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By J M TORLACH

Learning is an iterative process, and we might reasonably expect that after more than a century of mining during an era of sustained technological development, (following a millenium or two of unrelieved hard physical graft), that the more obvious physical hazards could by now be competently managed. It is perhaps a reflection on the perversity of human nature that we have not fully learned our lessons in this exacting environment, and that worse, we have still too often failed to profit by the experience of those lessons. The more obvious underlying factors which impact on this situation are examined briefly, as a prelude to consideration of some outstanding examples of recurrent problems experienced in recent years. Reasons for the continued existence of sub-standard practices are outlined, with a focus on the human element, and finally proposals for appropriate remedial strategies are summarised. This paper therefore seeks to examine and discuss some of our deficiences and to suggest some directions for the way ahead.

Jan 1, 1992

Mining and mineral processing makes a vital contribution to AustraliaÆs national export income, and our society today is critically dependent on its products. Despite the importance of this industry, its operations often come under scrutiny because of its high potential impact on local environments û both social and ecological. The challenge for the minerals industry today is to make the most responsible and best possible use of the national resource base, maximising overall resource utilisation.Research efforts and industry implementation of improvements have been moving in this direction for a considerable time already, and the industry has a long history of process innovation and improvement in Australia. Examples range from the early development of gold cyanidation and mineral flotation to more recent work undertaken under the auspices of AMIRA or through the various CRCs and research organisations such as the AJ Parker CRC for Hydrometallurgy, the Cooperative Research Centre for Mining Technology and Equipment and the Julius Kruttschnitt Mineral Research Centre.However, the nature of research and innovation in the mining and mineral processing sector is changing, as the industry itself copes with the pressures introduced by globalisation, industry consolidation and commodity price cycles. Large firms that have historically maintained a tradition of corporate technology and a culture of innovation are moving to outsource their technological and research competencies and are adopting æfast-followerÆ mentalities. At the same time, the challenges of sustainable development that need to be addressed are many-faceted, multidisciplinary, and require a holistic approach for significant achievements to be realised. Many sustainability issues, particularly those pertaining to environmental and safety issues, are shared across large sections of the minerals industry, and are seen as æindustryÆ problems beyond the scope of a single company.In this environment, collaborative research efforts are becoming the dominant mechanisms for building on past innovations and ensuring the continued success of the mining and mineral processing industries within a framework of sustainable development.

Jan 1, 2004

Lime is the common reagent used for pH control in cyanide gold circuits. Lime can be supplied as either quicklime (CaO) or 'hydrated lime(Ca(OH)2). Both are dry powders with variable flow properties. These properties demand special attention when designing machin- ery to handle them.

Jan 1, 1987

By Wadsley MW

This paper gives an overall view of the CSIRO-SGTE computer system for thermodynamic calculations. The basis of the system is the coupling of a large self-consistent numeric data bank of thermodynamic information to a modular set of application programs. These seven programs cover management of data files, calculation of thermodynamic properties for species and reactions, plotting of predomin- ance area diagrams, equilibrium and enthalpy balances for complex processes, analysis of thermodynamic efficiency and the estimation of unknown properties. The data bank contains a wide coverage of species and data types so that the system may be applied to many areas of chemistry and metallurgy.

Jan 1, 1984

By M Darvall

Magnetite ore blending has yielded signifi cant performance improvements in OneSteel’s magnetite concentrator. The magnetite concentrator beneficiates magnetite ore from the Iron Magnet Deposit and produces concentrate, which is pelletised, then fed to the OneSteel Whyalla blast furnace. Concentrator feed variability severely detracts from the concentrator’s performance, affecting both concentrate yield and grade, which impacts on all downstream processing costs.A coordinated approach has integrated mine planning, geological modelling and grade control, to minimise concentrator feed variability, through effective ore blending throughout the mining and stockpiling process.Mine planning personnel design shots that extend the full width of the orebody and hence across the stratigraphic profi le. Based on geological information contained in block-outs and in consultation with Geology, the Grade Control team allocates material to each primary stockpile, potentially from every stratigraphic domane in the orebody. This ensures primary stockpiles are designed with maximum practical homogeneity and consistency.Using only primary movement, the allocated ore is stockpiled in a layer-cake fashion. The ore is pimple dumped across the width of the stockpile footprint and on completion of a layer, it is dozed flat with an access ramp that allows dumping to commence on the next lift. The primary stockpiles are reclaimed normal to build direction and the magnetite is crushed, all in, to a concentrator feed stockpile.The ore is sampled at the crusher from a falling stream cut. These assay data, are used for benchmarking and control charting the grade and variability of concentrator feed stockpiles. The concentrator feed stockpiles have demonstrated a statistically signifi cant reduction of within pile variation, between pile variation and pile to pile variation, primarily attributable to the development of ore blending. The concentrator has seen sustained, improved performance as a direct result, which translates into lower concentrate cost per tonne and improved yield and quality.

Jul 11, 2011

By G J. I dos Santos

The risk assessment of mining projects is directly related to the possible failure in estimating, and as estimates are made from sampling results, this activity should be done in a judicious and planned manner, to avoid surprises at the start of project operation. Pierre Gy’s (1995) sampling theory addresses the issue of sample representativeness and indicates that only the certainty that the sampling procedure was performed with quality may result in samples being recognised as representative. To validate the representativeness of samples from sampling boreholes selected for studies of mineral processing, the team of geology resource assessment of VALE has proposed a methodology based on the use of statistical analysis tools, which in addition to considering the spatial distribution of these samples in deposit, considers whether they are representative of the populations studied, allowing the geologist to make a quick analysis of sample representativeness.

Jul 11, 2011

Most mining dredges are adapted from canal/harbour dredges. Their automation and control systems are generally not designed for integrated mining operations. Consequently they have a number of limitations. This paper describes a new dredge control concept which paves the way for improved efficiency and increased production.

Jan 1, 2001

Engineering availability of the 120/200 tonne Wabco haulpak fleet at Mt. Whaleback was in the mid fifties and unstable. The project to achieve a reliable 66% during 1980 highlighted "plannable" maintenance, short cycle scheduling, condition monitoring, backlog control, and, above all, the importance of involving all affected people. It is not sufficient for consultants to design systems and make them work. The people who use the system must understand it, support it and "own" it. In this way, they will develop it and improve results after the outside help has been withdrawn INTRODUCTION In early 1979, PA proposed a programme to improve engineering availability of the Mt. Newman Mining fleet of 70 Wabco haulpak trucks of which 53 were 120 tonne and 17 were 200 tonne units. (Subsequently five 200 tonne trucks from Hamersley Iron were added to the fleet). The ore truck workshop was also responsible for 75 tonne trucks used as water trucks and general purpose vehicles. The need for action was clear. The fleet was achieving availability in the "mid fifties" with wide variations indicating that the fleet was becoming unreliable. Projected tonnages required a reliable 66% availability to be

Jan 1, 1982

Fundamentally, the development of a minerals processing project is a very risky enterprise. Most mining companies do not have sufficient financial resources to undertake significant projects and hence have to undertake external financing. Indeed, most resource companies understand the high risks associated in developing their projects and therefore, wish others to share in the risks. Most merchant banks, on the other hand, are searching to find suitable resource development projects in which they can share their risk and also share a large proportion of the ærewardÆ. To resolve this issue a Feasibility Study is completed by the project developer and assessed by the merchant bank often with the assistance of an æIndependent EngineerÆ (IE) who assesses the validity of the development proposal. Generally speaking, unless the Feasibility Study has been prepared improperly, the technical aspects of most mineral projects are reasonable. Some of the more recent so-called æhigh techÆ projects are exceptions but these still do not present major technical mistakes or misconceptions. p> In most cases, the major criticism the IE presents after discussing the validity of the ore reserves focuses on production plans, capital costs and operating costs. Of these three parameters the production plan is one in which owners tend to be far too optimistic and financiers, until recent years, have not taken a position. The most critical part of the development plan is the ability of the project, as designed, to attain the required design performance and, even more critically, the ability of the owner to reach and sustain this level of production. In short, how long should the æramp-upÆ be planned to take? Financiers have become more circumspect and are now taking a more conservative view of new project performance by factoring into their project financial analysis longer periods of ramp-up, higher capital costs and higher operating costs. However, these financiers can also be part of the æproblemÆ if they become overly conservative. This paper attempts, by way of case studies available from the public arena, to identify the pitfalls the project owners can meet and possible means of avoiding the disastrous financial conundrum whereby the second or third æownerÆ is the company that reaps the rewards initially extrapolated. The paper briefly discusses this problem by referring to projects known to the author and including previous studies that looked at this very problem. It is emphasised that many of the opinions stated within the paper are strictly those of the author and could be subject of much debate.

Jan 1, 2003

The development of metallurgical training is briefly reviewed. The reasons for the current trend for Metallurgy Schools to become Schools of Materials Engineering or Materials Science are mentioned as is the role of Departments of Chemical Engineering in the teaching of extraction metallurgy. Some problems on academic staff recruit- ment are highlighted and predictions concerning future difficulties in industry getting adequately trained professional staff are made. The need for a special effort to attract and retain the best undergraduate students is put Forward.

Jan 1, 1987

By C Mann, S Swapp

"The mining industry is often challenged with the task of evaluating narrow vein open pit deposits. A realistic mineable solution from optimisation needs to accurately represent mining dilution and the practical limitations of mining equipment. Open pit dilution is driven according to mining method and fleet selection as this dictates the ‘selective mining unit’ (SMU) that can be practicably mined.Common evaluation methods represent dilution by:a mathematical dilution assumption addition of a dilution skin reblocking of the model to an appropriate SMU.This paper will explore an alternative method of applying dilution by adapting an underground stope modelling tool. By considering an SMU as a stope, automatic stope shape creators such as Datamine’s Mineable Shape Optimiser (MSO) can be used to create wireframes for each mining unit over the entire deposit. Using these wireframes, the model can be subblocked and assigned as either ore (inside the wireframe) or waste (outside the wireframe) prior to optimisation.The MSO process considers SMU geometry and a depth specific value-based cut-off. The result is an optimised solution for the deposit based on practical and achievable mining constraints rather than one based on generalised modifying factors.To evaluate the economic impact of the methods above, results have been costed and scheduled and a comparison of operating cash flows made.Citation:Swapp, S and Mann, C, 2016. Optimisation Improvements for Narrow Vein Open Pit Deposits Using Mineable Shape Optimiser, in Proceedings Ninth AusIMM Open Pit Operators' Conference 2016, pp 50–59 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Nov 15, 2016

By T Tan, C P. Holmes, C E. Hartford

Transportation of iron ore from the mine to the plant is critical to business success. Ore from the mine may have to be transported across states, countries and even continents to get to the processing plant or export facilities, and ultimately to the client. Numerous transportation steps may result in potential logistical difficulties. Companies are continually seeking ways to increase production rates, decrease delivery times and reduce operating costs. Transportation cost is a major component of the total cost of mining iron ore and therefore requires effective use of transport systems.Bottlenecks in iron ore transport systems, due to material handling issues, can result in loss in profit in the order of millions of dollars per hour. Bottlenecks can be seen anywhere in the transport system where the desired flow rate cannot be achieved. These bottlenecks occur for various reasons such as increasing throughput in a transport system originally designed for a lower throughput resulting in plugged transfer chutes, changing material characteristics (eg finer material, increased moisture content), changing to a new type of material or blend that again alters handleability, or changes in operational philosophy due to equipment availability or process utilisation.Stockpiles may have limited live capacity such that an adequate amount of ore may not be readily reclaimed when required (eg to fill a complete train’s railcars). In bins and hoppers, material may discharge through a central flow channel resulting in the formation of a stable rathole, which can then collapse causing material to flood the downstream system and cause significant downtime for clean-up (eg railcars beneath train load outs). In transfer chutes, bottlenecks can be caused by pluggages or downtime required for the change-out of liners due to excessive wear. In ship loading, long settling or de-aeration time, or material exceeding its transportable moisture limit (TML) may result in further bottlenecks. These bottlenecks all have associated costs because of the need to address their causes and because of the lost opportunities for throughput.This paper will discuss how bulk material technology and proper understanding of material flow characteristics can be applied to mitigate bottlenecks. It will discuss how to predict potential bottleneck locations through a scientific method of analysis and evaluation to determine if an increase in throughput of an existing transport system is possible, as well as whether or not a new material will flow reliably through an existing system.CITATION:Hartford, C E, Holmes, C P and Tan, T, 2015. De-bottlenecking iron ore transportation from mine to plant, in Proceedings Iron Ore 2015, pp 393–398 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

The history and milestones in the evolution of support systems utilised in the mass-mined chrysotile mines of Shabanie and King are discussed in detail. The use of block caving, false footwall or sublevel caving mining methods brings with it some major support problems, which are exacerbated, in our low rock strength mining environments. The paper discusses the various support elements and systems that have been used successfully or otherwise in these operations. Some predictions for the future of rock reinforcing in our ground conditions are highlighted, in relation to geomechanics, levels of mechanisation and production risk analysis.

Jan 1, 2000

By E M. Rykaart

The design of soil covers as part of the remediation initiatives for mine waste facilities is common practice and more and more engineers are faced with designing these facilities. The design issues associated with these soil covers are complex and requires a good understanding of unsaturated flow. More engineers are making use of numerical models to predict how cover designs would perform, and this has been necessitated by the high non-linearity associated with solving unsaturated flow problems. There are numerous numerical models available to the prospective users and they are all simplifications of reality using different assumptions. The users of these models often do not understand the limitations of the models but rather select a model based on ease of use, and that lends to increasingly erroneous designs being proposed for construction. This paper describes a comparative evaluation of a cover design using four different codes available today; SoilCover, SWIM, HYDRUS-2D and HELP. The paper does not propose to measure these codes up against each other and make statements about which is better than the other but rather illustrates how the assumptions in each code affect the outcome. The data set used for the comparative study is a well calibrated data set that that has been collected over a long period in time and that has been collected according to strict controls. The authors present the pitfalls of numerical modelling of the surface flux boundary conditions, as well as present guidelines towards appropriate use of these modelling tools.

Jan 1, 2003

By O Otgonbayar, B Bayarmaa, D Batbyamba, S Amar-Amgalan, K H. Natsagdorj, J Nomin-Erdene, B Boldkhuu, T S. Sainzaya

The Argyle deposit in the Kimberley region of Western Australia was the world’s largest accumulation of natural diamonds. Following its discovery in 1979, the mining of associated alluvial diamonds commenced in 1983, followed by the pipe in late 1985. Over the life of the mine to its closure in November 2020, Argyle produced approximately 900 million carats of diamonds. Argyle diamonds are distinctive in having a predominance of brown colours and rare highly-prized pink diamonds, which are a signature of the deposit. The 3D geological model developed from mining and deep drilling shows that Argyle is a composite pipe formed by the coalescence of several steep-sided diatremes, each with their own feeder zones at depth, that were erupted along a NNE-trending fault. The ~1.2 Ga Argyle pipe is comprised of diamondiferous olivine lamproite volcaniclastic rocks and intruded by sparse olivine lamproite dykes. The volcaniclastic rocks are predominantly comprised of unconsolidated quartz-rich lapilli and coarse ash deposits formed by numerous phreatomagmatic eruptions of olivine lamproite magma through Mesoproterozoic water-rich sands and silts. Post-emplacement deformation has tilted the orebody 30° to the north and regional strike-slip faulting has offset, segmented, and elongated the orebody. Recent significant modifications of the geological model resulted from underground block cave operations, producing several critical lessons learnt. Diamond grade and quality reconciliation issues warranted a geological investigation which resulted in the recognition of new volcaniclastic olivine lamproite domains with a broad range of diamond grades, including some very high-grade units. The new lamproite domains had a significant effect on the block cave mining and resultant recovery of diamonds. The new findings enable a more coherent and detailed geological understanding of the volcanic emplacement and paragenetic sequence of the Argyle AK1 pipe. Structural modelling of the deposit also played a major role in the block cave mining tonnage recoveries and daily operations. The re-examination of the geology of the Argyle pipe and the results of this new information reinforces the need for ongoing robust geological work both in the early stages of mining a deposit and continued during the life of the mine.

Mar 22, 2022

By T Mahlangu

The leaching of gold in alkaline aqueous cyanide solutions may be reduced significantly by the passivation of the gold by a surface layer of polymeric aurocyanide. This passivation of the gold is typically countered by the presence of Pb(+2) species in solution, which may be present as an impurity in the solution, or specifically added for this purpose. The speciation and availability of Pb(+2) in typical cyanide leach solutions is illustrated as a function of pH, and the presence of S(-2), S(+6), Cu(+1) and Ag(+1) species. The probable role of the Pb(+2) species in efficient gold leaching is discussed.

Jan 1, 2007

By D Matthews

With a brownfield project comes control integration challenges. The Khumani Iron Ore Mine’s second phase expansion posed a number of challenges as there was substantial brownfields work conducted. The fi rst phase was the compilation of the modifi ed process functional specifications for the project. The second phase was an audit on all of the operational sequences; this included a comparison between the SCADA sequences, sequential starts analysed from the historian data (with the potential for improvements made by the plant operators in manual start-ups) and what was proposed in the process functional specification. Differences, inclusions and missing equipment were highlighted. The third phase was the comparison of interlocking and control in the PLC with the updated process functional specification; this was done during the coding process. Running parallel to the three phases was the SCADA integration; tie-ins to the existing SCADA were conducted on maintenance days and shutdowns, in many instances with ‘dummy’ equipment to get the operational staff accustomed to the new interface. This paper details each of the phases, the success of this methodology as well as the pitfalls experienced.

Jul 11, 2011

Stress Mapping Technology is aproprietary technique developed to target epigenetic mineralisation located in dilatant (low stress) sites. It is a computer based technique, based on rock mechanics principles and stress-strain relationships, which seeks to transform strain data, in the form of a solid geology map, to stress data.The main assumptions in the conceptual model are that:The strain pattern of faults and lithological contacts have not been changed since mineralisation i.e. that ore formation is late in the structural history.Stress orientations and magnitudes are known.Rheological properties of faults and rock units can be deduced.The 2D geometric and rheological data is then treated by a mathematical technique which permits the geometry of the elements to be defined by the spacing and orientation of the discontinuities in the rock mass.

Jan 1, 1990

By D S. Terekhov, N Victor, M F. OÆMeara

The current extraction method of the Platinum Group of Metals (PGM) from an ore concentrate and the subsequent separation of one PGM metal from another is a timeconsuming complicated multi-step process. The use of the Chemical Vapour Metal Refining (CVMR) process for the extraction and separation of PGMs is a simple and economical alternative. The paper covers the CVMR process, which is based on the formation of volatile metal compounds, followed by extraction and thermal decomposition into the pure metals and reagent gases. In the case of PGMs, CVMR does not use CO, and hence, the process is quite different from the carbonyl process previously attempted by a number of organisations and test facilities. CVMR extracts PGMs via synthesis of trifluorophosphine complexes at low pressures and low temperatures (80 to 100¦C). These two facts alone make the process highly economical, compared to other methods available. This paper presents a comparison between the process of extraction of PGMÆs and CVMR proprietary carbonyl process for the extraction of nickel and cobalt. In the carbonyl process, CVMR also uses very low pressures and temperatures, compared to those other processes currently use.

Jan 1, 2002

By G Simpson, S Dressler, A E. Levett

Tailings storage facilities often represent a mining operation’s most significant liability, posing serious environmental, social and safety risks. Almost all mining operations dispose of wet tailings (Valenta et al, 2023), which represents a risk of failure due to the potential for a rapid strength reduction of the unconsolidated materials leading to static liquefaction and subsequent dam wall failure. As a waste stream, tailings disposal, decommissioning and relinquishment aim to be inexpensive processes, ruling out many highly engineered solutions. Advantageously, tailings consolidation does not need to be immediate, opening the door for relatively passive, inexpensive consolidation methods that aim to gradually increase the strength of tailings over extended periods (ie years). In this paper, we present the prospect of novel in situ tailings stabilisation, learning from studies that have investigated the most erosion-resistant landforms on Earth.

Aug 2, 2023