Search Documents

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

By J Heyes

Historically mining engineers haven't spent enough time planning waste dumps, but waste movement costs often outweigh ore haulage costs. There is a real incentive to plan waste dumps right the first time to minimise rehandle and final closure costs. At BHP Billiton Iron Ore there has been an increasing sophistication in waste dump design and they are becoming as important as the pit design. Closure landforms are now included in mining studies. Closure is embedded in the business planning cycle. The results from the recent life of mine study at Whaleback is a case in point where a base case of the shortest hauls with no closure constraints was compared against a closure case. A properly planned and executed waste plan revealed that no rehandle was required and haulage costs were eight per cent less if closure design implementation was carried out concurrent with mining. At cessation of mining the landforms were such that decommissioning of critical acid rock drainage dams and coverage of exposed pyrite areas could occur straight away, without the need for additional rehandle.  The paper also covers design and scheduling elements of waste design both in-pit and ex-pit, management of potentially acid forming material (PAF) and trends in PAF management and designing for final landform closure. This paper illustrates that there is value in terms of costs savings, sustainable outcomes and reputation if the mine planners are involved in the closure planning process.

Jan 1, 2009

By Stevens LG, Mok JK

With the long lead time requirement for engineering and construction of mineral pro- cessing facilities and the costly financing arrangements necessary, effective project management is essential to the successful and timely start up of these major production units. An added complexity is the frequently remote location of such projects and the demands this imposes on efficient project staffing, scheduling, logistics and cost control. Parsons recent experience with major projects such as Greenvale in Queensland and La Caridad in the desert of Northern Mexico and at remote locations like Sar Cheshmeh in Iran are described. The applications being developed for improving project controls through the use of computer techniques such as MSCS-COPES, and readily accessible and versatile transportation means are reviewed.

Jan 1, 1981

Batch centrifugal gravity concentrators have become standard equipment in gold grinding circuits for recovery of gravity recoverable gold (GRG). The downstream benefits of installing a gravity circuit are well understood, and in general, if there is a reasonable amount of GRG in the ore, a gravity circuit is usually installed. The benefits of gold gravity recovery have also been well documented, with a large database of successful case studies. As well, predicting production scale gravity recovery results ahead of installing gravity has become a common practice. The missing link between lab and full scale has always been the ability to predict the recovery benefit of installing gravity ahead of actually doing so. Being able to predict the recovery benefit in advance would help an operation in assessing the economic benefit and help justify the capital costs of the gravity circuit with much less uncertainty.

Aug 1, 2010

By B Hooper

Deep cuts in CO2 emissions will be required to stabilise and, in the long term, decrease CO2 concentrations in the atmosphere. Technologies for capturing CO2 from major stationary sources (power stations, industrial plants, etc) and storing that CO2 for long periods of time is one of few near term options for decreasing CO2 emissions. This transition to low carbon intensity energy and possibly the hydrogen economy through renewables and in the long-term technological developments such as artificial photosynthesis.Capture of CO2 from post combustion emissions can be done using a range of technologies though costs are currently high and dependent on the concentration of CO2 in the emissions. Techniques include solvents, pressure swing adsorption and the use of membranes. Options for decreasing capture costs by increasing the concentration of CO2 in the emission stream include the use of oxyfuels (in pulverized fuel types boilers) and by moving to integrated gasification combined cycle (IGCC) operations either simply for power generation or for poly-generation opportunities. Once the CO2 has been captured it can be stored using a variety of methods. Storage in the ocean has been suggested but is considered an unlikely option because of environmental uncertainties and political opposition. Mineral storage is a niche opportunity. The greatest potential lies in geological storage of CO2 and this option is commanding increased attention from the Australian and international community.In Australia, the Cooperative Research Centre for Greenhouse Gas Technologies (CO2CRC) is an important new initiative that will support energy companies and energy intensive industries in meeting challenges posed by greenhouse gas issues and assist them in their efforts to reduce their emissions profile.The progress of geo-sequestration and the challenges in the capture and separation of CO2 in the process industries are discussed.

Jan 1, 2004

By A Coulson, J Hussey

Noranda Inc is a Canadian mining and metallurgical company with its activities managed through businesses in copper and recycling, zinc, aluminum, magnesium and various metals through its interest in Falconbridge Ltd. Noranda operates three base metal mines, three copper smelters, one copper refinery, one zinc refinery, one lead smelter and refinery, three copper recycling and sampling facilities seven aluminum producing facilities and one magnesium production facility in the construction stage. The mining side of Noranda has a strong history of open stope, cut and fill and shrinkage mining. The 1999 Noranda Annual Report lists a 206 million tonne resource located at Porphyry Mountain in GaspT, QuTbec. Mont Porphyre is a large tonnage, low-grade porphyry style Cu-Mo deposit that was discovered in 1994. It is located at a depth between 1.0 and 1.7 km below surface and characterised by a very competent rock mass. The Mont Porphyre resource is located adjacent to the town of Murdochville, close to NorandaÆs Mines GaspT operations. Mines GaspT closed its open pit and underground operations in 1999 after approximately 45 years of mining, but still operates a copper smelter near Murdochville. The low-grade and great depth of the Mont Porphyre resource suggested that mine design could not be based on the conventional Noranda open stoping mining practice. This paper will review NorandaÆs approach to evaluating the Mont Porphyre deposit. The approach included two definition diamond drilling campaigns, a review of current caving practice, an in-house scope study, a geotechnical logging program for diamond drill core and participation in an international study on cave mining. One interesting component of NorandaÆs approach was the scope study that involved a team of multi-disciplinary personnel drawn together for a short period of time. The objective of the scope study was to determine what conditions would be necessary to mine the deposit and to assess the merits of continuing with further exploration work. A review of current worldwide underground bulk mining practices, and in particular an evaluation of the applicability of caving mining methods, were key components of the scope study. The scope study team concluded that derivatives of caving could be applied to the mining of Mont Porphyre, but additional diamond drilling was recommended to further define the deposit and improve the level of geotechnical information. Following the recommendations of the scope study team, a diamond drilling campaign was completed during the summer and fall of 1997. The 1997 drilling campaign had two secondary objectives, in addition to the primary objective of defining the limits of the orebody. The first objective was to improve the level of geotechnical information available for the characterisation of primary block cave fragmentation. The second objective was to improve the delineation of a lower grade intrusive core. A geomechanical investigation was conducted and included particular emphasis on geotechnical data collection and analysis. A review of the actual data collection process, including several trials of different core orientation techniques, will be included in the discussion.

Jan 1, 2000

By R Pax

Feed ore variability, the major disturbance into a mineral processing plant receives considerable attention operationally, and at research and strategic levels to ensure that the throughput of the ore are maintained at all times whilst encouraging a sustainable approach to recovering the valuable minerals from ore bodies. Effort and insights from mineralogical and processing characterisation (eg. ore hardness) of sub-ore body domains allows sequencing for processing to ensure consistency and throughput for the size sensitive grinding unit processes. Optimising the blast fragmentation has benefit as does pre-concentration using ore sorting. Blending of ore domains with different characteristics is common for operations. In recent years a number of technologies have become available for on-line and more rapid assessment of ore and have been discussed in a recent paper by Cameron et.al. (2016) as an opportunity for further utilisation of mine-to-mill (and mine to product) strategies. Current concepts have focused on extensive characterisation of ores so that current control practices can be realised and made more effective with relatively slow measurements and actuation. CITATION: Pax, R, 2018. Dynamic concepts for mine to mill operation and optimisation, in Proceedings Complex Orebodies Conference 2018, pp 124–125 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 21, 2018

By Gallet M, Watsford R. M S

The 1989 feasibility study of the chessy, france, copper, zinc, pyrite and barite orebody was based upon a classical flowsheet. The flowsheet included, three stages of crushing, conventional rod and ball mill grinding in series, and sequential flotation of four products utilising conventional mechanical flotation cells. To improve the profitability of the project the partners commenced a search for ways to reduce the projected capital and operating costs of the proposed development. This paper presents the improvements in the projected capital and operating costs as a result of design and concept changes. The major changes included: ò the simplification of the crushing section with the adoption of semi autogenous grinding (SAG) milling of primary crushed ore. ò the deferral of pyrite and barite flotation circuits until market conditions were positive. ò the simplification of the flotation circuit by the use of column flotation cells for combined rougher/cleaner duty. ò the purchase of second hand equipment. The result of these changes was to reduce the capital cost estimate of the plant from US$ 21 million to US$ 11 million and operating cost estimates from US$ 18.90 to US$ 13.60 per tonne of ore for a decrease of approximately ten per cent in potential revenues.

Jan 1, 1991

By Cousens DR, Benhamou M, French DH

Techniques appropriate to petrographic image analysis are being developed using digitized backscatter electron images of well characterized mineral assemblages obtained from a Cameca scanning electron microprobe. Emphasis is on developing descriptors for size, shape and association of mineral grains as these all convey important information concerning the nature of rocks and the processes that have operated upon them. Processes, for example, that could indicate the proximity of mineralization. For convenience, the work is being carried out on the PDP11/73 host computer of the electron micropt be, although it is recongnized that such a multi-user environment is not appropriate for practical image analysis. The eventual aim is to develop a low-cost microcomputer-based package for quantitative description of mineral textures and rock fabrics as an objective aid to the petrographic analysis of ores and host rocks.

Jan 1, 1989

The three papers reviewed here consider different problems of mine management. Comparison of two of the papers demonstrates a marked contrast between the old and the new, in terms of mine management and impacts. The third paper discusses post-mining rehabilitation. The paper "The impact of a derelict base metal mine on the aquatic environment", by Brooks and Mclveen contrasts strongly with the paper "Narbarlek Uranium Mine design, construction, operation monitoring and decommissioning of the water management system" by McLoughlin, Grounds and Weatherhead. Brooks and Mclveen detail the contamination emanating today from the Conrad Mine in New South Wales which was mainly operated for 15 years at the turn of the century and later for 7 years in the 1950's. The mine was apparently developed over the years on an intermittent, ad hoc basis with no regard to contamination management, resulting Ti significant contamination persisting through time. This type of mining development is the antithesis to the type of planned mining and management operation which was carried out in Arnhem Land at Narbalek, and which apparently resulted in no uncontrolled contaminant release and successful decommissioning of the mine.

Jan 1, 1988

By N Fullelove

The Renison Bell Tin Mine on the West Coast of Tasmania has recently installed a new underground ore handling system incorporating underground crushing, conveying and hoisting facilities. Contracts for the sinking of the shaft and the development of the mine were let and managed by the operator, Renison Limited. Hardcastle & Richards was responsible for the design, procurement and construction management of the fixed plant and equipment including civil, structural, mechanical, electrical and instrumentation services. The system demonstrates worldÆs best practice in design and incorporates a state-of-the-art integrated control system allowing the entire system to be controlled by a single operator located in the underground crusher chamber. A rapid construction period was achieved, despite the difficult and constrained underground environment, without affecting the ongoing operations of the mine. The mine, which was established in the mid-1960s, had previously operated by trucking ore to the surface via a decline. Truck haulage distances and costs had increased as the mine became deeper over the years. By the 1990s it had become apparent that, in order to remain economically viable, it was necessary to reduce truck haulage distances and allow the mine to go still deeper to access orebodies such as Rendeep beneath the current workings. The Internal Shaft System achieved this by eliminating approximately 5 km of truck haulage. It allows the production rate to be increased to up to 1 Mtpa compared with a limit of 628 kt per annum by direct truck haulage to surface. The access it provides to the Rendeep ore and other deep orebodies greatly increases the amount of ore which can be economically mined.

Jan 1, 1998

The Northern Mariana archipelago in the W.Pacific forms a classic intra-oceanic island arc system far from the influences of continental crust. As such it offers an ideal location in which to study many of the problems of subduction-related volcanism. Radiogenic (Sr, Pb, Nd and Hf) and stable (0, S and H) isotope systems have been applied to the question of the possible involvement of components from the subducting slab in arc magmagenesis. The results contrast with earlier studies based upon limited sample suites and suggest that fluids, derived from the slab and enriched in mobile elements, substantially modify the composition of the mantle wedge and contribute to the characteristic geochemistry of arc magmas. Trace element data, including the occurrence of negative Ce-anomalies in the lavas seem consistent with this conclusion. Major and trace element variations within the arc lavas can be modelled in terms of crystal fractionation of a gabbroic mineral assemblage and mixing calculations indicate that this has the approximate composition of PLAG:CPX:MAG:OLIV = 60:25:10:5. This observation is compatible with the widespread occurrence of gabbroic nodules in lavas throughout the arc. Consideration of Rare Earth Element and phenocryst data leads to the conclusion that many of the more basic lavas may be the products of cumulus enrichment. The results of this study constitute a model for magmatic processes occurring in simple island arc systems, and may be generally applicable to other, more complex settings. The recognition of a return flux of material with 'continental' affinity to the mantle, via sediments on the subducting slab, also places strong constraints on geochemical models of crust-mantle evolution.

Jan 1, 1987

An approximate rapid design system for tunnel liners and underground structures is presented which permits the effects of structure geometry and stiffness, rock quality in terms of its deformation modulus, and the applied system loading to be entered as data to produce direct designs conforming to stress limitations, optimum reinforcement requirements and restraints on section dimensions. An 'equivalent column' concept is introduced for modelling the rock mass in contact with the structure. Only the rock treatment is given in detail but the results of sensitivity analyses, with reference to rock quality, for a typical liner design are given and these results related to a number of empirical design approaches.

Jan 1, 1976

By A Quigley

The Northside Storage Tunnel Project in Sydney includes over 20 km of TBM driven tunnels, over 3 km of declines and major caverns and pump rooms. The paper describes methods used for design on the project. Emphasis is given to the refinement of the use of empirical rock mass classifications, and to the use of discontinuum numerical methods.The use of empirical rock mass classifications in Sydney sandstone has usually led to conservative design because the systems are based on a random orientation of joints in the rockmass. Because the joint sets are usually oriented in a way that is beneficial for tunnelling, limits must be placed on the parameters used in the classifications system. The paper discusses these limits and the derivation of the parameters.The use of numerical methods in Sydney sandstone is discussed. Continuum methods have their uses, but discontinuum methods are preferred. The use of UDEC has been validated against a previous project, the New Southern Railway. Recommendations are given for UDEC models.

Jan 1, 1999

By J L. Merritt

The mining industry seeks to engage with and respond to stakeholders through open consultation processes during the various phases of a mining project (Department of Industry, Tourism and Resources, 2006). Two Australian Coal Association Research Program (ACARP) funded projects conducted in the Bowen Basin coalfields in Central Queensland investigated the use of a stakeholder panel for the evaluation of mine site rehabilitation. The panel members were drawn from the local and regional area, and represented neighbouring landholders, traditional owners, AgForce, local government, conservation groups and non-governmental organisations (NGOs) such as Greening Australia and the Fitzroy Basin Association. The approach of utilising stakeholders to establish rehabilitation criteria was proposed as an alternative to the established practice of assessing rehabilitated areas against a suite of quantitative completion criteria; eg >70 per cent vegetative ground cover or <5 t/ha/a soil loss. The basis of this approach recognises the reality that the definition of completion criteria has proved problematic over the last 40 years with no broad consensus reached on the suite, let alone the metrics; eg the exact cover level that will benchmark acceptance of the mine site rehabilitation.CITATION:Merritt, J L, 2016. Zooming out – learning to see rehabilitation through stakeholders’ eyes, in Proceedings Life-of-Mine 2016 Conference, pp 163–165 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jun 28, 2016

The Olympic Dam Project constitutes a major resource of Copper and Uranium and has been under intensive evaluation since the discovery in 1975.A 500 metre deep rectangular shaft has been sunk into the deposit and this has been followed by 8400 metres of level, incline and decline development. 5 surface ventilation raises have also been constructed.Large scale trackless equipment is used to carry out the development, and productivity statistics are given.The paper describes the functionalised system used in the development program and discusses the maintenance support, and services required to carry out these works.The objectives of the Exploration Development program and the satisfactory results obtained from this work are also discussed.

Jan 1, 1985

By Struthers M. A

The basement contact zone, a major fault structure underlying the copper orebodies at Mount Isa, has a significant influence on orebody extraction. The zone is comprised of a variety of weak, barren lithologies which often create very difficult mining conditions, contribute to stope dilution, and have an adverse effect on concentrator recoveries.The geological characteristics of the contact zone are described, and the importance of timely, accurate geological information emphasized.A variety of mine design strategies have been employed to reduce the impact of the contact zone on orebody extraction. Some of these are discussed, together with current trends in the southern areas where orebody geometry and hence mining methods change markedly.Recent developments in ground support techniques, such as cable dowel reinforcement, have significantly improved ground conditions in the contact zone. An example of the methods employed to improve knowledge of ground behaviour is presented. The trend towards increasing automation and larger equipment requires larger excavations; consequently ground support practices and knowledge of ground behaviour must continue to advance. Rock mechanics investigations will remain an essential part of the mine design process.

Jan 1, 1990

Lafayette Mining Limited, a listed Australian company, is developing a polymetallic Project on the island of Rapu Rapu, located to the east of southern Luzon in the Philippines. The Rapu Rapu Project is based on the Ungay deposit, which has proven and probable reserves of 6.0 million tonnes of 2.5 g/t Au, 28 g/t Ag, 1.2 per cent Cu and 2.1 per cent Zn. The Project will produce copper and zinc concentrates from a sulphide flotation plant as well as dore from a CIL gold plant. Average annual metal production over the projected six-year mine life is 9800 tonnes of copper, 14 000 tonnes of zinc, 50 000 ounces of gold and 590 000 ounces of silver. Despite a rich mineral endowment and long mining history, there have not been any significant new mine developments in the Philippines since the early-1990s. The investment climate has been affected by legal challenges to the 1995 mining code, civil unrest in parts of the country, the impeachment of the previous President and community concerns about the industryÆs environmental performance. As a consequence, the Rapu Rapu Project is viewed as a test case û within both the country and the international mining industry û on whether minerals investment in the Philippines is an acceptable business proposition from a risk perspective. Lafayette has faced formidable challenges in managing the development risks of the Project. The major risk areas of the Project for which the company developed strategies include: regulatory, environmental and approvals issues, technical evaluation, project development, social and community issues, land acquisition, and financial and marketing issues. This paper describes the risk management strategies successfully pursued by the company, and which have the Project on track to commence construction in 2003. Dealing with each of the areas in turn, Lafayette sought to develop strategies which either effectively neutralised, minimised or otherwise addressed the key risks most likely to be experienced.

Jan 1, 2003

Applications of chlorine metallurgy to the extraction of metals often result in the production of volatile metallic chlorides, most of which condense directly to a solid phase at 1 atm pressure. A stirred-bed condenser suitable for the recovery of these materials is described.The unit, developed from the concept of a fluid bed condenser, has the advantages of versatility of operation and ability to control fog and dust formation. Test work using aluminium chloride vapour (as an example of a volatile chloride) gave recoveries approaching 100 per cent. The yield was dependent upon halide content of the vapour, flowrate, and, to a lesser extent, upon coolant temperature. Analysis of the heat transfer dataindicated condensation side coefficients in the range 10 to 30 B.T.U./hr sq. ft. 0p.

Jan 1, 1971

THERE is available a considerable amount of literature concerning the practice, and, to a smaller extent, the theory of ventilation as it applies to coal mines. Publications considering the subject of ventilation of metal mines from a practical viewpoint are much less numerous, whilst the treatment of the theoretical aspect of the question (except in so far as is common to coal mining) appears to have been almost neglected. This may be due to one of two causes (a) That in many metal mines (especially those which have not attained a great depth), on account of the greater number of connections with the surface, as compared with coal mines, natural ventilation has sufficed.(b) That in metal mines where the foregoing is not the case the solution of the ventilation problem from theoretical considerations has been regarded as involving so many complications that any attempt at the determination of a set of concrete ventilation figures applying to and throughout the mine would be futile. Whilst it is freely admitted that the difficulties inherent in the application of theory to the ventilation of metal mines are numerous, it must also be admitted that few attempts have been made to overcome them. The ultimate aim, of course, would be the collection of sufficient data to enable the probable behaviour of the air-currents throughout the whole of the workings of any mine to be accurately predicted under any particular set of circumstances. Failing the attainment of this goal of perfection, it would at least appear that much valuable information might be obtained. In ventilation, as in...

Jan 1, 1921