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By M Hood, X S. L, W J. T Daniel, H Gurgenci

It is believed that disc cutter shape affects rock fracture and therefore cutter performance and cutter life. However, the current generation of disc cutters is made of hardened steel and these cutters wear rapidly and consequently they are unable to maintain their original shape in strong and abrasive rock. This wear problem could be reduced if the cutter was made from a harder material. Unfortunately as material hardness increases so does the propensity for brittle failure. In this study the optimum cutter shapes were identified by studying the mechanics of rock/tool interaction. The results showed that bevel and wedge cutters are better than cutters with dome and flat edges. A new cutter was designed, based on this result, using a harder material to increase the life by a factor of 20.

Jan 1, 1998

In most mining operations the ore undergoes several processes such as drilling, blasting, loading, hauling, crushing, grinding and liberation to become the final salable product. Drilling and blasting is an important step in this process chain and itÆs results such as fragmentation, muckpile shape and looseness, dilution, damage and rock softening effect the efficiency of downstream processes. The value created per ton of broken ore is the difference between the price it commands when sold as the final product and the cost to produce it. Traditionally, the total process in the mining industry is classified into two groups as mining and milling. These are managed as separate cost centres inspite of the interdependency. Each process has a budget and production target and emphasis is usually on maximising production (tons) and minimising cost rather than the overall profitability of the whole business unit. The efficiency of each process is considered to be satisfactory as long as they are within budget and meet the production targets. The mine and mill managers usually try to optimise each process independently rather than the entire process. This paper discusses the potential pitfalls of decreasing the drilling and blasting cost per ton of broken rock without considering its impact on downstream processes. It introduces a holistic approach to blast optimisation by identifying and measuring the leverage that blast results have on different downstream processes and then optimising the blast design to achieve the results that maximise the overall profitability rather than just minimising the drilling and blasting costs. This paper demonstrates the benefits of such a holistic approach to blasting based on computer model simulations and field studies from metal and open cut coal mining.

Jan 1, 2001

By B Belle

"Mines around the world are inherently and operationally diverse. Current methodologies for the design of mine ventilation and cooling infrastructure involve controlling major safety and health hazards. Globally, it can be estimated that mine ventilation systems from various commoditiescirculate over 150 000 m3/s of exhaust air through shafts. Additionally, over 2 000 000 workersare transported every day through shafts in labour-intensive mining countries like China, India,Southern Africa, and the Americas. A key objective of this paper is to share experiences and provide a case for the revision of ætime-honouredÆ ventilation design parameters based on a benchmarking exercise on design exhaust shaft velocity from various global operations (gold, diamond, platinum, coal and base metals). An active fi eld observation on exhaust shaft velocity has indicated that, regardless of the commodity or continent where the mine operates, almost all life-of-mine (LOM) design parameters provided are in the same range of 20 m/s to 22 m/s, which is not convincing considering signifi cant variations exist in shaft depths, geography, commodity, operating and capital costs. From a due diligence perspective, there are no documented views that are available on the most widely used design exhaust air velocity. Based on the global exhaust shaft velocity data, it is noted that a significant portion of shaft velocities are outside the current design velocity of 20 m/s (some operating up to 30 m/s) and other signifi cant portions of the exhaust shafts operate in the critical velocity range. In the case of Australian coal mines, limited data suggests that none of the mines have ever reached the LOM design exhaust shaft velocity. It is self-evident that when the shafts are not operating at their design quantities either the mine system resistance is low or the ventilation and main fan is operating ineffi ciently. The most common reasons given for not reviewing the shaft system were, ætime-honouredÆ design parameter are being used and cannot be changed, mine fan pressure limits, possible fan blade damage, possible spontaneous combustion risks, leakage or simply did not consider such a possibility. In conclusion, the study has reiterated the historic lessons that a safe and expensive airway should not be utilised uneconomically by circulating too litt le air through it."

Jun 1, 2012

By D H. Laubscher

The in situ rock mass rating system û IRMR - leading to the mining rock mass rating system - MRMR - for jointed rock masses has been used (and abused) in mining operations around the world for the past 27 years. Despite the recent development of elaborate design procedures and computer-aided design packages, MRMR remains one of the most versatile and practical mine design systems available. It is important to realise that the rock mass classification system should not be replaced but rather complemented by more sophisticated and detailed design procedures. The classification system is not only the æcrudeÆ method used for initial assessment (as described in some geotechnical literature) but also in many respects a very effective and practical engineering tool. MRMR could, and should be used during the entire stage of mine life as an integral part of the design process. The objectives of this paper are to illustrate using practical case histories from the past decade, some of the pitfalls of the MRMR classification system, to clarify certain misconceptions in its application and update its mining application.

Jan 1, 2000

By S Kodate, Ö Aydan, Y Suda, J Tomiyama

Fracture zones are commonly found in the Earth’s crust. These zones may cause very severe engineering problems. Therefore, the formation and the assessment of the mechanical characteristics of these zones is of great concern for rock engineers. A new double shearing jig was used to study the formation of shear zones in rock under static and impact loading conditions using the device developed by the authors. A series of experiments were undertaken to investigate formation on the formation and characteristics of fracture zones in laboratory. Although actual fracture zones are more complicated, various tests give some insight view of the formation of fracture zones as well as some information on their mechanical behaviour under both dynamic conditions and static conditions. The authors report the outcomes of these experiments and discuss their implications in practice.

Nov 29, 2022

By MattelmSki M

Outokumpu Harjavalta Metals Oy has been producing nickel since 1962, based on conventional flash smelting technology followed by electrowinning of nickel. In the 1980s, a research project was initiated to develop a converterless direct smelting process to produce matte for further refining in the then existing refinery. The process was tested on a pilot plant scale at Outokumpu's research centre in Pori and was found to be viable. The process was named the Direct Outokumpu Nickel Smelting Process or the DON Process. At the turn of the 1990s, Outokumpu studied various options to develop its nickel business and the Harjavalta operations. As a result of this work, the DON Process was further developed to produce two mattes: low iron matte in the flash furnace to be leached in the existing leaching circuit and high iron matte in the electric furnace to be leached in the new leaching circuit. In Harjavalta's case, it was essential and important that the process could use the existing flash furnace and electric furnace without converters.

Jan 1, 1996

By A C. Robertson

Studies by Tennent, Isokangas Pty Ltd (TIP) have indicated that underground quarrying of backfill may be a cost competitive option for providing backfill for specialised situations in underground mining. Situations where suitable bulk fill material may not be available on the surface, and where the total cost of setting up a fill distribution system are prohibitive, could favour the mining of fill material underground adjacent to the stopes being mined. Considerations include environmental impact, scheduling, surface constraints and total costs. The examples quoted in this paper, and the case studies are based on the authorsÆ personal observations and experience.

Jan 1, 1998

By R Stosch, D Lohberger, J Rodler, E Schnell and A Bassler, H Ramseier

In the last two decades three-dimensional (3D) computational fluid dynamics (CFD) simulations have become an important tool in engineering sciences. More recently, the safety requirements in underground railway stations have increased with regard to incidents. For this reason, existing underground stations (eg Munich, Strasbourg and Berlin) are being equipped with smoke extraction facilities to protect passengers from smoke and visibility impairment in the event of fire. In addition, designs of planned underground stations (eg Karlsruhe, Doha) also include these facilities.For the commissioning of ventilation engineering systems with complex structures, the functional testing of the whole technical installation are important, as are the acceptance tests of ventilation and equipment parts. This functional testing includes not only the technical inspection of the equipment but also the acceptance measurements of the capability of the equipment and the execution of hot- or cold-smoke tests to confirm the effectiveness of the ventilation system.Due to the fact that the overhead contact line and other sensitive installations were already installed in the tunnel roof at the time that smoke tests were proposed, hot-smoke tests with fire loads up to a maximum of 1 MW could only be executed. Therefore, the evidence of the attainability of the safety objective had to be provided computationally in this special case with a fire scenario of a heat release of 10 MW using CFD simulations.This paper presents the interplay between the results from acceptance testing and smoke tests and the use of 3D CFD simulation and virtual reality using the example of Allmend station, which was repositioned underground and is part of a new section of track from Lucerne railway station to Kriens in the Zentralbahn network. The steps of the verification and validation of the computer model are presented with the real tests and measurements.CITATION:Stosch, R, Ramseier, H, Lohberger, D, Rodler, J, Schnell, E and Bassler, A, 2014. Safety in underground railway stations – an example of the interplay between testing and 3D computational fluid dynamics simulation, in Proceedings 15th Australasian Tunnelling Conference 2014 , pp 103–112 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 17, 2014

By W Roy

When it comes to plan implementation and securing success in organisations in the 21st century, if there was such a thing as the secret to success it would be effective communication. Commoditisation brings financial, operational and cultural advantages to organisations that use effective communication. Effective communication tools turn æpeople problemsÆ into system control solutions, removing personality clashes that hide procedural malfunctions. By introducing communications frameworks available in the market place today, and case studies of their use, this paper provides insights into the successes available to organisations courageous enough to redefine their communications for the 21st century.

Jan 1, 2006

By B Lindqui, M V. Knyazev, L S. Tsemekhman

Gipronickel Institute JS that is a Research and Development Centre affiliated to the worldclass Norilsk Nickel Mining and Metallurgical Company, and Outokumpu Technologies AB (Boliden Contech AB) have jointly developed the reconstruction project of Pechenganickel metallurgical operations using a two-zone Vanyukov furnace. The international expert group appointed by the Nordic Investment Bank has examined the project. The project financing should be partly executed by the Norway government. Current annual rate of sulfur dioxide emissions is 100 000 t. The aim of the project is to reduce it to 12 000 tpy. Pechenganickel Combine is owned by MMC Norilsk Nickel. Currently it produces nickel high-grade matte from sulfide copper-nickel concentrate with up to ten per cent MgO content. The existing production is in accordance with the following flow sheet: agglomeration û electric furnace smelting with matte production û converting in horizontal converters. Annual production capacity is about 36 000 t of nickel in high-grade matte. Converter gases report to sulfuric acid production. The principal results of studies on high magnesia materials smelting in two-zone Vanyukov furnace, engineering solutions, and technical and economical parameters are offered.

Jan 1, 2004

By K Dagdelen, I Traore

This paper presents an iterative net present value (NPV) maximisation method to determine the optimum surface to underground transition depth for an orebody to be mined by multiple open pits and an underground mine. The determination of transition depth from open pit to underground mining is based on global production scheduling optimisation of open pit and underground mines using mixed integer linear programming. The method is applied to a case study coming from a gold mining complex with six open pits and a large underground mine using longhole open stoping. The results indicate potential improvements of the NPV of global operations when compared to the traditional techniques based on independently optimised open pit first, followed by underground mining.CITATION:Dagdelen, K and Traore, I, 2014. Open pit transition depth determination through global analysis of open pit and underground mine production scheduling, in Proceedings Orebody Modelling and Strategic Mine Planning Symposium 2014, pp 195–200 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 24, 2014

Under South Africanncoalmining conditions, in the majority of instances coal is won using the bord and pillar system without pillar extraction. Examples demonstrate that strata control policy has an effect on practically all aspects of mining: (1) the choice of mining method; ((2) degree of coal recovery; (3) effect on productivity; (L}.) integration of'-support techniques with other operations. This is confirmed by use of modern research results and computer simulation. Although the examples are drawn from South African experience, the conclusion is generally valid. Strata control problems cannot be solved in isolation but as an. integral part of overall mining policy.

Jan 1, 1971

By D Rattray, D Macfarlane, I Robb, N Halpin, G T. Dale

Mining faces many environmental, social and regulatory liabilities of which water management is just one. Others include site rehabilitation, carbon emissions, biodiversity offsets, strategic cropping land, subsidence, and noise and dust generation. Management of these liabilities is commonly seen as a cost of doing business and each is often independently addressed, bypassing the opportunity to reduce costs through integrated approaches. Furthermore, approaches to dealing with these liabilities tend to be constrained by a prevailing culture of engineered solutions and lack of appreciation of risk associated with alternative and hybrid alternative-engineered solutions. Suboptimal outcomes can also be reinforced by rigid regulatory constraints. While the cost of addressing operational liabilities may be a small proportion of overall mine management costs, failure to do so effectively may influence social licence to operate and, as recently demonstrated by the decision of the NSW Land and Environment Court to block expansion of the Warkworth Mine near Singleton, absolute licence to operate.Integration of environmental, social and regulatory liabilities with value-creating and risk-reduction opportunities such as beneficial water use, carbon bio-sequestration, habitat connectivity, keyline farming, improved grazing design and management systems, windbreaks and visual screens, presents opportunities to reduce risk and create value. This potential may achieve overall improved outcomes in both economic and non-economic mine performance criteria.Two case studies in beneficial use of waste water from the mining and coal seam gas (CSG) sectors (which operate under different legislation) will be used to illustrate the potential to address mine development, operational and closure liabilities by understanding opportunities to reduce risk and create value through a holistic water management framework. The technical requirements and alternative approaches to beneficial use of mine water are addressed, along with the direct economic benefits for mine operational costs and opportunities to positively engage communities and build resilience into social licence to operate. Regulatory barriers to achieving improved outcomes will be discussed.CITATION:Dale, G T, Robb, I, Halpin, N, Macfarlane, D and Rattray, D, 2013. Opportunities for integrated mine management to minimise risk and create value, in Proceedings Water in Mining 2013 , pp 227-234 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 26, 2013

By K Li, C Zhang, i, J Oh, S Saydam, H L. Ram

Rock surface roughness plays an important role in excavation engineering projects and applications related to surface support structures, such as shotcrete and thin-sprayed liner (TSL). The morphology of the substrate affects the mechanical behaviour at the interface significantly. Therefore, it is necessary to quantify the roughness to investigate the relationship between roughness and mechanical properties. The joint roughness coefficient (JRC) proposed by Barton and Choubey (1977) is widely used in practice. It initially estimated the roughness by comparing it to 10 standard profiles visually. However, this method has lots of limitations, it is not only subjective but also a two-dimensional parameter with a small lab scale (Beer, 2002). The subsequent research on JRC, from visual comparison with Barton’s standard profiles to measuring the roughness with a profilometer (Weissbach, 1978; Alameda-Hernández et al, 2014). Then, 2D profiles or 3D surfaces by different technologies with higher resolution and accuracy, such as 3D laser or optical scanners (Fardin, 2004; Jiang, 2020, 2021). These 3D scanners are expensive and only suitable for laboratory scales. LiDAR scanners (Lato, 2009; Aubertin, 2022) have been applied in industrial size, but it is difficult to achieve a millimetre-level accuracy, which is mostly used to detect the thickness of shotcrete in practice. Thus, finding a cost-effective surface roughness measurement method with high accuracy is necessary. Photogrammetry is another method to digitalise the roughness of the surface. Similar to 3D scanners, photogrammetry also generates the point cloud of the objective surface and then reconstructs the 3D model of the objects. 3D reconstruction technology is a trendy technology in recent years. The structure from motion (SfM) algorithm (Westoby, 2012) to rebuild the 3D model with a flexible workflow, aligning photos, building dense point cloud, mesh and texture, which has been proved that can rebuild an accurate model in variable fields.

Nov 29, 2022

By J F. C L Costa, J C. Koppe, C Diedrich

Currently mineral resources evaluation is firstly expressed in terms of volume. Next the resources are transformed into tonnes by using an average bulk density applied to the whole deposit or, in some other circumstances, various different densities to distinct geological domains. Previous work in uranium, copper and nickel deposits used linear correlation between grades and bulk density to derive the density. Geophysics methods are also another good way to obtain density indirectly.These approaches do not take into account that two samples with the same grade but with different bulk densities can characterise different sample supports, leading to severe bias in grade and tonne estimates. It is important that the systematic measurements of bulk density are included into the estimation process, particularly when density is not correlated with the grades. Additionally, the extra time and costs involved in obtaining the bulk density data have made the mining industry disregard it.This study reports the impact in resource estimates by using a methodology that includes the bulk density variability. It involves the determination of a variability model for the bulk density and another model for the composite that was weighted by density as well as by its length. Next, these variables are estimated by kriging and the final grade estimates are obtained. The tonnages are obtained with the bulk density estimates. The conventional methodology was also applied and both estimates are compared to the reconciliation data from a major copper deposit. The results show a significant difference between the tonnage and grade estimates obtained from these two methodologies.The results show that considering density variability when compositing leads to a more accurate methodology resulting in better grade and tonnage estimates locally and globally.

Sep 26, 2011

By Singh RN

Monolithic packing systems have gained in popularity as a gate side packing method. However, there has been no detailed investigation to assess their underground strength behaviour. This work includes the laboratory and in situ investigation for strength behaviour determined on various monolithic packing materials namely Tekpak-XX, Hydropak-20, Hydropak-30, Astrapak-3R, Flashpak, Thyssen pack and Aquablends. A simple technique for assessing the pack strength was developed at the laboratory by using a penetrometer, of which penetration resistance can be directly correlated with the uniaxial strength of the pack. The in situ strength investigations were made on core samples obtained from three pipes inserted inside the pack, while the penetration test were made on the pack surface. The in situ results indicated that the packing material develops an inconsistent strength on various part of the pack which was mainly related to an inadequate mixing of grouts inside the pack.

Jan 1, 1992

By M S. El Salmawy

In order to develop the HF-free flotation reagent system, the main objective of this investigation was to study the possibility of separation of quartz from feldspar using non-ionic surfactants as the collector. The non-ionic surfactants used were polyoxyethyl cethyl ether (PECE) and polyethylene glycol monocethyl ether (PGME). The flotation behaviour of quartz and microcline with PECE and PGME was investigated. Each surfactant was a good selective collector for quartz with its recovery being influenced by pH and surfactant concentration. Quartz is floated favourably by both types of polyoxyethylene non-ionic surfactant whereas microcline was not so much. The floatability of quartz increases as the oxyethylene length of surfactants increases. Zeta potential measurements in the system of PGME/mineral were also carried out. It was determined that in the absence of PGME the points of zero charge for quartz and microcline should be approximately at pH 2.5 and 1.8, respectively. The addition of PGME to the system causes both minerals to become less negatively charged. Differences in the zeta potential value between quartz and microcline, in the presence of PGME, were detected. It can be suggested that the interaction of the oxyethylene group to the microcline surface should not be as strong as that to the quartz surface. In the mixed surfactant system of PGME and dodecylamine acetate (DAA), a small addition of DAA causes drastic enhancement of quartz flotation in the wide pH range of 1 ~ 10. In the mixed surfactant system selective flotation of quartz from microcline would be anticipated at pH

Jan 1, 2005

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 Rosenblatt M, Gilroy J. A C Cunningham C V B

Vaal Reefs Exploration and Mining Company Limited operates one of the largest producing gold mines in the world. The annual production of 76 tons of gold from 12 million tons of ore treated is obtained mainly from underground sources. Daily some 6.6 km of stope face is blasted and 41 tons of explosives is used to break the rock. The mine employs 45 000 men of whom 35 000 work underground. The company operates nine large vertical shaft systems of which seven extend more than 2000 m below surface and an eighth, currently being sunk, will bottom at 3700 m below surface.

Jan 1, 1995

By A Scott, S Kanchibotla, J Segui

The æMine to MillÆ concept is not new. In fact, it is the underlying objective of every mine. Unfortunately, in many operations the management structure and reporting systems have created independent æbusinessesÆ within the overall mining enterprise. This has created incentives to optimise the performance of each component of the operation rather than the enterprise as a whole. The Mine to Mill Conference organised by The AusIMM in October 1998 documented a number of case studies where run of mine ore was not presented to the mill in the best possible form for subsequent stages of comminution and processing. A number of examples were quoted where modest expenditure in the mine had a very significant impact on downstream process efficiency and hence costs. Examples included:the minimisation of fines in the mining and handling of iron ore; the management of fines in blasting and crushing for a copper heap leach operation; the control of blast damage, mining recovery and dilution in open cut coal operations; and the optimisation of mine fragmentation to increase mill throughput in gold and copper operations. The latter topic has been trialed at a number of mines and is referred to as æMine to MillÆ fragmentation. A number of æMine to MillÆ type investigations have been reported in the literature including Pease et al, Simkus and Dance, Nielsen, Scott et al, Kojovic et al, Kanchibotla et al, Bulow et al and Hawkes from the 1998 Mine to Mill Conference. In addition, a number of studies are in progress or the results have yet to be published. These studies have demonstrated the feasibility of obtaining the data required to characterise the breakage behaviour of ores and to model the impact of changes to blasting practices on process efficiency. Characterising the breakage behaviour of ores is a vital step in the management of fragmentation and comminution in mines. The characteristics of importance to fragmentation fall outside the parameters conventionally required to describe the economic geology of a deposit. æMine to MillÆ optimisation of fragmentation means that the mining engineer needs information from the geologist in order to be able to help the metallurgist. Providing this information requires close interaction between these groups.

Jan 1, 2000