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By L Lorenzen

The selection of samples for metallurgical test work is generally focused on providing geologically representative samples. One of the major problems experienced with metallurgical test work using drill hole data, is the small sample sets selected for metallurgical testing. Major process and financial decisions are being made from results obtained using snapshot samples. Snapshot samples means that samples are basically selected only by grade and spatial location with the assumption that the rest of the orebody or portion of orebody is similar and will respond metallurgically the same way – ie the assumption is that the mineralogy and lithology are basically the same as the test sample. From the test work, algorithms were usually developed and used to describe throughput and recovery using some explanatory variables including grade (mineral chemistry) and ore hardness. These algorithms were then used in the recovery models to determine tonnes produced and plant throughput. However, the metallurgical parameters are a function of many geological factors including grade, lithology, alteration, mineralogy, spatial relationships and SG. In previous years, the limited mineralogical information available was deemed enough for the metallurgist to make decisions as to how many samples are needed to evaluate the metallurgical performance of the ore during processing, and subsequently the basis for the plant design. If the orebody is consistent and not complex or refractory (thus, relative simple lithology), then only spatial and grade samples will be needed to evaluate the throughput and recovery, so limited mineralogical information may be acceptable. There is now, however, an increasing realisation that the mineralogy and geology change, as do the metallurgical characteristics of the orebody, so limited samples may not be sufficient for effective metallurgical test work.It is the purpose of this paper to discuss the effect correct mineralogical information has on the subsequent metallurgical test work program and process selection using a case study. Factors such as type of rock, rainfall and topography are thought to influence the minerals that ultimately form in various orebodies, with the result that different orebodies often react differently during metallurgical test work programs. It is therefore important to obtain accurate mineralogical and elemental deportment data, which will also indicate where the valuable metal containing minerals are located within the orebody. The better you plan and execute your metallurgical test work program during the early phases, the more accurate the decision-making process will be during the selection phase. Improved integration between geology and metallurgy data gathering (geometallurgy) during early phases will result in more accurate predictions with regard to throughput and recovery during modelling and process. Equipment selection will be considerably simpler in later phases with early planning, with improved mine and process scheduling and subsequent net present value (NPV).

Sep 5, 2011

By G F. Brent, S Hawke, M Rothery, P Dare-Bryan

Mine-to-mill studies have previously demonstrated downstream productivity benefits from relatively modest increases in blast energy, or powder factor. These increases have up to now been limited by safety and environmental constraints, since excessive blast energy can result in flyrock, unacceptable vibration, airblast and wall damage.Here, a new blasting method that overcomes these constraints is presented. For the first time it is possible to employ powder factors that are several fold higher than conventional blasting. Independent modelling has shown that such powder factors can potentially increase mill throughput by 20 to 40 per cent. The economic implications are substantial, both in terms of increasing production in existing operations and in consideration of capital and plant requirements for greenfield sites. In addition, mill electricity and grinding media consumption and their associated costs and energy and emissions penalties can be reduced.This method represents a step-change in blasting practices. It involves a novel design utilising dual blast layers within a single blast event, all initiated with state-of-the art electronic blasting systems. The energies in the lower layer can be as high as five times the standard energies, providing for intense fragmentation of the ore. Results from blast models have been confirmed in field trials of the method.Open cut gold mining, in particular, stands to benefit from this method. As gold grades decline, milling costs and throughput increasingly become constraints on production that can be alleviated with this new method. Additionally, it opens possibilities for improved recovery. Blast modelling studies show that dilution of gold ore within the blast can be managed with the new method. Furthermore, it has been shown that vibration from the new method is actually lower than from conventional blasting, allowing the use of the technique in proximity to mine highwalls and other key infrastructure such as underground orepasses.It is concluded that this new method could substantially increase gold mine production and profitability while reducing overall energy consumption and associated emissions.CITATION:Brent, G F, Dare-Bryan, P, Hawke, S and Rothery, M, 2013. Ultra-high-intensity blasting - a new paradigm in mining, in Proceedings World Gold 2013 , pp 395-400 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 26, 2013

By B Flynn, P Knights

Low-loaders or 'floats' for relocating equipment in surface mines are limited to a capacity of approximately 350 t. In the iron ore industry it is desirable to be able to rapidly relocate excavators in order to maintain production rates within appropriate quality limits. In addition, the ability to rapidly relocate heavy equipment raises the possibility of improving the quality of repairs by performing maintenance in controlled shop conditions. However, many iron ore operations operate hydraulic excavators in the 600 to 800 t range, with newly released excavator models exceeding 800 t. These excavators are too large to float using conventional technology. This paper examines the potential for using multi-bogie transporters to relocate large hydraulic excavators in surface mines. Recent innovations have seen the development of modular transporters which can be coupled together to achieve larger platform areas. When separated, and with their drive bogies neutralised, these units are able to be towed behind prime movers and relocated between mines via public roads. The potential cost savings for relocating a Terex RH170 excavator in an open pit coal mine are examined. In the first six months of 2008, the analysis showed the potential for a 38 per cent reduction in total travel time with a corresponding revenue increase of approximately $350 k. The paper recommends that a feasibility study be conducted into offering a heavy equipment relocation service within the Pilbara region.

Jan 1, 2009

By G Zhao, S Hapugoda, E R. Ramanaidou, P Hapugoda, Y Jin, G O’Brien

In 2021 the ports of Port Hedland and Dampier in the Pilbara Region of Western Australia handled 900 Mt of iron ore. This ore was produced in the Hamersley’s mines and transported by trains to the ports for subsequent export. Dust, which is generally considered to be particles less than 100 μm in diameter, is generated at all steps in the supply chain. Whilst all dust may have potential impacts on human health and mangroves and buildings a proportion of the dust is classed as respirable (PM10) dust, which consists of particles <10 μm in diameter. In 2021, in response to the community concern with iron ore dust, CSIRO commissioned an internal study to characterise and benchmark the dustiness of the different ores and to develop targeted strategies to minimise dust impacts, without affecting other iron properties, such as stickiness during transportation. A specific concern is that that the dust in the PM10 fraction may contain significant amounts of particulates, such as free silicates which may have health implications for the workers and residents. This study provided detailed mineral and chemical characterisation of the dust generated from the railed fine ore products for five generic Australian ore types: Australian Channel iron Deposit (ACID), Australian Brockman (AB), Australian Marra Mamba (AMM), Australian Pilbara (AP) and Australian magnetite (AM). The dust from these fine ore products were compared to that generated from a sample of Brazilian Hematite (BH) type ore fines. The ores were evaluated for their physical, chemical and mineralogy properties, dust generating potential and understandings of the relationship between the dustiness of iron ores and their physiochemical properties. The size distributions of the railed fine ore products were determined and a suite of analyses were conducted on subsamples of total (-106 μm) and fine (-38 μm) dust. For all the ores, the total dust fraction contains less Fe and more contaminants (SiO2 and Al2O3) than did the bulk ore. The fine dust fraction contained even less Fe and more contaminants (SiO2 and Al2O3) than the total dust fraction. This suggests that the iron ore dust contains more clay and potentially free silica than does the bulk ore. These findings were supported by optical and Scanning electron microscopy analyses of the samples. Dustiness measurements were made for each of the different ores (-106 μm) to investigate the relationship of dustiness of various iron ores with their physiochemical properties and assess their responses to dust suppression by the application of water sprays.

Sep 18, 2023

By Turnbull AG

The direct smelting of zinc sulfide con- centrates has been investigated by an extensive series of computer-based thermodynamic equili- brium calculations. The study covers both pure 7.n-S-O-C-N systems and practical concentrate- coal-air-flux systems. It is shown that for a zinc concentrate containing iron and lead sul- tide impurities, a 97% yield of zinc vapour with autogenous operation can be obtained under carefully optimized conditions. The possible integration of this process with existing zinc condensation and recovery processes is Discussed.

Jan 1, 1980

By Johnson MT

The microprocessor revolution of the 1970&apos;s dramatically improved the price/per- formance of graphics hardware. Together with improved communications and new software concepts and standards this has resulted in the emergence of a new tool with particular application to the mining industry. The Distributed Graphics Processor (DGP) offers more natural means of interaction with com- plex technical models.

Jan 1, 1983

By R Ballantyne, M Adams

Time Usage Models, used as a basis for calculating performance indicators for mobile mining equipment, have developed from very simple to very sophisticated models. This development has paralleled the increased collection and analysis of production data that itself has been enabled by the evolution of underground voice and data communications along with the relevant information systems. A Time Usage Model divides the hours that equipment is (or is not) used into standard components, by a hierarchical breakdown, so that measures of productivity can be used to compare performance of both people and equipment. The calculation of equipment availability, and thus the underlying Time Usage Model, has always been an extremely emotive topic as different groups use time usage information for different purposes. The direct link between measuring performance Key Performance Indicators (KPI) calculated from these models and employee rewards impacts upon the workforce. This paper discusses the conflict in use by various stakeholders and proposes ways to address some of the more contentious issues each supported by case studies. The simple status code functionality used by early systems has proven inadequate, leading to the evolution of “work-arounds”. These workarounds have become the norm and unfortunately have become embedded in the next generation of models and the information systems that incorporate them. This paper contends that the industry should stop building Time Usage Models to accommodate shortcomings in proprietary systems, but rather collaborate with suppliers to develop innovative methods to deal with the fundamental requirements. There are many points of differentiation that are not clear-cut. Pitfalls are discussed as well as threats to success. A framework of rules is developed as guidelines for how a Time Usage Model should be developed and applied. This will hopefully stimulate the on-going discussion as to how Equipment Availability and other components of the model should be calculated.

Mar 15, 2021

By T Raynlyn, J J. Campbell, R J. Holmes, J R. Manuel, S P. Suthers, A Poliakov

Prediction of the downstream processing performance of iron ore needs detailed information on mineral composition, textural peculiarities, particle density, porosity, mineral liberation and association and mineral grain size. Optical image analysis and automated iron ore texture classification systems are a way of obtaining such information. Furthermore, this information can be used for predicting the output of specific processes and their combinations. Several examples of the application of such an approach to process performance studies for iron ore are discussed. These include the application of classification by ore texture to modelling and optimisation of hydrocyclone performance, the effect of including textural information in modelling of sinter properties, and combining textural information with an experimental study of stirring and ultrasonic treatment of haematitic-goethitic iron ore fines to understand the deportment of fines and the breakdown/deagglomeration of particles. In all cases, the availability of textural information is important and helps provide a better prediction of process performance and/or understanding of the unit process.

Jan 1, 2008

By S Harrison

Work health and safety duties around Australia include duties to manage psychosocial health and safety (mental health) of workers engaged by businesses or undertakings and of other persons impacted by the operations of the business or undertaking. Persons conducting a businesses or undertakings must develop systems of work and policies and procedures for ensuring, so far as is reasonably practicable, the safety and health of workers and other persons. Officers have a duty to exercise due diligence and to ensure effective systems are developed, implemented and resourced. The developed systems will only be effective with worker’s co-operation and engagement. The duties placed on workers by work health and safety laws are an important part of the safety matrix of obligations. Supervisors and Leaders are workers and they play a critical role in delivering health and safety outcomes. To deliver these health and safety outcomes with respect to psychosocial safety Supervisors and Leaders need to understand their obligations and have a framework to use to assist them in understanding what workers require and what steps need to be taken to meet their duties. They also need to take steps to assist those workers that they supervise to meet their duties.

Apr 16, 2024

Mine pit slopes in the Pacific Rim are a geotechnical challenge because of the complex geology in which they are developed. Mines are currently being fast-tracked to meet the increase in commodity prices, often resulting in some reduction in ground studies and short-cutting of design procedures. In addition, the resources boom means that skilled personnel are in relatively short supply. At a time when mine pits are getting bigger and deeper, and the engineering is getting more demanding, there is an increased demand on managers to effectively implement the work. &nbsp; Experience both in New Zealand and the Philippines, display the complex range of geological environments in which pits are being excavated. Working in these conditions has shown that successful geotechnical design requires a strong geotechnical model based on sound geology. An appropriate level of investigation and analyses results in a certain level of understanding for the mine design. There is a point where additional expenditure (on investigation and analyses) is not warranted based on the expected minimal impact on decreasing the level of perceived risk on the project. For most projects in our experience the analytical methods and complexity of geotechnical assessment changes increases as the level of knowledge grows.

Jan 1, 2006

By J Zhou

Gold in sulfide ores is associated predominantly with sulfide minerals and occurs as both microscopic and submicroscopic particles. In non-refractory sulfide ores, gold occurs mainly as coarse- and medium-grained particles. Minute inclusions and submicroscopic gold usually account for a minor portion. In contrast, gold in refractory sulfide ores occurs mainly as minute particles and submicroscopic gold, and microscopic gold usually accounts for an insignificant portion. In gold ores containing carbonaceous material, the preg-robbing nature of carbonaceous material may impose challenges on gold extraction and cause gold losses. To extract gold from refractory sulfide ores, the ore needs to be finely ground and preoxidation is often required. Sulfide host minerals must first be oxidised to create a porous structure through which the cyanide leach solution can penetrate to reach the colloidal gold particles. The oxidation is traditionally achieved by roasting, autoclaving or bacterial oxidation. In carbonaceous sulfide ores exhibiting a preg-robbing nature, the carbonaceous material needs to be treated by roasting, autoclaving or other means to minimise the preg-robbing effect. As a predictive and troubleshooting tool, the gold deportment study plays an important role in gold metallurgy. It determines the deportment of gold in an ore or mill product and identifies the mineralogical issues that may affect or may have affected gold extraction. The information acquired from a gold deportment study can be used to assist in process selection, flow sheet development, recovery improvement and reagent optimisation.CITATION:Zhou, J, 2013. Deportment of gold in sulfide ores and implications for gold extraction, in Proceedings World Gold 2013 , pp 433-442 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 26, 2013

Extensive geophysical exploration and drilling operations have been: conducted in, South Central Queensland by Phillips Petroleum Company and Sunray DX Oil Company since late 1959. The main outlines of subsurface geology are now known, but many problems must be solved before a comprehen sine. picture can be presented of the geology and petroleum prospects e Interpretations to date suggest that -fiddle Paleozoic sedimentary rocks, probably, related to the Tasman belt of geosynclines, once extended. over. most. of the area An oro;eny 2.n late Paleozoic time, succeeded by deep pre-Pexmian erosion, removed the older sediments over large. areas, but Paleozoic sediments, were preserved from erosion in the Adavale and ancillary structur-a.l basins. Marine sediments of Devonian age are con-sidered prospective source beds for petroleum. Current work is directed toward finding favorable structure and reservoir beds to test the oil prospects of the area.

Jan 1, 1962

By G B. Smith

Barrick (Australia Pacific) Limited initiated a trial of Caterpillar’s Minegem autonomous loader technology in 2009 at the Kanowna Belle mine in Kalgoorlie. Autonomous loader technology offers the potential to improve loader productivity, reduce operating costs and improve safety through removing personnel from the mine operating environment. This paper discusses the implementation of the technology at the mine site, the data collected during the trial and quantifies the benefits of using automated loader technology in comparison with teleremote loader operation. The lessons learned from the trial and work planned for the future in respect of this technology is also discussed.

Mar 21, 2011

Australia has been an important producer of zinc minerals and metal for many years.Late in the last century Edgar A. Ashcroft, a versatile and enterprising electrical engineer proposed the treatment of zinc rich ores by roasting, followed by leaching to extract zinc, purification of the solution and electrolysis of the purified solution to produce zinc. Residues from the leaching operation were to be smelted in a lead blast furnace to recover lead, silver and gold.Ashcroft (1897-98) and (1898) has.given us a most interesting record of the attempts made at the Sulphide Corporation&apos;s plant at Cockle Creek near Newcastle, NSW, to put his ideas into practice. In spite of the best efforts of all concerned, including the use of electrolysis of aqueous chlorides and sulphates, zinc could not be deposited consistently and the project failed although lead smelting continued until 1922 (Woodward, 1965, p. 158). Based on later experience with Broken Hill materials the presence of undetected cobalt in the solutions was the likely cause of the inability to deposit zinc (Kirk and Othmer, 1956).

Jan 1, 1985

The standard charge weight scaling laws imply that only one particular delay (that possessing the maximum instantaneous charge) contributes to the ppv. However, the present analysis clearly demonstrates that a varying number of blastholes contributes to the ppv. This number also increases with distance, x, between the blast source and the detector, and is caused by waveform broadening due to attenuation. Thus the operative charge weight, itself, is also a function of the distance, and so makes the standard charge weight laws difficult to implement. If the delay time scatter is neglected, then, under certain conditions, relatively simple expressions can be derived for the ppv magnification, FN, as a function of the number, N, of blastholes. When the influence of delay scatter and random fluctuations in each blasthole vibration is included using Monte Carlo simulations, then, to a first approximation, the condition FN=KNx applies, where KN is a constant dependent upon N. Unfortunately, however, for any particular blast this condition cannot be distinguished from the standard charge weight scaling law. The dependence of ppv on N would only be apparent if blasts of differing N were to be compared in an otherwise identical environment. Since this situation is very difficult (if not impossible) to realise, then the influence due to N, although significant, goes largely undetected. Another problem associated with standard charge weight scaling laws is the difficulty of accurately assessing the appropriate charge weight, even if attenuation broadening is neglected. For example, if a number of blastholes are very close, then they experience a vibration interaction which is non-linear. However, if the same blastholes were to be widely spaced, then the separate vibration signatures add linearly. The standard charge weight scaling law fails to distinguish between such linear and non-linear regimes. Unfortunately, in many production blasts, both regimes exist throughout various portions of the blast spatial pattern and so makes it difficult to determine the operative charge weight. The solution to the combined influence of waveform broadening and linear/non-linear interactions will obviously require substantial future research. A possible solution may be found in the use of numerical dynamic codes.

Jan 1, 1990

By M Berry, F MacCorquodale

The ownership, management and employment structures operating in the Australian minerals industry have dynamically evolved during the last 30 years. One of the most dramatic changes, from an exploration and mining geology perspective, is the reduction of in-house geological expertise and an ever increasing reliance on contract and consulting services.For all companies - big and small - two key issues resulting from these changes are the management of core geological intellectual property (IP) and competitive advantage. This is because there are less experienced geologists at exploration and mine sites, there are fewer head-office technical service teams to support mine sites, exploration teams are smaller with less specialists employed, and there is an ever-greater dependence on contract and consulting services.This paper reviews and explores these issues with an industry-wide geological context, then provides a case study of how Newcrest Mining Limited (Newcrest) has dealt with these issues in exploration. Newcrest has grown from a one-mine company with an Australian exploration focus, to a large global company with multiple operations and an extensive international exploration portfolio. NewcrestÆs management of its geological IP and competitive advantage has evolved as the company has grown and responded to market conditions, including its internal restructuring in mid-2013.CITATION:Berry, M and MacCorquodale, F, 2013. Managing geological intellectual property and competitive advantage - Newcrest Mining LimitedÆs experience, in Proceedings World Gold 2013 , pp 37-44 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 26, 2013

Wollongong* is Australia&apos;s largest single centre of mining and metallurgy. Wollongong&apos;s total employment in manufacturing of basic metal products (over 26,500 in 1972/1973) was almost 50 per cent higher than that of Newcastle and double that of any other Australian city. Although the great bulk of this employment was in steelmaking, Wollongong&apos;s copper industry was also a significant employer. Wollongong&apos;s total employment in mining (4,900 in 1971) was second only to that of Newcastle among Australian mining centres. Although the bulk of Wollongong&apos;s mining is of coal, there is also considerable mining of blue metal, sand and clay. In all, over 40 per cent of Wollongong&apos;s work force is employed in mining and metallurgy. The great bulk of the other

Jan 1, 1976

By Giles C. N, Loughnan F. C

Bentonites and active earths from N.S.W., previously analysed with respect to occurrence, mineralogy and physical properties have been evaluated for use as bonding agents in quartzose moulding sands in terms of green properties and behaviour both with and without coal dust for iron castings poured at 1400&#176;C.INTRODUCTIONIn the paper by Loughnan .and See (Part I) the occurrence, mineralogy and physical properties of the fuller&apos;s earth and bentonites of New South Wales were discussed and it was shown that some of the materials approached the quality of Wyoming bentonite. In the present paper the same samples from Marulan (Bl), Boggabri (B2), Wingen (B3), Muswellbrook (B6), Swansea (B8), Dubbo (89) and Trida (Bll) have been investigated with respect to their potential value as bonding agents in compounded moulding sands. Inaddition, the -20 micron fractions of the Boggabri (B2t) and Swansea (B8t,&gt; were recovered and the former converted to a sodium clay, in order to assesE; the beneficiation possibilities. A sample of Wyoming bentonite (S2) also has been included for comparison.GREEN PROPERTIES OF THE ARTIFICIAL MOULDING SANDSA quartzose base sand (Botany Dune) previously oven pried and screened to 1&#183;65 mm., was subjected to a sieve ana]ysis in accordance with standard A.F.A. practice to yield a calculated&apos; fineness number of 45. All tests were carried out on mixtures of this sand with2t per cent clay, since such mixtures were found most suit...

Jan 1, 1959

By E A. G Marques, P M. Dight, T A. V Costa, K Mercer

Brazilian banded iron formation (BIF), known as ‘itabirite’, is the main host rock for iron ore in the Iron Quadrangle mines, Brazil. Their geneses are controversial and it is agreed that diagenetic, metamorphic and tectonic events, as well as weathering processes, were responsible for the iron concentration. In addition, it is understood that weathering processes are mainly responsible for reducing the original high intact rock strength, and for generating deep weathered profiles with low strength rocks commonly observed in Vale’s mines.A considerable amount of work has been done to correlate the macro and micro aspects of the itabirites as physical, chemical and geotechnical characteristics that directly or indirectly affect the intact rock strength; however, it is not yet clearly understood what effects the weathering processes have on the strength reduction of these rocks and its associated impact on pit slope stability. This forms a key focus of the lead author’s current research work.This paper presents a review of the geological, geotechnical and weathering characteristics of the itabirites, and early results for the evaluations of fresh itabirites from the PhD thesis research being undertaken by the authors at the Australian Centre for Geomechanics, School of Civil, Environmental and Mining Engineering, The University of Western Australia, sponsored by Vale SA.The results showed that to evaluate the density and unconfined compressive strength (UCS) correlation, not only the porosity but also the geological features should be considered, as they are responsible for data dispersion; however, the presented data suggested a trend that provides the confidence to develop advanced studies and a data population increment to establish proper correlations to support a reliable UCS method.CITATION:Costa, T A V, Dight, P M, Mercer, K and Marques, E A G, 2015. An overview of the weathering process, preliminary density and unconfined compressive strength correlations for fresh itabirites in vale mines on the western side of the Iron Quadrangle, Brazil, in Proceedings Iron Ore 2015, pp 241–254 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

Blast furnace slags which fall into the quaternary system SiO2 - A1203 - MgO - CaO have latent hydraulic properties which depend on the degree of vitrification. When the oxides com- bine to form Calcium Silicate Hydrates and other products of hydration the bonds between elements are at a lower energy level than those which exist in the glassy state. Transition from the glassy state to the crystalline state is thermo- dynamically favoured and, in the context of this paper, such slags possess internal energy. Manufacture of Portland cement is respon- sible for about 3.6 per cent of total industrial energy consumption in Canada. Pyroprocessing accounts for about 83 per cent of this figure or 3 per cent of the total. The processing of blast furnace slag to a condition in which it can be used as a partial substitute for Portland cement requires no pyroprocessing and, on average, only about 11 per cent of the energy needed for Portland cement. In North America the benefits of slag as a cementitious materials have been obscured by other considerations, the most important being commercial strategy. This situation has under- gone radical change as a result of the rising cost of energy, and government pressures to conserve energy.

Jan 1, 1979