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By A Deakin

It has been almost a decade since the release of the International Council of Mining and Metals (ICMM) Health and Safety Critical Control Management: Good Practice Guide (2015a). During this time the ICMM member companies, along with many others across industry, have been busy designing, deploying and enhancing their own critical control management (CCM) programs. So, what have we learnt? This paper discusses the scope, application and learnings from the implementation of CCM within the mining industry. What’s going well? What are the common challenges? What are the opportunities to strengthen the approach? What are the threats to successful implementation? The paper draws on the author’s experience as one of the key contributors to the development of the CCM Good Practice Guide and an adviser to many mining companies, including six of the ICMM members. The paper focuses on the practical (operational) application of CCM and the cycle of identifying, defining, implementing, verifying and improving critical controls at the frontline. The paper also includes a discussion on the safety performance of the ICMM member companies over the past decade and provides a recommendation for how CCM can be incorporated into a more proactive model to measure safety performance. The paper concludes with practical recommendations that mining companies, regardless of their CCM maturity, can consider as they look ahead. They are supplemented by three additional recommendations for consideration at the industry level.

Apr 16, 2024

By B Reynolds

The process design for green- or brown-fields metallurgical plants typically starts with two fundamental elements: the detailed mass and energy balance and the plant flow availability. The detailed mass and energy balance is generally developed using process flow-sheet simulation software and represents the steady-state operation of the plant at normal operating conditions. The plant flow availability, also known as a range of other industry-specific terms such as ‘flow availability’ and ‘operating factor’, describes the ratio of plant production to the steady-state mass balance. These elements are then used together as the basis for equipment selection and design.Plant flow availability takes into account a myriad of production loss factors including planned and breakdown maintenance, feed availability and composition changes, variability in operational performance and the interaction of batch and continuous unit operations. The combined impact of these loss factors are complex and as such plant flow availability is usually derived using a top-down approach such as comparison to an existing operation, a group of similar operations or to an anecdotal ‘industry leading’ benchmark. These top-down approaches are fraught with risk however, as they cannot factor in changes to equipment selection, flow-sheet or plant operating philosophy, and can result in over-expenditure of scarce capital or shortfalls in plant production.The use of dynamic simulation to provide a bottom-up alternative to quantifying the plant flow availability in metallurgical plant design has been growing rapidly in recent years. It provides a technique to quantify the combined impact of the loss factors described here and a tool to support process design and equipment selection by facilitating a range of sensitivity and what-if analyses. This paper presents a case study of how dynamic simulation has recently been used to support the

Aug 8, 2011

Drilling has disclosed a sequence of Cainozoic sediments immediately to the west of the Ediacara mineral field containing little or no dolomitic debris in the lower and middle sections, but with gravel beds of dolomite derived from local rocks in the upper part. It is suggested that the lower and middle sequence of Cainozoic strata was deposited over the area of the Ediacara Range, and that this range was uplifted, probably as a horst block, during Quaternary times and was first exposed to subaerial erosion during the upper Pleistocene epoch.Lower Cambrian dolomites with associated stratiform lead mineralization, which formed the target of drilling on the western downthrown block of the Ediacara Fault, were eroded before deposition of Cainozoic sediments.Intense leaching of basal Cambrian dolomites around the periphery of the Ediacara Basin took place during Mesozoic and Tertiary times. This leaching process has resulted in enrichment of copper and lead mineralization in a thick marginal zone of residual clayey material overlain by dolomitic collapse breccia. These zones of leaching and enrichment were preserved under Cainozoic sediments which have subsequently been eroded. The Ediacara Fault appears to have been a major conduit for mineralizing fluids and is the main lineament of the Torrens Hinge Zone. Contemporaneous movements on this fault have controlled rates of depositionand thickness of sediments across the fault during Adelaidean and Cainozoic times. Though latest movements of this fault have been west block down, the predominant movement has been east block down with associated thickening of sediments to the east in the Adelaide Geosync1ine.

Jan 1, 1972

When, in 1985, Marty McFly is accidentally sent back to 1955 in a DeLorean ‘time machine’ in Back to the Future, he encounters young versions of his parents, and must make sure they fall in love or he will cease to exist. This Conference celebrates 40 years since the inaugural Mill Operators’ Conference in Mt Isa in 1978; over this period, great technological advances have been made in almost all aspects of mill operation, resulting in considerable improvements in grades and recoveries from ever-more complex ores. However, in 2018, the mining industry is facing challenges that might have been difficult to predict in 1978 (or were they?). The computer revolution, the information revolution, and the bio-technology revolution have all contributed to the increase in operating efficiencies, but, combined with the social revolution, they also call into question the existence of the mining industry as we know it. This presentation looks back at the ‘way things were’ in the 1970s, and at what was then considered to be the ‘basics,’ and attempts to sketch what the mining industry might be like in 2058. As Back to the Future Part II demonstrates so vividly, it is much easier to review the past than predict the future. It is difficult to know what form the mining industry will have in 40 years’ time. Nevertheless, as this presentation will argue, it is important to take action now, to ensure that it (like Marty McFly) does not cease to exist. Some courses of action are proposed, including going back to the basics of a very different past.*This is an abstract only. No full paper was prepared for this abstract.*CITATION:Franzidis, J P, 2018. Back to basics or back to the future?, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 3–4 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

Benchmarking of mining operations has been in vogue for a number of years: it seems teams are forever flying around the world to try to understand what other operations are doing. However, unless a benchmarking exercise involves data gathering at a fundamental level and a rigorous analysis process is applied, the trip will be nothing more than industrial tourism. When benchmarking is performed thoroughly, the range of comparisons that can be made is extensive and informative, and need not be restricted to sites with similar conditions and equipment fleets. This paper describes the detailed and rigorous process for benchmarking used throughout AMC benchmarking studies. The paper demonstrates how, through drilling down to the underlying drivers, the often heard cry of æyou canÆt compare us, weÆre differentÆ can be overcome. Included in the discussion are a number of significant issues that have been identified during AMC benchmarking studies. The paper then considers the types of opportunities that have been identified and the potential for improvement. The paper concludes with a discussion of the implications for planning, measuring and management of operational performance.

Jan 1, 2003

By D MacKay, W J. Bruckard

One of the mining worldÆs greatest challenges is to effectively use consumables (ie reagents and grinding media) to maximise metallurgical response, while minimising operating costs. It is anticipated that this paper will provide a logical frame work within which this can be achieved. The current study, at PerilyaÆs Broken Hill concentrator in the lead primary grinding/roughing circuits, examines the dependency of collector adsorption on Eh. The data demonstrates clearly that under the right grinding chemistry the addition of a xanthate collector during grinding can improve galena flotation. Further, operating the ball mill under the desired grinding chemistry regime leads to significant reductions in collector consumption whilst maintaining the metallurgical benefit.

Jan 1, 2008

Technical control in an industrY invariably leads to a basic contribution from the science of chemistry. It is interesting to note. that the change from the "Assay Office" to the "Chemical Laboratory" has already taken place on the majority of progressive mining fields.Although the serlvices of an efficient chemical staff are freely availed of by operating departments, it is not generally realized that practical chemistry is definitely expensive. A great deal of misplaced energy and expense can be involved in an enthusiastic research campaign where a full appreciation of laboratory economics and a balanced sense of analytical values are lacking.In order to supply data to the various departments concerning individual costs, it was decided at the North mine to issue a supplementary sheet concerning laboratory activities.The costs are compiled under the Unit System, which is based on a relative comparison between the total cost of the various determinations. carried out and the number of such determinatiQns converted to an equivalent aggregate of units.The introduction of the system necessitates the initial compiling of a table of relative units for the various estimations carried out on the works. Each laboratory will find it necessary to draw up such a table governed by local conditions, and, as will be anticipated, a relative comparison of the cost for any particular estimation will show a variation on a lead field, a copper field, or a steelworks, etc.This is due, of course, to the predominating type of routine work, cost of landing reagents, frequency of assays, etc. The satisfactory preparation of the Unit Table requires a good knowledge of laboratory procedure.

Jan 1, 1940

Structural geological modelling is a process which results in a 3D computer model that represents the essence of the geological and structural understanding of an area and is presented in a way that is directly useable, typically by internal customer groups. BHP Iron Ore operates a number of open cut iron ore mines in the Pilbara Region of Western Australia. The largest mine is the Mt Whaleback Mine located at Newman close to the southern margin of the Pilbara Craton. The structurally complex Mt Whaleback Mine is the largest metalliferous single pit open cut mine in Australia with over 1.6 billion tonnes of original iron ore resource. Additional to the Mt Whaleback Mine, a number of satellite open cut iron ore mines are operated by BHP Iron Ore (BHPIO) in the Newman area. BHPIO also operates the Yarrie mine approximately 400 km north of Newman at the northern edge of the Pilbara Craton Most of the BHPIO mines are located in the Archean- Proterozoic Hamersley Province that overlies the Archean granite-greenstone terrain of the Pilbara Craton. The orebodies are considered to be the result of supergene enrichment of the approximately 2.5 Ga Brockman Iron Formation and the slightly older Marra Mamba Iron Formation. Folding represents the most prevalent and penetrative structural element in the Newman area. Four folding phases have been identified regionally (Fj, F2, F3, F5), while a more local folding deformation (F4) developed mainly in the Mt Whaleback and Orebody 29 mine area. A northeast trending, southeast dipping, 45 km long, high angle, normal fault zone, the Whaleback Fault Zone, cuts through the Mt Whaleback mine resulting in an approximately 1400 in gap in stratigraphy. Additionally, two large, low angle, normal faults, the East Footwall Fault and the Central Fault, are present at the Mt Whaleback Mine. During the formation of supergene orebodies, up to 40 - 45 per cent volume loss occurred resulting in local non-tectonic deformation in the orebodies.

Jan 1, 1997

Byproduct coking is practised in three of the major Australian ironmaking centres, the Newcastle and Whyalla works of the Broken Hill Proprietary Co. Ltd. and the Port Kembla works of Australian Iron & Steel Pty. Ltd. Coking first commenced at Newcastle in 1915 and at Port Kembla in 1938. The installations established at these centres include coal cleaning facilities and com- plete byproduct streams. The Whyalla plant, because of its location is somewhat less extensive, having no coal cleaning plant and a comparatively restricted byproduct section. As new batteries have been built every opportunity has been taken to incorporate modern design features and improved operat- ing techniques. This has included the provision of equipment to reduce atmospheric and water pollution. A marked reduction of markets for byproducts has had serious repercussions on the profitability of this section of the Industry.

Jan 1, 1972

The aim of the study was to determine the ranges of stability and instability of the metal hydroxides and metal cyanide species that may be formed during the gold extraction process, Merrill-Crowe gold precipitation, and Inco S02/Air or ferrous ion cyanide removal processes.Following cyanide detoxification by the Inco S02/Air process, the main components of concern in the tailings will be:

Jan 1, 1997

By Oliveira JF

Thiourea is an alternative reagent for cyanide in gold leaching. The recovery of gold from acidic thiourea solutions by adsorption on activated carbon is based on methods similar to those applied for the extracting of gold from cyanide solutions, but the mechanism involved in the process is not completely understood. In the present work, studies were carried out to evaluate the adsorption of gold onto activated carbon. Experimental data showed good agreement with both the Freundlich and Langmuir isotherms. The adsorption of gold from acidic thiourea solutions proved to be an endothermic process, while the adsorption from cyanide is known to be exothermic. The isosteric heat of adsorption of -11.3 kcal/mol in the early stages of the adsorption is an indication of a process involving chemisorption. The effect of temperature was studied between 15¦C and 55¦C. An activation energy of 3.5 kcal/mol was determined by the Arrhenius plot, which indicates that the controlling step in the kinetics of adsorption is the diffusion onto the porous structure of the activated carbon.

Jan 1, 1993

By D Suppel, Y Miezitis, S Jaireth

The competition between various options for the use of land is ever increasing. Commonly in Australia large tracts of land were un-encumbered by sweeping land use option limitations, but this situation has been rapidly altering in recent decades as governments are obliged to maximise the utility of the land for a broad range of competing interests. While the interests of miners have always been considered, the effects on limiting access to land for exploration and possible mining have not always been effectively incorporated into decision-making processes. As a result the challenge for national and state organisations representing these interests has been to develop a transparent process to allow for the mineral potential of an area to be systematically assessed and for information to be presented for use by specialists and non-specialists. Government agencies are called upon to implement government policy but also to provide accurate and meaningful advice which can assist in policy and land use decisions. Commonly timeframes are short and information can be less than complete. Nevertheless on-going decisions are made based upon the best available understanding. It is in this operational framework that the methods described in this paper are set. The paper describes a process for quickly and systematically providing advice on mineral potential for use by government agencies and ultimately the community within tight time and resource constraints. It is a method of combining the accumulated knowledge about mineral resources and their potential and presenting this information in an easily accessible form which can be used in a negotiation and policy development environment. Development of the method was undertaken to meet the needs of the Regional Forestry Agreement process in Australia. The method has been applied to study areas in New South Wales, Tasmania, Western Australia and elsewhere. Examples in this paper are taken from north eastern New South Wales.

Jan 1, 1999

By I Elias, E Moya, S Chaffer

This paper is based on a case study from a mine site that operates two gyratory primary crushers. These crushers were encountering problems, which included inconsistent P80, reduced liner life tonnage and, on some occasions, catastrophic failure of the liners.As part of an evaluation process, both crushers were ‘mapped’ using a technology for condition monitoring and modelling of the crusher’s wear components. The technology provides comprehensive coverage of the crusher’s concaves and mantle at 100 mm intervals. It also automatically assesses wear rate between inspections and determines the highest wear areas. Outcomes include projected optimum reline dates at target replacement thicknesses, the identification of asymmetrical wear patterns, and the accurate measurement of open and closed (OSS/CSS) side settings.A comprehensive study was performed to optimise the performance of both these crushers at site. Over a period of seven liner service lives, the strategies to improved performance included liner analysis (concaves and mantle profile analysis), tonnes per day (t/d) and tonnes per hour (t/h) analysis, mantle reutilisation, detection and control of loose concaves, and detection and control of uneven wear and hot spots.These strategies resulted in the improved mechanical and operational performance of both crushers through concave and mantle redesign, OSS/CSS control, accurate wear forecasting plus other initiatives.As a result of these initiatives, the site now experiences benefits which include consistent product size, increased tonnes per hour (t/h) for both crushers and the liner life tonnage has doubled. Additionally, further benefits include less downtime for crusher liner maintenance and the reduced cost of inventories by mantle reutilisation.CITATION:Elias, I, Chaffer, S and Moya, E, 2015. Improvements in service life and cost reduction for gyratory primary crushers through mantle and concaves optimisation – a case study, in Proceedings Iron Ore 2015, pp 115–128 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

By N Madani, Y Abildin, E Topal

Mine planning is a crucial part of all mining industry projects, and nowadays, geometallurgical mapping through advanced computer technologies provides an opportunity to involve metallurgical responses of a deposit into 3D block model in order to optimise mine planning activities, especially for production forecasting. Including these metallurgical parameters apart from traditional geology and grade-based attributes into resource modelling leads to an extensive approximation for the economic maximisation of mine production due to better forecasting, planning and increasing certainty and the reliability of the resource model (Macfarlane and Williams, 2014). Commonly, geostatistical techniques and algorithms are used to produce models with the high resolution (Brissette et al. 2014; Deutsch et al. 2014; Tolosana-Delgado et al. 2015). The accuracy of the modelling procedure deeply depends on a reliable block model, produced by spatial analysis of corresponding variables that define the geological, metallurgical, mineralogical and chemical behaviour of the deposit. However, there are special cases, where the application of enhanced geostatistical methods is required, to solve the occurred difficulties between variables with multivariate complexities. For example, in oxide copper deposits, the soluble copper grade is a percentage of total copper grade and recoverable by heap leaching processes (Emery, 2012; Hosseini and Asghari, 2015). Hence, the joint spatial modelling of these variables has two difficulties.CITATION:Abildin, Y, Madani, N and Topal, E, 2018. Forecast the mineral processing destinations based on spatial interpolation of geometallurgical variables, in Proceedings Complex Orebodies Conference 2018, pp 2–5 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 21, 2018

Material sampling theory is well established in mineral process monitoring, improvement and control. It has been much enhanced by fundamental contributions due to Gy. When GyÆs sampling theory is applied to sampling inspection and monitoring, it provides estimates of average quality or extent of contamination. It also provides estimates of uncertainty, but these often ignore uncertainty in estimated variograms or other measures of variability. Risk assessment is often an implied task in sampling inspection and quality monitoring. A valid technique of risk assessment needs to take into account the uncertainty in the variational measures themselves. Standard statistical tolerance limit calculations which do take such uncertainty into account can be adapted to develop a technique for handling uncertainty in variational measures such as the variogram. Data from a published example is used to illustrate the technique.

Jan 1, 2005

This paper summarises the current status of the mining sector in Poland in terms of vertical transport system safety. Selected results of research programs conducted at the AGH-UST relating to mine hoist system safety are reviewed. The conclusions support the notion that the costs of vertical transport systems can be reduced, while at the same time maintaining the required safety and reliability levels. Novel solutions: movable fender beams HWR, linings modar« and the integrated shock absorbers PHH for conveyance guiding systems fully confirm this hypothesis.

Jan 1, 2005

The mining industry worldwide relies upon the identification of resources that can be economically developed and operated. Access to land is paramount through all stages of the exploration, development, operation and rehabilitation stages. Clear rights to use of land for the purposes of mining must be available and protected throughout the life of the project. Stable and enduring criteria for mining of the resource, once identified, are required to attract exploration and development expenditure. The purpose of this paper is to investigate the varying approaches to granting access to land for use for exploration and mining development, including the processes by which a project is approved by community and government and the time scale for such approval. The paper concentrates on the legal issues arising throughout this process. The law is stated as at September 1997.

Jan 1, 1997

By J Loeb, R Ramanathan, H Ingham, P Cameron

Most mining operations, including iron ore, maintain a focus on continuous improvement and asset optimisation in their operations. As all the unit operations in the Mine-to-Mill value chain are interdependent, available technologies that address efficiencies across the value chain are once again in the spotlight as companies are driven to improve productivity and maximise mine site profits to increase return on capital invested. Core to continuous improvement is the need to understand the baseline and impact of changes to the process. In this paper, we discuss some of the critical attributes in the Mine-to-Mill process, including their influence on productivity and cost, the need for direct measurement and areas where they should be applied. Many initiatives can be considered to improve Mine-to-Mill processes. Mining operations are planned and executed based on designs and models to achieve the operation's objectives. However, there are many variables in the different parts of the value chain, such as blasting, material handling, crushing and screening. Therefore, measurement of the key attributes establishes the baseline for Mine-to-Mill (or Pit to Plant) performance, which is necessary to understand the impact of any proposed improvements to the process design and execution and monitor the outcomes on an ongoing basis sustain the improvements that have been implemented. This paper focuses on two types of measurement – blast movement and particle size of materials through the Mine-to-Mill process. Several innovative technologies and control loops are readily available to measure these attributes and assist operations to improve productivity and mine site profits. The size of the tangible benefits, which can flow from measuring and optimising fragmentation and blast movement, provide a remarkable return on the investment. Realising these benefits needs a focus outside conventional operation silos as a successful Mine-to-Mill project requires a multidiscipline approach across all the silos in the value chain. Required technologies are available; adding the necessary ingredients of communication and co-operation by all concerned across the silos will ensure the benefits are realised.

Nov 8, 2021

The introduction of cement into underground backfilling at The Zinc Corporation, Limited and New Broken Hill Consolidated Limited mines to improve mining efficiencies gave rise to several major problems, the magnitude of which had not been anticipated. These problems were 1. A loss of recovery in the milling circuit due to the presence of cement 2. The presence of cement-rich slime layers on the surface of the fills 3. The introduction of a safety hazard due to the slippery nature of the surface of cemented fills 4. The deposition of cemented slimes on the levels and in underground sumps and dams. The loss of revenue due to decreased metal recoveries considerably offset the gains from increased stoping efficiencies and the use of cement was substantially reduced while, (a) the Metallurgical. Department attempted to identify the chemical nature of the problem and overcome it, and (b) the Mining Department investigated methods of reducing cement contamination of the ore stream. As a part of this investigation the Mining Department added polymeric flocculants to the cemented fill pulp. Testwork was carried out in the following steps 1. The available Alfloc polymers were screened to determine which was the most effective and what was its optimum dosage rate. 2. This polymer was used in the laboratory to determine the reduction of surface slime, clarity of water, and effects on strength and percolation of fill. 3. Fills were placed underground to substan- tiate the laboratory work. /+. The polymer was then added to all cemented fills going underground to study its effect over a long term. The use of flocculants not only improved the distribution of cement in the body of the fill, but also the distribution of the fines fraction of the filling material, practically eliminated slippery surfaces and improved the clarity of the drainage water. Flocculant is now added to all cemented fills and restrictions on the use of cement are gradually being lifted.

Jan 1, 1973

By K Nesbitt

Draw control at Premier Mine is considered important to avoid conditions of isolated draw, which results in early waste ingress, compaction of the kimberlite ore and loss of ore reserves. The Premier Mine kimberlite pipe is unique in that the pipe is cut at a depth of 400 metres below surface by a 75 metre thick gabbro sill. All cave mining at Premier is below the sill and failure to exercise good draw control could cause early ingress of gabbro waste. Gabbro causes problems in the diamond recovery plant and the amount of gabbro sent to the plant needs to be closely monitored. Fortunately coarse gabbro fragments are easy to recognise in drawpoints. It was anticipated that only 85 per cent of available ore would be drawn from the blocks immediately overlain by the gabbro sill before excessive gabbro waste forced the closure of drawpoints. Data on tons drawn per drawpoint and loaded per LHD as well as the tons tipped per pass is gathered by the vehicle monitoring and control (VMAC) system and information recorded by the load-haul-dump (LHD) drivers. Draw control staff monitor drawpoints on a shift basis and record the occurrence, type and height of hang-ups. Information pertaining to the status of the drawpoint in terms of support, waste and availability is also recorded. A database has been compiled that has been used to analyse the overall pattern of draw control, the frequency of occurrence of different types of hang-ups, secondary blasting efficiencies and drawpoint and LHD productivity. The gabbro sill has provided a unique marker horizon that has allowed the arrival of rock from a level 100 metres above the production level to be recognised. Data shows that ore migrates extensively towards groups of drawpoints that are heavily drawn with many drawpoints more than 100 per cent drawn before gabbro waste was recognised. This indicates that an accurate mixing algorithm is essential for good draw control. Data on tons drawn, drawpoint availability, productivity and the occurrence of various types of hang-ups has allowed better control of the mining operation and provided data for planning future caves. In the BA5 mining block a drawpoint spacing of 22 metres, horizontally across the major apex, has still allowed drawpoints to be pulled to waste with no loss of ore. In the BB1E mining block the drawpoint spacing has been increased to 23 metres and no problems have been experienced to-date. Future initiatives centre on improving the data gathering integrity of the vehicle monitoring and control system and a linear programme that will optimise draw control and productivity.

Jan 1, 2000