolia holds mineral resources that make it one of the largest known copper and gold deposits in the world. The project is operating an open pit mine on the near surface of Southern Oyu deposit and developing underground block-caving mine at the Hugo Dummet North where 80 per cent of total resources exists. Oyu Tolgoi (OT) commenced open pit mining in 2011 and implemented an industry standard blasthole sampling, and ordinary kriging grade control estimation with block-out process. Since 2017, grade control improvement projects have successfully completed that have led to the implementation of current, improved grade control system. Geological model is updated by blasthole logging on Leapfrog® and used for daily grade estimations. GC estimation is proceeded solely on Vulcan® by running Lava script and integrating with a relational database. Combination of block-out procedure produces GC model which is updated in Vulcan® and as well as in the database simultaneously. Switching to the integrated database eliminated many manual processes such as importing and exporting data and enabled access to the database anytime, anywhere and from any device. Thereby, these improvements allowed to increase an efficiency, create a comprehensive reconciliation system and reduce operational risks. We are looking forward to expanding applications of integrated grade control data stored in the database. This paper outlines how the grade control system was developed at OT’s open pit mine, and how it is integrated into the short range mine planning, mine reconciliation workflow and ultimately enabled development of various automated reporting systems.

Mar 22, 2022

By K Nakashima, K Aya, T Sumita, N Saito

Electro slag remelting (ESR) is one of the methods used to produce high-cleanliness steel. In the ESR method, the product steel electrode is immersed in flux, and the electrode is melted by the Joule heat of the flux generated by high current. CaF2-based melts are mainly used as fluxes, but the electrical conductivity of CaF2-based melts varies widely among researchers and measurement methods. Therefore, this experiment aims to measure the electrical conductivity of CaF2-based melts based on the van der Pauw-Ohta method, which does not require the cell constant that is a fundamental error factor in electrical conductivity measurement at high temperatures. The measurement temperature was set at 1450–1600°C, and dehydrated Ar flowed through the furnace at 200 mL/min. Electrodes were fabricated by Pt-30mass per cent Rh alloy, and the electrodes were connected to an impedance analyser using a four-terminal probe. The electrodes were immersed in the melt, and the impedance and phase angle were measured by AC frequency sweep (50 Hz to 200 kHz). The electrical conductivity was then calculated by utilising the impedance’s real part values when the impedance’s imaginary component was zero. The electrical conductivity showed a positive temperature dependence. The electrical conductivity of 60(CaO⋅Al2O3)-40CaF2 melt increased with increasing temperature but was found to be roughly one-third of those of the previous studies. In the conductivity measurement of 60(CaO⋅Al2O3)-40CaF2 melt, the AC frequency with a phase angle of 0° was found to be different depending on the temperature and immersion depth. By sweeping the frequency, the impedance at the phase angle of 0° can be obtained, which enables us to measure the electrical conductivity more accurately.

Jun 19, 2024

The MIMDAS geophysical data acquisition system developed and tested by the former MIM Exploration Pty Ltd (MIMEX) is now commercially available worldwide through Geophysical Resources and Services Pty Ltd (GRS). The system implements several new features in its design that give it significant advantages over conventional systems and allows for new approaches to electrical exploration. In particular, the achievable signal to noise levels permit exploration to depths once thought beyond the range of electrical exploration. The flexible multi-channel configuration lends itself to truly 3D surveys in the style of modern seismic techniques. Each of these aspects is illustrated with a number of case histories from both Australia and South America.

Jan 1, 2004

By E Broers, J Goh, S Davies

With recovery being important in optimising the business performance of a laterite and sulfide plant and with water being a precious resource in Australia, there has been increased pressure for companies to improve their methods of improving liquor recovery and improving water recovery in both laterite and sulfide plants. This has resulted in new control technologies such as the Manta Cube being applied on countercurrent decantation (CCD) and thickening circuits which is necessary to improve stability and optimise the liquor and water recovery in these processing plants. This paper describes the benefit of applying these new control techniques on CCD and thickening circuits in some of the mineral processing plants in Australia.

Jan 1, 2009

By Armstrong M

The Clermont Coal Mine will export steaming coal from the Wolfang Basin in Central Queensland, Australia. It is expected to be developed in the mid-1990s.The majority of the reserves lie in the 30 m thick Wolfang Seam. Overburden depth varies from 80 m at the subcrop line to 190 m in the centre of the basin.

Jan 1, 1992

By Lin Bin, Minggao Qian, Zhiyi Yang, Fullan He

There are no efficient methods and instruments available in China at present for diagnosing the leakage problem for a hydraulic support system in underground coal mines. A new method has been developed to solve the problem. It is proposed that

Jan 1, 1998

By M P. Schwarz

A major issue presently faced by companies producing and processing iron ore is the need to maximise throughput while minimising capital expenditure. While present high demand means this is of prime importance, the perennial issues of maintenance, operating costs, reliability, quality and environmental sustainability are also critical to profi tability. Attempts to address these issues generally require modifi cations to existing equipment, or trials of new equipment when designing plant for new projects.The risk involved can be substantially minimised by testing equipment improvements using advanced computational models prior to implementation. Examples of application of Computational Fluid Dynamics (CFD) and Discrete Element Method (DEM) modelling to sampling, cyclones, conveyor transfers, classifiers, dust control, banana screens, comminution and smelt-reduction will be given to illustrate the benefi ts of such an approach. *This is an abstract only. No paper was provided for this abstract.*

Jul 11, 2011

By Bluck R. G

The Murray Basin is known to contain major deposits of heavy mineral sands and intensive exploration for new deposits is being conducted in Victoria, South Australia and New South Wales. The western Basin was well served in the Pliocene and Early Pleistocene by a variety of appropriate sediment sources, and potential coastal traps. Immature, fluvially-sourced sediments forming the Pliocene coastal complex of the Marmon-Jabuk Range in South Australia are part of a marginal marine assemblage containing a suite of economically important heavy minerals that include ihnenite, zircon, rutile and tourmaline. From a consideration of Pliocene palaeogeography and coastal dynamics, specific targets where concentrating processes are likely to have operated are identified in the South Australian portion of the Murray Basin. Such palaeo-environments include the down-drift, littoral zone of discrete foredunes or coastal barriers, the source area for transgressive dune complexes, tombolo facies, and intertidal shoals and sandbanks. Similar coastal processes are recognised for a preserved Early Pleistocene barrier complex.

Jan 1, 1990

By I H. Jung, W O. Choe

Gallium (Ga)-containing compounds such as Gallium Arsenide (GaAs) and Gallium Nitride (GaN) are widely used in electronic devices due to their superior electro-optical properties and their usages increase rapidly. For the sustainable supply of Ga to electronic industry, therefore, the recycling of Gallium becomes essential. Pyrometallurgical Ga recycling process involves the complex chemical reactions between slag, matte, liquid metal, gas, refractories, etc. Therefore, the accurate thermodynamic information and phase diagram data for the oxide system containing Ga2O3 is important. In the present study, new phase diagram experiments for binary SiO2-Ga2O3 and ternary CaO-SiO2-Ga2O3 system are carried out using Differential Thermal Analysis (DTA) and quenching experiments followed by Electron Probe Micro-Analyser (EPMA) and X-Ray Diffraction (XRD) phase analysis. Based on new phase diagram data and available literature data, the thermodynamic modelling of the entire CaO-SiO2-Ga2O3 system is performed for the first time.

Jun 19, 2024

By Peck WH

For many years it was realised that the methods used for unloading concentrates at Port Pirie were inefficient and labour intensive, therefore, when a decision was reached to standardise the east-west rail link from Sydney to Perth, the opportunity was taken to consider entirely new schemes for the handling of concentrates at Broken Hill and Port Pirie. After considerable testing and investigation, it was decided to install a completely new concentrates handling plant incorporating a tippler at Port Pirieòto replace the previous long established methods of unloading and dis- tributing concentrates to the operating plant.and the shipping berths. To achieve this, wagons of concentrates from the various mines are marshalled in a set order at Broken Hill and conveyed to Port Pirie in 56-wagon trains. On arrival at Port Pirie, the wagons are checked and moved to a position where they come under the control of the automatic wagon marshalling equipment.

Jan 1, 1975

By L van Latum, A Koh, I Thomas

Haul truck drivers are at a high risk of developing fatigue due to the monotonous nature of the work and demanding shift rosters. In the mining industry, fatigue is identified as a major contributing factor in several fatal accidents a year. A number of fatigue detection devices are now available, that can contribute to improved fatigue risk management in the mining industry. This paper describes the technology and algorithms behind one particular product which is both predictive and un-obtrusive to the operator. The Advisory System for Tired Drivers (ASTiD), was developed by Fatigue Management International (FMI) in collaboration with the Loughborough Sleep Research Centre (LSRC), both in the United Kingdom. While this system includes a model of the human circadian rhythm as a bias for predicting expected fatigue risk by time of day, it also uses yaw data generated by a solid-state gyroscope in the horizontal plane. Algorithms analyse this data to determine the level of monotony of actual driving conditions and to detect changes in steering control caused by driver fatigue. During normal levels of attention, a haul truck driver applies continuous, small adjustments to the steering wheel. As the level of fatigue increases, steering adjustments become less frequent and more erratic. Differentiating between these modes of control in the highly variable mining environment is accomplished by chromatic processing of the gyroscope data. This paper will go into some detail explaining the principles behind chromatic processing and the specific application of these in detecting fatigue in haul truck operators.Technology in itself is not the solution to addressing operator fatigue, but it plays an important role in ongoing monitoring and maintaining awareness with mining personnel. Furthermore, the specific principles behind ASTiD technology support a risk-based approach to fatigue management, allowing optimisation of the mining operation for productivity as well as safety.

Sep 26, 2011

By K Williams

Marvel Loch South Pit has had a number of stages of open and underground mining activities before acquisition by Sons of Gwalia. The historical pit had achieved a completed pit depth of 150 metres and the shaft and decline mine had reached approximately 220 metres in depth using open stope mining methods. The various mining methods reflect the various economics and industry practice at the time. The South Pit ore zones are medium grade (~2.5 g/t) but have a regular geometry and large tonnes per vertical metre. A number of studies have been completed up to a pre-feasibility stage looking at options to extend the pit depth and to lower the unit cost of gold production. The options considered were the re-optimisation of the pit to determine further cutbacks or the innovative use of an in-the-wall ramp. The in-the-wall ramp (tunnel) would permit the removal of the in pit ramp to expose additional ore that was within the footprint of the ramp design and to provide the opportunity to increase the final pit depth. Similar mining method has only been used at Three Mile (Coolgardie, WA) and Chalice Mine (Norseman, WA). The tunnel would serve as a gateway for further extension of the south mine and the central ore zone via underground mining methods. The ultimate depth of the South Pit has been extended to 310 metres below surface and significant additional ore has been recovered. This paper will give an insight into the various studies to optimise the Tunnel mining method, the determination of the various tunnel dimensions, and the phases of mining to arrive at the completed design.

Jan 1, 2003

Using a new type of laser surveying instrument named Particle Dynamics Analyser (PDA), the distributions of the radial and axial components of the mean velocity, the size and the concentration of solid particles at selected positions within a transparent hydrocyclone were directly measured out for the first time, from which profiles of the flow field of solid particles were obtained. And some new points were put forward such as the locus of zero vertical velocity (LZVV) of solid particles was not the same as that of liquid, and some particles in inner helical flow could also be separated. The results are of great significance to farther ascertain the separation principle of hydrocyclones and improve the separation efficiency.

Jan 1, 1993

By J-P Franzidis

Mill operators have traditionally been forced to rely on grade-recovery curves and overall flotation rate constants when analysing proposed improvements to plants. This has led to loss in money and time when a proposed change that showed potential in laboratory scale tests failed to show improvement in the plant. Frequently, this is a result of the operators being unable to gain insight into how and why the proposed change affected the flotation performance. This is due to the classical models not including any description of the subprocesses of flotation and their individual contribution to the overall flotation performance. A new flotation model has been developed as part of the AMIRA P9 project that separates the flotation process into subprocesses and includes the contribution of both the pulp phase and froth phase to the overall flotation recovery. It is not possible to determine the individual components of this new model on traditional pilot plants as they lack the required flexibility and scale. Therefore a new pilot plant has been developed known as the Floatability Characterisation Test Rig (FCTR) that has the flexibility and features required for the determination of the flotation subprocesses. The flexibility and features of the FCTR also make it an ideal tool for investigations into many different aspects of flotation research. These include the effect of reagents, grinding, and power on the flotation performance. This paper will describe the methodology for using the FCTR in these fields of research and highlights the advantages of using the FCTR over traditional methods.

Jan 1, 2000

The Pacific Rim and its environment involves a vast array of natural phenomena, and a vast array of situations which show the impact of man. Almost half the world's population of over five billion live in nations" which border the Pacific, but the concentration is focussed in the North. Great experiments are occurring in this region, the industrialization and energy development in- Japan and China, the growth of Indonesia, (now 168 million - soon 368 million; Brown and Jacobson, 1986), the enormous developments of agriculture and the metals resource base in Australia and China. At the same time, the Pacific Rim does not project images of hopelessness, the mood is upbeat. Over the past decade, incomes have increased substantially in most of the major countries of Pacific Rim (e.g. over the period 1980-86, + 58% in China, + 21% in Japan, + 34% in South Korea; Brown and Jacobson, 1986). In September, 1986, at the general assembly of the International Council of Scientific Unions (ICSU) in Bern, Switzerland, representatives of over 50 nations approved a new initiative, "The International Geosphere Biosphere Programme: A Study of Global Change". The focus of this new program is "To describe and understand the interactive physical , chemical , and biological processes that regulate the total Earth system, the unique environment that it provides for life, the changes that are occurring in this system, and the manner in which they are influenced by man. The IGBP will be a tightly-defined programme of research, directed at providing fundamental knowledge that will serve as a basis for assessing likely future changes on the Earth in the next 100 years" (ICSU, 1986). For the earth scientist, and all resource scientists, there is an emerging agenda; new priorities are appearing, new questions are being asked. The recent report of the World Resources Institute (1986) focusses on this emerging agenda. Topics which are at centre stage in this report include the following: The environment and human health Tropical deforestation The atmosphere as a shared resource and climates Soil-degradation Rural-urban migrations Food and agriculture The diversity of species-ecosystems Freshwater as a finite resource Coastal areas and resources

Jan 1, 1987

Renison Goldfields Consolidated Limited (RGC) and Consolidated Gold Fields Plc (CGF) purchased New Guinea Goldfields Limited (NGG) in 1982 as an exploration venture. Following an intensive drilling programme in the Upper Ridges area sufficient ore reserves were outlined to justify the installation of a new 700 tonnes of ore per day gravity gold extraction plant. Major considerations in the design of the new plant were to minimise production inter- ruptions in the existing plant and to include simple, but technically efficient, equipment that could be operated and maintained by a workforce with limited experience in modern technology. These goals were achieved over a six month period, commissioning being carried out in April, 1983. Mining the epithermal gold deposit is by open cut benching and truck haulage. The gravity concentrator includes a scrubber, wet hammer mill and rod mill, to crush, grind and prepare the ore for sizing and desliming. Gold recovery units consist of a jig, spirals, shaking tables and amalgam barrels. Although the majority of the gold is in the minus 100 plus 20 microns size fraction a recovery of 63 percent, from a head grade of 2.0g/tonne, is Achieved.

Jan 1, 1984

By M Mee, R L. Gwyther

Accurate measurement of rock mass response during the mining of massive underground orebodies is essential, as mines become larger and deeper. These measurements enable: provision of quantitative data for optimal pit slope design and engineering; monitoring of the stability of deep pit slopes, the long-term integrity of shafts and large-scale underground infrastructure, and long-term measurements of deformation or rock mass creep following the mining process for environmental management. Strainmeters traditionally used for deformation measurement have neither the long-term stability nor the high sensitivity to perform measurements in these applications. This paper describes a new precision borehole strain monitoring system (GTS) currently deployed by CSIRO Exploration and Mining, which has the potential to solve these new issues in rock mass deformation monitoring. This technology was originally developed for use in hard rock mines (Gladwin, 1977) and refined considerably for earthquake research (Gladwin et al, 1994; Gwyther et al, 1992). A case study of the use of the GTS in monitoring longwall coal mining over the period 1993 - 1998 is presented.

Jan 1, 2000