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Development of Grindability Tests Based on Direct Measurement of Energy Nowadays, for the characterisation of the grindability different grindability indices - Bond-work index (Wi), Hardgrove Grindability Index (HGI) or Zeisel specific grindability (Wt) - are used. Generally, the grindability tests are carried out under relatively simplified circumstances, in a special dry batch mill with defined feed size material until prescribed conditions are reached at room temperature. However, in the fine- and ultra fine grinding, which is a frequent task (fly ash, tailings, alumina, etc), a fine material (<50 - 200 ¦m) is usually ground down to the few micrometers. The conventional grindability testing methods and apparatuses (Bond-, Hardgrove-, Zeisel-processes) for their determination, although, are not suitable directly to measure the grindability of such fine materials, since the maximal particle size of the feed material (0.5 - 3 mm) to be tested is much higher. One of the important goals of the research carried out in our Institute was to develop the novel grindability testing methods, which are suitable for the fine and ultra fine grinding, and additionally provide the possibility for the fast determination of the grindability. In order to realise the above aim the conventional Bond- and Hardgrove- mills were modified in order to directly measure the grinding work. In particular, the Hardgrove-mill was equipped with a simple torque-meter (load cell). The Bond-mill was rigged with a digital electric power measurer. The systematic experiments were carried out parallel in both mills using the conventional and the developed methods. Finally the results of both were compared. The measuring results have proved that the Bond-work index can be determined based on the developed methods. The new grindability testing methods were applied successfully in several industrial research tasks for the determination of the specific grinding energy and the Bond-work index. These methods can be also used in the industrial practice for the control of the grinding process.

Sep 13, 2010

By A Duran

When dealing with rocks in the geotechnical profession, a common activity involves providing an estimate of the intact strength. The tactile approach and descriptions of strength that apply to soils is well documented, can be readily checked through the use of a pocket penetrometer and are known to provide reliable estimates of strength. Moreover, although different soil strength classification systems are present, the bounds between classification classes are compatible across almost all documented classification systems. However, this is not the case for rock strength materials. There are numerous systems within the literature, some with different concepts, and almost all have different bounds to each strength classification. In this paper, the author presents seven classification systems for estimating intact rock strength and highlights issues in their implementation. Example cases are presented to discuss the typical concerns confronting field strength estimates.CITATION:Duran, A, 2014. Comparison of field estimated strengths, in Proceedings AusRock 2014: Third Australasian Ground Control in Mining Conference , pp 101–106 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 5, 2014

By Misra V. N, Spottiswood D. J

In recent years the column flotation process has gained worldwide acceptance for processing various types of minerals under different circuit configurations. In an age when real prices of many mineral commodities are in decline and mining and labour costs are rising in real terms, it is more important than ever that concentration processes be not only efficient but also cost-effective. The column flotation process can give better metallurgical performance as well as involve lower capital and operating costs compared to conventional mechanical cells.This paper reviews the literature on columns and the effects of various column parameters on performance of the column flotation process. The history and principles of operation of the column flotation process are briefly discussed by way of introduction.

Jan 1, 1995

By Best R. J, Poulos H. G

The method for design of primary roof support for the large todoidal cavern constructed to house the Sydney Opera House parking station is presented. The cavern was constructed with 5 m of rock cover beneath Sydney's Royal Botanic Gardens. Design of rock reinfonnent using a combination of fully grouted rock dowels and Macalloy bars was based on control of horizontal shear movement along bedding features in the roof. A combination of linear arch type analyses and non-linear jointed finite element analyses were used in the design study together with an analysis of the shear resistance offered by fully grouted bolts under shear deformation.

Jan 1, 1993

By P K. Singh

Recent advancements in understanding the detonation process are noteworthy, but they are still based on somewhat hypothetical situations. The actual variables that are essential parts of normal blasting practice have not yet been taken into account in such treatments. These include the various initiation practices employed to detonate a column of explosive, from single point initiation to multi-point initiation in blast holes, and the effect on detonation characteristics of both detonators and explosives under multi-deck and multi-hole blasting conditions. The in-the-hole velocity of detonation (VOD) of an industrial explosive is dependent on explosive’s charge diameter and blasthole diameter. The relationship between blasthole diameter and VOD provides a fundamental guideline to the rate of energy conversion and energy release within the detonation front on the interaction of explosives with the confining medium.The in-the-hole VOD of explosives was measured at four experimental sites in India for different blasthole diameters, ie 150 mm to 311 mm, but for identical explosive composition being same particle size, density, viscosity and loaded into blastholes with the same degree of confinement. The results of the studies demonstrated that there is definite relationship in in-the-hole VOD of the explosive and the diameter of the blast hole. The study also confirmed that the explosives initiated with concentrated boosters yielded higher VOD in comparison to those explosives that were initiated with multi-point priming. The measured increase in VOD of explosives for increasing diameter of holes was up to 24 per cent. The rate of change in in-the-hole VOD of explosives increases with increasing blasthole diameter. It can be further stated that the in-the-hole VOD of the explosive reaches a fairly constant value after reaching a limiting/threshold diameter of 311 mm.

Nov 8, 2011

By D Rubery, C Croker

The Boddington Gold Mine (BGM) is located 120 km south east of Perth, Western Australia. The operation is managed by Worsley Alumina Pty Ltd and mined by contractor Henry Walker Eltin (HWE). The mine has been operating since 1987 with ore extracted from a series of pits along strike. Ore is contained within the basement rock, which is overlain by a cap rock layer and transition zone. Cap rock and basement zones require blasting.As the mine neared completion, a high-grade deposit was discovered within 50 m of an existing Western Power substation and 100 m from the processing mill. The substation provides power to the Boddington area and is a back-up power supply to the city of Perth. Due to the delicate nature of the transformers located at the power station, overhead power lines and the mill, blasting in the area was considered very high risk. As such blasting needed to be controlled for flyrock, airblast and most importantly peak vibration and frequency limits which had the potential to damage the transformers.The mine was due for closure in March 2001. The decision to mine the pit was based on its high grade, ability to be blended with lowering grades from other pits and changing of the processing technique with the expansion. This decision extended the life for a further six months.Due to the high potential risks a detailed risk assessment was conducted by Orica, Worsley and Henry Walker Eltin. The completed assessment and the major design parameters were presented to Western Power for approval. The ability to reduce the blasting risk was focused on limiting of vibration through controlling maximum charge initiated per delay, blast timing and firing direction, and other innovative control measures. OricaÆs SHOTPlan« and Sabrex« computer modelling packages were used to predict the outcome of blasts.The success of this project has opened the doors for other high risk blasting projects, which otherwise may be left unmined.

Jan 1, 2002

By Jarvensivu M, Ylinen R, Jamsa-Jounela S-L

The paper presents a new integrated system for control of concentration processes. The system is based on cluster-based modelling taking the ore quality into account and a new on-line particle size analyser capable also for reliable measuring of particle size distribution of concentrate. A metallurgical precontrol audit was performed at the Hitura concentrator in order to design the control strategy of the integrated grinding and flotation control. A new analyser PSI-200, was used to the measurement and control of the distribution of nickel in the total particle size range. An expert control system using the cluster model together with a new control strategy for decision of necessary control actions is outlined. The method has been tested to real data from mineral processes. The results are in good correspondence with empirical process knowledge. KEYWORDS: Cluster analysis, expert control, flotation control, mineral processes, modelling, particle size.

Jan 1, 1993

By Tamura S, Maekawa M, Nagai C, Deguchi M

Heavy fuel oil has been injected into blast furnaces in order to reduce the coke rate, to improve productivity and to control the furnace heat condition. However, in the first oil crisis at the end of 1973, it became necessary to develop an injection technique of new fuels into blast furnaces to reduce oil consumption. In Kobe Steel, Ltd., it was thought that the injection of a coal-oil mixture (COM) into blast furnaces could be developed in a shorter time than pulverised coal injection. The development of this technique was under- taken in 1974, and COM was injected through two tuyeres of the No.3 blast furnace at the Kobe works in 1977 and 1978. In addition, in order to study the combust- ibility of COM and the phenomena in the tuyere zone, the development of a gas sampling method was under- taken in 1975. In this paper, the results of the injection tests and gas sampling tests are reported.

Jan 1, 1981

By A Madera, R Watt

The Tampakan deposit is a strongly telescoped high-sulphidation-epithermal/ porphyry deposit pair which is hosted by a sequence of probable Pliocene age subaerial andesite flows. These host units lie on the western flank of a deeply dissected andesitic stratovolcano within the northernmost portion of the Sangihe Arc in southern Mindanao. The deposit was discovered by WMC geologists in 1992 and is currently undergoing resource evaluation. Preliminary resource estimations indicate a total inferred metal content of 12 million tonnes of copper metal and 16 million ounces of gold. Using a 0.2 per cent Cu cut-off grade, the deposit has a current mineral resource of approximately 2.5 billion tonnes with an estimated grade of 0.48 per cent copper. At a higher cut-off grade of 0.5 per cent Cu, the mineral resource is approximately 900 million tonnes with an estimated grade of 0.75 per cent copper. Mineralisation is open both to the west and at depth. The Tampakan district is centrally located with respect to a 100 km wide zone of left-lateral strike-slip deformation represented by the trans-Mindanao Cotabato Fault Zone. The district is transected by several WNW-striking wrench faults which represent strands of the regional Cotabato Fault Zone. High-sulphidation epithermal mineralisation within the Tampakan deposit is strongly controlled by NNE-trending faults which lie along a dilational orientation within the Pliocene stress field associated with the Cotabato strike-slip fault zone. The mineralisation is broadly hosted by a gently-dipping, tabular zone of partial to massive silicification which displays multi-phase brecciation, acid-leaching, related vuggy porosity and which is developed within a district-scale advanced-argillic and argillic lithocap exceeding 90 km 2 in area. High-sulphidation epithermal mineralisation is associated with a silica-pyrophyllite-dickite-alunite-diaspore¦sericite alteration assemblage which is transitional downward to sericite-chlorite alteration and relict potassic biotite-chlorite-magnetite-anhydrite alteration associated with pervasively developed but weakly mineralised porphyry quartz stockwork veins. The high-sulphidation mineralisation is dominated by disseminated, vein and vug-filling enargite-bornite-digenite-chalcocite-covellite ¦ molybdenite which has overprinted an earlier phase of porphyry copper stockwork veins associated with high-level porphyritic hornblende diorite stocks. The distribution of high-sulphidation alteration and mineralisation reflects strong stratigraphic and structural controls. The high-sulphidation mineralisation covers a surface area of approximately 1.6 km by 2.0 km and forms a tabular, flat-lying to gently-dipping body between 200 and 500 metres thick. It is intersected at RL-1200 m ASL (at surface) in the northern portion of the deposit and extends down to RL-600 m ASL at the southern end. The deposit has been diamond-drill tested to a depth of 400 - 500 metres where low-grade chalcopyrite-bornite-pyrite mineralisation is hosted by pervasive quartz stockwork veins. This deep-level mineralisation represents the outer portion of a porphyry Cu system hosted by both andesite flows and the uppermost portions of high-level hornblende diorite stocks. Deep drilling to test for higher tenor porphyry Cu mineralisation is planned.

Jan 1, 1999

By J M. F Clout, E Donskoi

The ability to design a beneficiation process for a new orebody based on particular feed characteristics is a powerful and practical tool. A new technique has been developed where beneficiation outcomes can be calculated by combining feed size-by-size chemical analysis, mineralogy, liberation and particle characteristics with a series of simple theoretical unit separation models rather than a simple mass balance approach or an exhaustive beneficiation test program. The new technique provides the ability to rapidly identify ore types that have the potential to meet product specifications whilst also rejecting others that will not meet specification even if a perfect separation was achieved. Beyond the broad scale decision making process, practical mineral separation curves from actual plant data can be used to more closely simulate the proposed process. This approach reduces the amount of laboratory and pilot plant work necessary by targeting what process stages will be required, increases early rejection of uneconomic options, identifies problematic ore types or unit operations and is a step towards estimation of final grade and recoveries achievable in potential circuit configurations.

Jan 1, 2004

By J Loeb, D Thornton

Blast movement measurement is a key component of grade control, enabling mines to carry all of the precision involved in locating ore blocks, through a chaotic blast, to production. A monitoring system was developed about ten years ago so that mine operation personnel can measure three dimensional movement in every production blast. Research has shown that blast movement is always highly variable with a significant non-deterministic component. The consequence is that modelling will be inaccurate and therefore optimal ore recovery can only be achieved by direct measurement of blast movement.Three dimensional movement vectors are measured at discrete locations in the blast. If blast movement is only measured at one location in a blast pattern, data is severely limited and has all of the inherent inaccuracies of modelling a variable population. It is intuitive that the accuracy of defining the post-blast ore block mark-ups are proportional to the number of movement measurement locations, however increasing the number of monitoring locations causes increases to the direct operating costs of the mine.A cost-benefit analysis is used to explore the optimal number of monitoring locations. Using the method described in this paper, an automated selection of the number and location of blast movement monitors are analysed against the value of recovered ore compared to the control, for each trial.CITATION:Loeb, J and Thornton, D, 2014. A cost benefit analysis to explore the optimal number of blast movement monitoring locations, in Proceedings Ninth International Mining Geology Conference 2014 , pp 441–450 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 18, 2014

By A Fern, A Hawkes, o, W Smith, K Mee

Serious Injury and Fatality (SIF) prevention remains a priority focus within high-risk industries sector. A major mining operation sought to strengthen their approach to the management of high-risk activities through an in-depth review of all historical incidents that had serious injury or fatality potential (SIFp) events (sometimes known as hi-potential events). The analysis found that the organisation invested a disproportionate level of resources, time and effort on low consequence incidents with a high proportion of SIFp incidents going under the radar. It was found that 76 per cent of SIFp incidents were rated in moderate or lower risk categories and conversely, almost half of those incidents with a ‘serious risk’ rating had little or no potential for a serious outcome. As a result of this project, the operation engaged in a renewed focus on critical risk management and enhanced its operating cadence in critical risk for the workforce. This included bow tie analysis, an update to critical risk standards and increased workforce engagement in the use of critical control verifications in the field. Data analytics with lead and lag indicators continue to provide senior leadership team and risk owners with an understanding of exposure for SIFp and control effectiveness. The audience will take away learnings from a real-world case study that provides data-driven insights of the human, local and organisational factors contributing to incidents with SIF potential. In addition, participants will understand the steps taken to categorise and analyse this incident data and the initiatives currently being implemented by the organisation as a result.

Apr 16, 2024

By D W. Evans

Research into the dynamic properties of ground support elements continues to grow at a global level, given the increasing importance of this field of application within underground hard rock mining. Measuring the mechanical response of such elements under the rapid onset of simulated rock burst loads forms the basis for this experimental work, typically utilising gravitational drop testing methods. This field of research is fundamentally driven by an increasing need for dynamic performance data, given the constant evolution of rock bolting product designs, materials selection, combination testing and specific application needs based on ground types and loading scenarios. A smaller number of globally recognised dynamic test facilities have predominantly lead research within this arena, typically in association with academic institutes, larger industry groups and government research institutes. However, due to the increasing requirement for dynamic performance data, additional facilities have now emerged in order to satisfy the overall demand for test work. These newer facilities are more typically associated with suppliers to the underground hard rock industry, with experimental designs looking to replicate, at least in part, the work of the primary facilities. For standardisation, repeatability and calibration purposes, the cross validation of test data between primary and secondary facilities becomes an obvious and important consideration across this field of research. This paper outlines the development of a new dynamic drop test facility for testing rock bolts, including the structural design and associated high speed data capture system. Based on the utilisation of identical bolt types, material grades, anchoring systems and decoupled ‘free-lengths’, comparative data has been generated to provide cross validation of the new test facility against data generated by a globally recognised primary facility. The cross validation of data provides increasing confidence in the repeatability and accuracy of the new facility as activity continues towards the provision of further experimental test work.

Nov 29, 2022

By R Austerberry, S Green

Highly weathered ground, limited collar options and the need to achieve a desired outcome at the lowest possible cost led to the need to adopt a construction approach that had no established design methodology. The newest ventilation shaft at Mandalay Resources’ Costerfield Operations had to be established to a depth of 30 m through poor ground best described as ‘sticky swelling clay’, some of which was contained within an old backfilled pit.The ability to excavate a traditional presink was not possible due to limited space and the introduction of men into the shaft was to be avoided due to the associated safety risks and corresponding increase in cost. Piling in conjunction with raise boring and remote fibrecrete application was identified as a possible solution that could achieve the desired outcome at an acceptable level of risk.Construction of the piles was challenging and required continual refinement until an acceptable level of productivity could be achieved. Limitations on concrete delivery was taken into consideration to ensure hole stand-up time was acceptable and re-drills were not required. The adoption of a set process from alignment, drilling, concrete placement and testing ensured the desired design was achieved. Mine operators should consider the use of piling as a method of shaft stabilisation for the portion of raise bored shaft that passes through the weathered zone.The importance of quality control and attention to detail through the entire shaft construction process cannot be underestimated as issues such as insufficient geotechnical investigation, pile and pilot hole deviation, concrete and fibrecrete quality, as well as delays in the application of fibrecrete can place the success of the project at risk.This paper outlines key learnings from a client’s perspective with regards to the concept, planning, design, execution and completion of a 3.1 m diameter raise bore shaft through both weathered and highly structured ground at the Augusta Mine.CITATION:Green, S and Austerberry, R, 2014. Piling and raise bore construction – key learnings from a client’s perspective, in Proceedings 12th AusIMM Underground Operators’ Conference 2014 , pp 35–42 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Mar 24, 2014

By A Roshal

It is anticipated that many future uranium mines in Australia will be using the in situ leaching mining process. It is fair to say that close to one third of uranium production will be generated by this method, whilst the other two thirds will fall on the uranium generated from hard rock mining and other mining methods, such as traditional open cut mining. For other types of deposits the in situ leaching mining method will remain the best technological, commercial and environmental alternative. It is important to identify and prevent all risks involved in uranium mining. The expertise in this subject is limited. Over the years there was only one mine using the in situ leaching process for uranium extraction in Australia. Computer simulation of propagation of leachate during and after the uranium in situ leaching is a crucial factor, not only for addressing the environmental concerns, but also for the most efficient recovery of the deposit. The decontamination can be modelled for a period of up to 100 years, with the acid neutralisation forecast for a period of up to 400 years. The results of the modelling are paramount for definition of the reserves, efficiency of the mining method and the environmental impact statement. The accuracy of the hydrogeological modelling and carefully selected environmental management program enables a mining company to quantify and minimise the impact of the mining activities on the regional aquifer and to prevent environmental disasters. In the study, the completed hydrogeological model allowed the client, the authorities and the community to make an informed decision about the environmental impact of the in situ leaching of uranium. In particular, the model proved that neither during the mining, nor during the neutralisation the toxic elements would interact with the local catchment area.

Jan 1, 2008

By D Espinoza, I Rees, J Pocoe, P Collier

P Collier, I Rees, J Pocoe and D Espinoza

Mar 22, 2022

The Small Pebble Process for Reducing Ball and Power Consumption in Secondary Grinding Ball mills are used widely for secondary grinding. A mixture of ball sizes can be used to optimise grinding efficiency, but the use of balls smaller than about 30 mm in diameter is not normally viable, particularly when alloy steel is required. Preliminary testing of the grinding efficiency of various combinations of 40 mm steel balls and crushed stone in the size range 7 to 25 mm was carried out in a 300 mm diameter mill, which has accurate power measurement.The primary interest was to assess the potential benefit of adding small pebbles (from a primary circuit crusher or mill) to a secondary ball mill, to reduce ball consumption and to improve grinding efficiency. The optimum proportion of pebbles was found to be about 25 per cent by volume. This mixture produced about the same amount of fines as balls alone, but with lower power consumption, due to the lower density of the pebbles. The net result was a 12 per cent saving in power and a 25 per cent saving in ball consumption. The production of fines was partly due to pebble wear. The use of portions of 15 mm balls, (ceramic and steel), was also tested for comparison. A few batch pilot-scale tests were conducted in a 1.2 m diameter, 0.31 m long mill to test the viability of the pebbles at a larger scale. The pilot-scale tests confirmed the reduction in power and that the rate of production of fines was the same as that obtained with balls. The same residence time was used and this implies that pebbles can be added to an existing full-scale ball mill, with no loss in capacity. Samples of secondary mill feed and pebbles were obtained from a copper mine and the steady-state consumption of pebbles was determined by locked-cycle laboratory-scale tests. These tests demonstrated that mill power could be reduced by up 13 per cent and that the consumption of 40 mm balls could be reduced by up to 38 per cent, while maintaining the same throughput and product size. The rate of pebble addition was about 4 per cent of the primary circuit feed rate. Application has been made for patent protection.

Sep 13, 2010

Sampling of CIL/CIP circuits is typically done by compositing samples of feed and tails over eight or 12 hour periods. As the residence time in the leaching tankage may be approximately 20 hours, the tails from any period being derived from material entering the circuit 20 hours earlier do not correspond to the head from the same sampling period. Moreover, mixing in the series of tanks in a circuit also modifies correspondence between input and output. A special purpose simulator has therefore been developed to allow for the mixing and delay in the tankage and permit estimation of the head assays corresponding to any tailings sample. Thus more accurate assessment of the day-to-day recoveries of gold and silver follows. The model, programmed in Excel, assumes that the tanks are perfect mixers. By inputting the sequential head grades and considering that no leaching has occurred, the head grade which corresponded to the tailings for each period could be estimated. Allowance is made for variations in feed rate over the sampling period by computing the average flow rate of slurry and thus the residence time of each increment of the tailings. This simple model and its application have been found to be subject to some limitations, which are discussed in the paper, resulting in some unresolved variability in results. However, for a typical circuit even the simple model was able to greatly improve consistency of recovery data with variations being approximately halved by eliminating much of the anomalous variation arising from the lack of correspondence between head and tail when changes in head grade are occurring. Therefore, this permits genuine variations in metallurgy to be identified with greater confidence and thus operational shortcomings can be identified and addressed more quickly.

Jan 1, 2006

By M Rayner, C Tsouris, A Komelkov

X-ray fluorescence (XRF) is a widely accepted technique for the elemental analysis of iron ores and their concentrates. Wavelength-dispersive, or WDXRF, and energy-dispersive, or EDXRF, spectrometers offer distinct advantages for particular applications, elements and concentration ranges and are, therefore, more complimentary than people might realise. A key example is the ability of EDXRF to identify, and often quantify, unexpected elements in production samples that would typically be missed by routine WDXRF. In this paper we discuss recent technological advances in XRF and present a novel application example that demonstrates the additional technical and practical benefits of using both EDXRF and WDXRF to characterise iron ores and concentrates.CITATION:Tsouris, C, Komelkov, A and Rayner, M, 2015. A novel approach to the characterisation of iron ores and concentrates using recent advancements in wavelength- and energy-dispersive x-ray fluorescence spectrometers, in Proceedings Iron Ore 2015, pp 591–594 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

By L Barro

There is currently a worldwide interest in coal-oil technology as the search continues for alternative energy sources to reduce the consumption of petroleum crude. An important aspect of this coal-oil technology study is to obtain information on the flow properties of coal-oil slurries. While some work has been reported on the flow behaviour of black coal-oil suspensions, very little work on brown coal-oil suspensions has been reported. In this paper flow characteristics of brown coal-oil suspensions for various coal concentration and temperatures have been presented. A capillary rheometer, designed to handle settling suspension, has been used for determining rheological properties. Brown coal of 0.0725 mm average particle diameter has been used in this work. The oil was a coal derived product having a boiling point range of 234¦C - 319¦C. Apparent viscosity of all suspensions was found to increase on storage due to ageing. Ageing might have occurred due to physicochemical interactions between coal and oil. Flow behaviour of some suspensions changed from Newtonian to non-Newtonian on storage. Apparent viscosity increased sharply with increase in solids concentration and suspensions at higher concentration behaved as non Newtonian liquids. Viscosity decreased with increase in temperature; rate of decrease slowed down with increase in temperature.

Jan 1, 1980