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By G M. Zhomin, A S. Arkhipin, A Kondratiev

Viscosity of multicomponent slags is one of the crucial physicochemical properties for many industrial processes and technologies. While the viscosity-temperature relationship of completely molten slags can well be described by an Arrhenian-type law, the compositional dependence of viscosity is still not fully understood, especially in compositional regions with the lack of experimental data (eg at the glass-former concentration of 90 molar per cent or higher). In the present work major compositional relationships of the activation energy of viscous flow have been revised for numerous binary and ternary slag systems on the basis of experimental data collected and stored in the viscosity database OxiVis. For example, it has been found that the activation energy relevant to the polymerisation effect in binary systems of the MO-GFO type, where MO is the modifier oxide (ie monovalent K2O, Na2O, Li2O and bivalent CaO, MgO, BaO, MnO, PbO etc) and GFO is the glass-forming oxide (SiO2 or B2O3) is not always proportional to the third power of XGFO (contrary to the Urbain formalism) and can vary significantly dependent on the slag system. Also, the activation energy of the charge compensation effect has been revised for ternary systems of the AO-MO-GFO and AO-MO type, where AO is the amphoteric oxide (Al2O3, Fe2O3 or other). A simple polynomial model has been proposed on the basis of the carried-out analysis for estimation of viscosities of multicomponent slag systems. The model has been optimised against the experimental viscosities in the selected binary, ternary, and higher-order oxide systems and has been shown reasonable agreement with the experimental data.

Aug 21, 2024

By P Holtham, K Duffy, W Valery, A Jankovic

In the face of increasing energy costs, limited water resources, more stringent legislation, and lower feed grades, the mining industry is searching for more sustainable technologies and practices. Metso Process Technology and Innovation (PTI) is undertaking a research project, ‘improving the resource and eco-efficiency of mining operations’, to help the industry meet these challenges. The project is investigating alternatives in mining and processing that reduce energy and water consumption, minimise emissions and waste, and maximise the value recovered from the deposit. The targets are to reduce energy usage by more than 30 per cent and greenhouse gas emissions by more than 50 per cent compared to current practice.Key areas of interest were identified across mining and processing operations. These were grouped into the following interrelated work areas for investigation: high intensity selective blasting, in-pit crushing and conveying, preconcentration, energy efficient comminution circuits and technologies, coarse particle flotation, and water recovery optimisation. Investigations have included reviews of industrial data, modelling, simulation, and laboratory and pilot scale trials. In some areas industrial scale trials will commence shortly. This paper discusses the investigations and key findings from the project so far; highlighting the possibilities for reducing energy consumption, water usage and carbon emissions. A particular mining process may incorporate any combination of the alternatives identified and requires tailored solutions based on a detailed understanding of the ore deposit, the process and local conditions. The focus is on improving resource efficiency; creating more value with less impact and consequently a better economic return from the available resource. Technologies exist today that can transform mining into a more efficient industry for tomorrow.CITATION:Duffy, K, Valery, W, Jankovic, A and Holtham, P, 2015. Resource efficient mining processes of tomorrow, in Proceedings Third International Future Mining Conference, pp 227–238 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 4, 2015

The geographical region of South East Asia is variously defined, but generally agreed to include the Asean group - Philippines, Malaysia, Thailand, Singapore and Indonesia. Other regional countries, such as Vietnam, Laos, Burma, Kampuchea etc. are of course geographically part of the region, however in economic terms, they play a minor role. It is the Asean group that dominates present economic activity and provides the overwhelming opportunity for commercial development. My experience in South East Asia has been gleaned over 15 years of regular travel in the region. More recently, we have established company offices in Malaysia, Singapore and Indonesia to extend and deepen contacts with major customers. This progressive development is an integral part of a planned growth pattern and will be discussed in more detail shortly. South East Asia is a rapidly developing economic growth centre, a fact which is clearly recognised and accepted by most commentators. An important question is then to be asked: Why has the region been relatively neglected by Australian, U.S. and European industrial supply companies? I will attempt to address this question in the context of industrial minerals and propose some ideas as to how effective sales programs could be developed. Firstly, let's consider the market potential provided by countries within the region. It is reasonable to suggest that industrial growth in S.E. Asia over the past 20 years has been generally steady and in some cases, explosive. Until recently, this growth has predominantly been driven by development of internal (regional) demand. Population growth and rising living standards have ensured that basic industries have enjoyed a solid uptrend in sales and production. The industries which most benefitted from regional economic development over this period were, interestingly, those which we understand to be major users of industrial minerals - glass, ceramics, paper, surface coatings, cement, refractories, rubber and plastics. Each of these industrial sectors has been influenced by different growth stimulii over a 20 year period. Nevertheless, they also enjoy a common feature which ensured an above average performance. All sectors are fundamental to an environment enjoying rising living standards and rapid growth in general prosperity. More recently, internal growth factors have been overtaken by a recognition that manufactured products from the region are competitive in export markets. This comparatively recent development provides the most interesting possibilities for higher value industrial mineral raw materials. Let me explain: For 20 years, industrial growth in South Asia has essentially been focused on satisfying domestic demand. Finished quality of manufactured items was orientated to a developing market more interested in cost than aesthetics or long life. This was reflected in raw material specifications, which often did not exist and at the best were undemanding.

Jan 1, 1989

By D Wei

Large tonnages of low-grade haematite ores need to be treated every day in China. One of the mineralogical characteristics of these haematite ores is that the grain size of haematite is smaller than that of quartz and is not uniform in the ores. Therefore, a flow sheet consisting of gravity concentration, low-intensity magnetic separation, high-intensity magnetic separation and reverse flotation is mainly used to separate haematite ores in China, to obtain acceptable beneficiation performance and reduce the operating costs. Nowadays, whether based on mineral processing practice or theoretical analysis, the results show that the application of the above-mentioned flow sheet is able to take full advantage of these mineral processing methods and achieves satisfactory benefi ciation of haematite ores. For example, when the iron grade of the haematite ore is about 29 per cent Fe, a concentrate assaying 68 per cent Fe can be obtained and the recovery of iron is over 80 per cent. In the future, research work on the beneficiation of haematite ores should focus on investigating the most feasible particle size for gravity concentration circuit feed so that the operating costs can be reduced and ultimately the separation performance can be improved.

Jul 11, 2011

By H R. Phillips

During the 1980s and early 1990s, the South African coal industry experienced a series of methane explosions in which well over 200 coal miners lost their lives. In addition, a fire and an explosion in the gold mining sector claimed a further 240 lives. These tragic incidents resulted in the establishment of a research facility at Kloppersbos dedicated to explosion and fires research and the funding of an extensive research program, and almost certainly influenced the government of the day in its decision to establish, in 1993, the Leon Commission of Enquiry into Mine Health and Safety. The results of this focused research program, the wide-ranging recommendations of the Leon Commission and the determination of the coal mining industry to improve its safety record all combined to result in the past 20 years without a major explosion.This paper lists some of the research outcomes and, through three case studies, illustrates what can be learnt from investigations following explosions. The paper concludes with an evaluation of some of the findings of the Royal Commission on the Pike River coal tragedy. Many of the Commission’s conclusions are pertinent and relevant to the coal mining industry worldwide and their implementation could significantly improve coalmine safety; however, a careful study of the available facts indicates there could well be an alternative explanation of the source of the methane, the location of the ignition and the size of the explosion at the Pike River coalmine.CITATION:Phillips, H R, 2015. Lessons learnt from mine explosions, in Proceedings The Australian Mine Ventilation Conference, pp 19–28 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 31, 2015

By M J. Nugus, S C. Dominy

Mesothermal lode-gold deposits often pose problems during sampling because of their complex and erratic gold grade distribution, and the presence of coarse gold. Effective sampling and sample preparation protocols must form the basis of any resource estimate at whatever stage a project is at. Design of a sampling regime must be based upon a thorough understanding of orebody mineralogy and geology. This should include consideration of gold particle size and distribution. The sample type, size and density employed must also be based on the underlying geology of the deposit. Choice of sample preparation procedure and assay type is of critical importance if fundamental sampling error and analytical errors are to be minimised. Traditional fire assays, using small charge sizes, consistently understate assays gained from large charge sizes and techniques such as screen fire assay and bulk leach extractable gold assay. The proportion of coarse gold within samples will have a profound effect on the requirements for sample preparation and assay method. The application of Gy sampling theory can help to reduce errors within the processing of samples of broken rock. Quality control/assurance of sampling regimes must also be critically assessed. The problems associated with sampling mesothermal lode-gold type deposits are presented as case studies from Western Australia and North America.

Jan 1, 2003

By C J. Ptacek, J G. Bain, D W. Blowes

The passive interception and in situ treatment of groundwater using permeable reactive barriers (PRBs) has, within the past decade, become an accepted remedial approach to the control of plumes containing dissolved organic and inorganic contaminants. Since the first applications of the technology in the early-1990s, there have been several field-scale PRBs that have provided excellent treatment of dissolved metals in groundwater. Additional commercial applications and demonstration projects continue to be developed. Three field-scale applications and supporting laboratory columns have shown that several thousands of milligrams per litre of sulfate, more than 1000 mg/L iron, and several tens of milligrams per litre of other metals can be removed from groundwater by PRBs that promote sulfate reduction. The reactive materials, which incorporate various forms of organic carbon, promote microbially mediated sulfate reduction, the generation of hydrogen sulfide, and the subsequent precipitation of sparingly soluble iron and other metal sulfide minerals. Effective performance has been achieved by PRBs installed at a mine-tailings impoundment in 1995 (Sudbury, Ontario) and at an industrial facility (Vancouver, British Columbia). These PRBs have removed iron and other metals from groundwater. Similar materials were also used to create reactive layers within test cells directly in a tailings impoundment in 1999 (Timmins, Ontario) with the objective of removing iron and sulfate from the pore water before it migrates from the tailings impoundment. Zero-valent iron (ZVI) has been shown to provide excellent removal of chromium (VI) in a PRB, which was installed at the US Coast Guard facility in Elizabeth City in 1996, by reduction and precipitation reactions. Laboratory tests have also shown that ZVI reduces As(V) to As(III), which is subsequently removed from solution by co-precipitation with iron oxyhydroxides. In groundwater containing sulfate, ZVI and mixtures containing organic carbon can promote sulfate reduction and the subsequent precipitation of sparingly soluble arsenic and other metal sulfides. A trial PRB system was installed in 2001 and was shown to attenuate arsenic and other electroactive metals in groundwater at an industrial facility in northwestern Ontario. Basic oxygen furnace (BOF) slag, a waste material generated by the steel industry, has shown excellent potential for the removal of phosphate, elements such as arsenic and water-borne pathogens from groundwater in field and laboratory tests.

Jan 1, 2003

Existing production facilities are constantly looking at ways to increase capacity. Many recent solutions have focused on the implementation of capital and infrastructure projects. It is accepted that capital expansions are frequently necessary for production gains; however, in many cases existing assets have the potential to deliver substantially better throughput than they are currently achieving. By focusing on automation of production control systems, production reporting and business processes substantial gains can be achieved utilising existing assets. This potential can be realised quickly and has been proven across several sites and industries. In the Pilbara region of Western Australia throughput gains of between two per cent and 25 per cent (translating to millions of tonnes per annum) have been achieved from existing assets using the methodologies discussed. The improvement process involves evaluating the entire production chain from the time the ore arrives at the plant to the time it is dispatched. A technical evaluation of the performance of the control system and plant automation interfaces to upstream and downstream processes is conducted. The relationship of these processes to the business systems and the human interface to the systems is reviewed to ensure a complete picture of the system is understood. Technical evaluation targets include: individual equipment operation, the engineering level of control systems, feed controls, etc; managing recirculating loads, surge capacities, dynamic inventories as well as management of in-feed systems and integration into yard and out-feed systems; and communication flow between control and other systems, data alignment between rail and shipping schedules, yard systems, sales systems and maintenance systems including such fundamentals as truck dispatch links to plant control. In parallel with the technical evaluation, business system evaluation takes place, including analysis of the operational systems, methods and personnel.

Jan 1, 2007

By K Biegaj, S C. Dominy

A high-nugget effect and presence of coarse gold characterises many styles of gold mineralisation. The effective sampling of these deposits is often difficult because of the relatively low concentrations involved and erratic nature of the gold or other minerals. Geometric and/or metallurgical complexities often compound this effect. Underground development, in-fill drilling and bulk sampling/trial mining are generally required to delineate Ore Reserves. Similarly expensive definition strategies often apply to surface mining in complex orebodies of gold and other minerals, including precious stones. Development, particularly winzing is a historical technique that was used to gather geological, grade and metallurgical data during underground and near-surface exploration. It permits access to the mineralised structure below the surface datum to determine viability. Winzing has always been considered an arduous and dangerous task. Modern winzing technology has led to the development of the Mobile Supersucker – essentially a giant vacuum cleaner with underground and surface capabilities. By the elimination of shovel-loaded blasted winze material into a kibble and hoisting, this system permits safe and highly efficient winzing activities, and allows the collection of bulk samples for grade and metallurgical evaluation, as well as access to the mineralisation for geological and geotechnical mapping. Bulk samples from horizontal development have long been collected to help define mineable grade via pilot processing. However, when defining blocks below current development, there has been over-reliance on ineffective ‘small sample’ drill data. The Mobile Supersucker permits the development of winzes and off-winze sub-levels. These provide critical information to a mine technical team when trying to justify capital to go deeper or commence or deepen an existing open pit. CITATION: Biegaj, K and Dominy, S C, 2018. Lowering risk in complex mineralisation: application of mobile supersucker development, in Proceedings Complex Orebodies Conference 2018, pp 113–115 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 21, 2018

By E Gabriel, J C. Koppe, A Gomes and P Crispim, R Schaarsdmit, I Pablos

Drill and blast (D&B) is one of the most important production operations in open pit mining. The resulting fragmentation of the D&B reflects in the downstream unit operation. Good fragmentation of the ore will minimise the cost of loading, hauling and crushing. The understanding of the geological model integrated with a software system for bench face surveying and planning of blast layouts based on three-dimensional images can help to achieve the fragmentation goals of the mine operation. A case study integrating these tools was carried out in a large iron mine in Brazil. The iron ore in the study area consists of hard and friable itabirites. More than three different ore types may occur on the same bench. Under these conditions, data integration becomes necessary to improve the results of blasting. A blasting plan was based on the generated geological model. The methodology helps understanding the factors that can interfere in the fragmentation process, allowing defining actions that can improve the blast design in those places that fragmentation wasn’t achieved. This condition is important for a continuous improvement of the drilling and blasting operation. In comparison with the previous blasting carried out at Itabira mine, which did not take into account the geological model, substantial improvements in fragmentation were observed, eliminating the need for secondary blasting.CITATION:Schaarsdmit, R, Pablos, I, Koppe, J C, Gabriel, E, Gomes, A and Crispim, P, 2015. Geological modelling and bench face survey to improve blasting fragmentation, in Proceedings 11th International Symposium on Rock Fragmentation by Blasting, pp 401–406 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 24, 2015

The cost of production from truck and loader fleets is influenced by management development of the culture of the organisation, work practices, systems and procedures of the production and maintenance teams. Establishing if the cost of production is the best that can be achieved then requires the measurement of results against established standards of performance. This paper provides a series of discussion points of the factors that influence the cost of production from men and machines for large scale open pit mining operation and provides some suggested performance standards in the form of Benchmarks. Most of the references have been drawn from established large scale deep pit mines in USA, Canada and Australia which have had to implement and constantly fine tune cost efficiencies in order to survive. The discussion provides:ò a review of priorities or the relative importance of the various cost elements for a mining system;ò suggestions of systems and procedures for the operation and maintenance of machines which are considered to yield the best overall results;ò examples of operations that have developed and implemented management systems and controls that are achieving good results in specific functions; andò suggested benchmarks of performance.

Jan 1, 1992

Permian ultramafic and associated rocks form a belt in East Nelson and contain widespread, but minor, chromite and copper mineralisation and some mining was carried out last century. Since mining ceased, about 1910, little mapping of the belt has been carried out although its origin has been debated vigorously. Recently it has been inferred to form part of a ophiolite sequence, which has been tectonically disrupted to form a melange, and several 'plate -tectonic' models have been proposed. Mapping in the central part of the belt has shown that mTlanges are to the east of the ophiolite sequence. Faulting is widespread so that in anyone section part of the sequence may be absent. Some of the faulting is difficult to recognise and probably took place during or soon after the sequence accumulated. Other faulting is clearly of Cenozoic age and includes major NNE striking faults, with large horizontal displacement, and approximately east-west striking faults with almost entirely vertical movement. The writer agrees that 'plate tectonics' could provide an acceptable explanation for the origin of the ophiolite sequence but the models so far proposed do not take into account the nature and field relationships of the rock units present. Copper Mineralisation is largely controlled by the younger faults, particularly those striking about north-east, and is largely confined to the western part of the ultramafic rocks particularly where slivers of the volcanics of the adjacent Lee River Group are enclosed. Mineralisation, along NNE striking shear zones, has recently been found in the volcanics some distance from the ultramafic rocks. The chromite mineralization is in the form of primary layering in the basal part of the ultramafic belt although in places it has been concentrated into lenses probably during serpentinisation.

Jan 1, 1977

By Davison GR

The cost of drilling consumables is always a large component of any mine budget. It is important that this cost be carefully examined with a view to reducing the overall cost per inetre or at least minimising its escalation.At Renison it is considered that the only way to ensure drilling costs do not rise unduly is through a total system of control from purchase to disposal.In 1979 extension of an existing drill supply service contract was carefully examined and abandoned in favour of a hybrid system. This system is providing a great deal of control over the use of drilling consumables and has maintained a relatively constant cost per drilled metre over the last five years.Current consignment stock contracts for drilling consumables are strictly specified by the Technical Services section of the Mine Department and consumables purchased under these contracts are distributed and refurbished/sharpened by a contractor.The total result of this package is individual drilling items that achieve the best cost per metre and careful distribution and maintenance to ensure maximum life.

Jan 1, 1985

By P Campi, M Dodds

The EastLink project is a 39 km tollway to the east of Melbourne and includes twin three-lane 1.5 km driven tunnels. The hard rock tunnels are being built to avoid passing the motorway through the Mullum Mullum Valley to help preserve the unique flora and fauna in the area. This paper describes the process of transferring the support requirements from the ædrawing boardÆ to the tunnelling face by integrating the temporary support design with the contractorÆs tunnel excavation and support procedures, including sharing of responsibility between the designer and contractor for selection of the support type and the production of a project specific rock mass classification system to enable more objective determination of ground conditions. The methods developed during the design phase incorporated a formal system of reviews, support selection and feedback by monitoring tunnel and ground responses. During construction, the process was implemented using a set of simple documentation and regular structured communication between the contractor and the designer.  

Jan 1, 2008

By A M. Robertson, R Lefebvre

Air movement and associated oxygen transport through waste rock dumps has the potential to significantly enhance the rate of oxidation of pyrite-bearing material. While this is a desired outcome for most heap leach operations, airflow in waste rock storage facilities can result in significant increases in generation and acceleration of acid rock drainage. Hence, a good understanding of internal airflow through waste rock dumps is required to control ARD and minimise any associated liability. The principal mechanisms contributing to airflow and oxygen transport in a waste rock pile include: diffusion; advection due to a thermal gradient (chimney effect) and/or wind pressure gradients; and advection due to barometric pumping. While diffusion is typically limited to a near-surface zone of a few meters depth, advection and barometric pumping have the potential to move air (and oxygen) to much greater depths into the pile. In general, the more permeable the waste rock material, and the greater the height-to-width ratio of the waste rock pile, the greater is the potential for advective air movement. The reactivity of the waste rock material as well as the coarseness (hence air permeability), and the spatial variability of these properties within a pile, have a strong influence on the magnitude of thermally induced advection. In contrast, air movement due to barometric pumping is controlled by the waste rock porosity, changes in ambient air pressure and the heterogeneity of air permeability of the waste rock dump. Results of field monitoring and numerical modelling using TOUGH AMD are presented to illustrate the concepts on air movement in waste rock piles discussed in this paper. During the design and construction phase, airflow can be controlled by judicious placement of reactive waste rock and use of selective placement techniques to control the internal structure of the waste rock facility (eg introduction of horizontal layering, prevention of inclined, high-permeability, channels (æchimneysÆ)). Several closure measures are available to minimise airflow including: placement of a low-permeability cover to reduce air entry; and placement of a non-reactive cover material to isolate reactive material from the zone of active airflow and/or regrading of the waste rock pile to obtain a geometry and internal structure less susceptible to advective airflow.

Jan 1, 2003

By Watt KL

Chemical anchors for use in rock bolting have been produced in Australia under licence for several years. These anchors are alternatives to the more normally used mechanical anchors and give improved anchorage strengths under some conditions, although at greater cost. Considerable development during this time has resulted in an improved sausage-type chemical anchor more competitive in price, to such an extent that its use is increasing markedly. Particular-improvements allow load application up to the strength of the bolt within 2 min, reduction in cost, self-extinguishing features in the resin, improvements in manufacturing techniques, and an improved water- insensitive casing. At the same time, smaller bolt sizes have allowed reduction in resin volumes with consequent cost reduction. At this stage several aspects remain to be improved, particularly specialty anchors for specific purposes and Packaging.

Jan 1, 1971

By Fickera M. A, Marshall S, Burgeese F. L, Burgees J, Estrina H

A new high intensity flotation process FASTFLOT was deployed to recover residual zinc from the zinc circuit tailings at Pasminco Mining's Concentrator, Broken Hill. Performance of the FASTFLOT process is discussed with respect to various size fractions. Results suggest that the process has an affinity not only for fine particles but also for +200 ¦m particles which the conventional flotation cells failed to recover. Various strategies for FASTFLOT deployment are also discussed.

Jan 1, 1995

Tonnes per Hour - Kilowatts per Tonne Tonnes of Mesh Size Produced Kilowatts per Tonne of Mesh Size Produced - Terms often heard in discussions of grinding mill and grinding circuit performance. All of them only tell a partial story as none of them relate to a fixed reference or overall standard measurement. Tonnes per Hour gives the production rate relating it to a specified or desired rate set as a goal or objective. As such it does not take into account changes in feed size, product size or grindability. Kilowatts per Tonne which accurately stated is kilowatt hours per tonne brings power consumed into the picture which is related to grindability but still does not take into account changes in feed size and product size without which power changes do not necessarily reflect the complete effect of changes in Grindability.

Jan 1, 1978

By A G. L Pratt, C Rossetti

The implementation of mass mining methods for large metalliferous deposits has led to the development and application of increasingly sophisticated automation and condition monitoring technologies in these mines. This technology aims to increase safety, equipment utilisation and monitoring of critical aspects of the underground ambient and geological environments. The communications networks required to support these aims and their associated technologies have evolved accordingly, and have done so in a demanding underground environment. The evolution of communication infrastructure for large underground mines has developed from basic analogue telephony to high-bandwidth optic fibre based systems. The latter is now the media of choice. More recently the developments in wireless broadband equipment designed specifically for underground environments have emerged to satisfy the needs of automation for mobile equipment and shaft conveyance communications. The use of internet protocols for industrial control and monitoring has led to the application of ethernet-based backbone networks as a standardised approach. There may also be a need for the integration of range of communications platforms in a mining operation to realise the full advantages offered by automation and condition monitoring technologies. As a result the design of the communications backbone networks for underground mines has started to become the domain of information technology professionals. Without these networks, the analysis of equipment utilisation is often not possible. The improvements that can be brought about by æsweating the assetsÆ and the transmission of business critical information are the most significant benefits of an integrated communications system. These benefits far outweigh the costs of strategic planning, subsequent specification and implementation of communication networks themselves. Future developments in mining systems and communications technology will continue to drive the demands placed upon communications networks as an essential mass mining infrastructure item. This paper outlines the benefits of secure high bandwidth backbone communications networks for mass mining operations and the need for a high degree of strategic thought and demand forecasting in the planning stages for these operations.

Jan 1, 2008

During the post war era, the requirements of the "Third" World for modern civil works, energy and industry, coupled with an insistence that these capital installations are understood and controlled by indigenous people, have crea- ted a demand and flow of technology from those countries with well developed skills. Thus has grown a real trade in technology - an activity in which consultants play an important role. An indication of the magnitude of this trade is given, together with an outline of some of the special problems. Australia is shown to be dis- advantaged and has been slow to offer the incen- tives to consultants which other countries offer.

Jan 1, 1975