Search Documents

By C Simpson

In 2011 the forecasted world demand for iron ore continues to grow, and during this time Australia is looked upon as a reliable supplier of high quality ore. The expansion of the current Australian mines is unlikely to meet the forecast demand. New mines are therefore being actively explored for and when discovered, are quickly being developed into mines in order to meet the world’s hunger for steel.The Solomon Project area is a large new iron ore discovery, located in the central Hamersley Ranges of the Pilbara province in Western Australia. The first Fortescue exploration drill holes commenced on the project in 2007 and to date three billion tonnes (Bt) of iron ore have been defi ned within the project area. Fortescue is fast-tracking the development of the ‘Solomon Stage 1’ project, with rail and mine construction commencing during 2011, and ore to be railed to Fortescue’s existing shipping operations at Port Hedland commencing in 2012. At a designed production rate of 60 Mt/a, the Solomon operation will be one of the biggest production centres of iron ore in the Pilbara.Deposit types include the three dominant mineralisation styles of the Pilbara province, being bedded iron deposits (BID), Channel iron deposits (CID) and detrital iron deposits (DID). All these mineralisation styles are present in large concentrations within the Solomon project area, and when mined will produce two product streams. These are a single product of CID, and a combined product from a blend of BID and DID material.This paper defines the geological characteristics of the Solomon iron deposits as recognised through the exploration and development of this vast resource over the three years since exploration commenced on the project.

Jul 11, 2011

By J Manuel, R Muddle

The demand for iron ore has increased significantly in recent years, with new iron ore sources being mined to meet this demand. As the composition of sinter blends changes with the availability and cost of iron ore, so too does interest in the impact of new ore types on granulation and ultimately productivity. This paper describes a study into granulating characteristics of seven iron ore types, including various hematite and goethite ores. The effect of ore type on feed moisture requirements, green bed permeability, green bed strength and granule size distribution was examined for single ore blends containing coke, flux and returns. The ore size distribution was varied in these blends and its effect on granulating characteristics examined. It was found that the optimum moisture requirement of the ore was more dependent on ore type than ore size distribution, but ore size distribution (and specifically intermediate particle loading) had a greater effect on green bed permeability. The saturation moisture value for an ore was found useful in predicting both optimum granulation moisture and green bed permeability.

Jan 1, 2005

By Quintiliani G, Giordano V

A research field of interest and a topical subject with the aim to reduce a considerable amount of coke in ironmaking is the injection into blast furnace stack of hot reducing gas combined with use of auxiliary fuels at tuyeres. In recent years evaluation studies and prelimirfary industrial experiments have been carried out on this subject in Europe and Japan. Even if these experiments seem to confirm the advantages theoretically expected, it appears as useful to cast more light on new problems concerning the improvements of this technique. In this report some aspects are analysed on fluid dynamics of blast furnace process with two gas flows: the main flow coming from the bosh and cross flow of the reducing gas injected in the lower shaft. A research on a blast furnace physical model was made with the aim to obtain information about the phenomena which occur in the full scale blast furnace. This work was carried out on cold models IN and tridimensional) in which the radial gas distribution was experimentally measured. A mathematical model based on gas diffusion was implemented aimed at simulating gas distribution inside the reactor taking into account the number of injection tuyeres. A good agreement between experimental and theoretical data allows for extending results to industrial practice in order to determine operating conditions assuring good performance of blast furnace with high amount of auxiliary fuels.

Jan 1, 1975

By J Player, P Evans, G Sweby

Achieving quick underground access after the completion of an open pit mine can be critical to maintaining project value and ensuring regular ore feed to the mill. This paper outlines the design and construction for two portals in an active open pit to commence underground development quickly whilst installing appropriate ground control to maintain long term access in an uncertain setting. Implementation of the portal designs was complicated by the change in underground design from hangingwall access to footwall access late in the life of the open pit due to preferable ground conditions. The portal locations did not have easy access for ground support installation integrated into the pit design due to the timing of the underground design changes. Practical implementation of the ground support systems subsequently became a key part of the project. Intact rock strength, rock mass characteristics, gradational weathering / alteration profile and structural information were modelled against pit displacement monitoring as the basis from which the portals were located and ground support schemes designed. Conditions around one of the portals necessitated numerical modelling to estimate the appropriate level of ground control for long term stability. The design was completed whilst the open pit was actively on-going and the portal areas not entirely exposed. The rock mass assessment and analysis for the two portals indicated different ground support scheme capacities would be required. The expected level of control for one of the portals also necessitated the use of monitoring with extensometers and load cells to ensure the rock mass response and ground support scheme performed as planned. Construction of the portals demonstrates the benefit of a considered design process, a plan which allows practical installation of ground support schemes where access is limited, the benefit of ongoing monitoring to ensure performance remains within design limits and the challenges involved working within an active pit with limited floor space.

Mar 15, 2021

By N J. Grigg

Gekko Systems has developed an underground pre-concentration plant (Python) to reduce mine operating costs. Many ores liberate favourably using either high pressure grinding rolls (HPGR) or vertical shaft impactors (VSI). Using these comminution circuits for mineral liberation; rather than for the final recovery process and by utilising a high mass pull, high recovery process route (gravity/flotation), a narrow, low head, compact processing plant was developed that can sensibly be operated underground. The Python underground processing plant can provide a number of advantages for narrow vein mines including lower haulage costs, improved mine call factor and lower operating costs. The focus on fine crushing reduces the power requirement of the plant to approximately 8 kWh/tonne. The Python underground processing plant has been designed to be towed down the decline or lowered down a shaft, and is capable of being installed in sloping, non-linear drives for placement close to the working face. The overall benefit to mining companies of this concept has been estimated to be a saving in mining costs and a significantly smaller environmental footprint.

Jan 1, 2008

By H Lemos, E Nunes, D Jacobson, R Costa, L Ono, A Alves, H Delboni Jr

Oversize rock breaking and metal tramp removal are key issues for reducing primary crusher downtime, as well as improving the safety associated with its operation. Remote operation of such tasks would thus not only increase productivity, but also reduce the risks related to work in confined spaces, fall risks, and overhead hazards. These issues are particularly relevant in high-capacity operations such as iron ore mining, where large machines are in continuous operation. This article describes the architecture, construction and advanced testing of a novel remotely operated robotic mechanism for assessment and removal of metal tramp from primary crusher chambers. The system essentially includes a robotic-arm equipped with a hydraulic clamp tool for handling oversize material, as well as an oxy-flame module for cutting metal pieces entrapped within the primary crusher cavity. The first industrial unit was delivered to a large iron ore mine in Brazil, where the installation and testing is scheduled within the coming months.

Nov 8, 2021

By S Vink, A Wolhuter

Increasingly the community and government regulators are calling for æzero dischargeÆ mines. Some mining companies are beginning to explore ways in which they can transition to zero discharge. When striving to attain zero discharge, mines must consider multiple variables in addition to water quantity. These include climate regime, water quality and regional water budgets. This paper explores the drivers behind the concept of zero discharge mines and will use examples to illustrate the feasibility of attaining this goal.CITATION:Wolhuter, A and Vink, S, 2013. Is zero discharge a viable or useful concept in mine water management?, in Proceedings Water in Mining 2013 , pp 329-334 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 26, 2013

By G Maude, R Ayres, R N McLean, N A. Reynolds

"An EXTENDED ABSTRACT is available for download. A full-length paper was not prepared for this presentation. The Mabilo copper-gold-magnetite skarn deposit is located in southern Luzon in the Paracale mineral district, where iron has been produced historically from several skarn deposits. Mabilo occurs in the south-west of the district and is distinct and significant because of its high grades of copper and gold compared to historical mines.The Mabilo licence surrounds the Venida prospect, where past small-scale mining has exploited iron, copper and gold mineralisation in oxidised skarn. A ground magnetic survey in 2007 defined a number of strong anomalies under Quaternary volcanic cover south of Venida. The property was acquired by Sierra Mining Ltd in 2011, the magnetic data were remodelled and drilling commenced in September 2012. Diamond drill hole MDH001 targeted the strongest anomaly, which was 500 m south of Venida and under 20 m of volcanic cover. It intersected 94 m with an average grade of 2.2 per cent copper, 1.6 g/t gold and 36.6 per cent iron. Subsequent drilling was targeted by magnetic modelling, incorporating magnetic susceptibility data from drill core, which resulted in a high percentage of successful drill holes.The mineralised skarn preferentially replaces a dipping limestone unit within an Eocene sequence dominated by volcanic siltstone and sandstone, metamorphosed to marble and hornfels in the aureole of a Miocene quartz-diorite intrusion. Skarn occurs discontinuously along the eastern and southern diorite contact, controlled by primary sedimentary facies variation, structural geometry, fault offsets and intrusive contacts.Coarse magnetite skarn with garnet and minor wollastonite and clinopyroxene contains variably abundant chalcopyrite and minor molybdenite. Magnetite skarn occurs in sharp contact with unaltered marble or grades into garnet skarn with minor chalcopyrite. Structurally controlled retrograde skarn alteration is strong to intense and is characterised by bornite, clinozoisite, iron carbonate and chlorite. The retrograde skarn is weakly overprinted by late-stage pyrite veining and brecciation associated with clay-silica alteration with arsenopyrite and tetrahedrite-tennantite.The quartz-diorite stock is interpreted as the source of the prograde skarn-forming and mineralising fluids. Late-stage porphyritic intrusions in the contact zone indicate continuing magmatism during uplift, when telescoping led to a high-level, high-sulfidation overprint. This suggests the potential for deeper porphyry-style mineralisation.CITATION:Reynolds, N A, Ayres, R, McLean, R N and Maude, G, 2015. The Mabilo copper-gold-iron deposit – a new skarn discovery in the Philippines , in Proceedings PACRIM 2015 Congress, pp 431–438 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Mar 18, 2015

By Smit J. G

Following an increase in the number of methane ignitions in South African coal mines a new ventilation system was developed. The "Hydravert" system conceived in late 1979 for use in low seam coal mines, where the bord and pillar method of working is used, has been extensively developed to include applications for mining seams up to 4.5 metres high. A brief history of the development is supplied including some of the pitfalls encountered in the hydraulic equipment design and selection.

Jan 1, 1988

By P Jago

KCGMÆs Fimiston Open Pit, located in the centre of the historic Golden Mile, is situated above some 3000 kilometres of old underground workings. These workings, both level and vertical, present significant safety and operational problems in the pit. One of these challenges is in safely drilling void areas so that they can be charged and blasted effectively. Current drilling practices in these areas require machines that can only drill 115 mm holes on a smaller pattern than the standard blast pattern. This results in more time and cost to both drill and charge these areas. Any other method currently available to drill out these areas involves putting operators in a potentially hazardous situation by being too close to the void area being drilled. Not effectively drilling and blasting these areas leads to hazardous situations further in the mining cycle including oversize, large toe and uncollapsed voids. Ineffective blasting also causes reductions in mining productivity and mine to mill performance. In response to these issues, KCGM has commissioned the implementation of a fully remote controlled DM45 blast hole drill rig to drill out selected void areas. The remote system, installed in conjunction with Ausdrill Ltd and GM Mining Electrics, is designed to operate similarly to a tele-remote bogging system with the operator controlling the drill rig from a separate control cabin via radio signals and video feed. This allows KCGM to drill in areas of higher risk without exposing the operators to voids. The drill rig will also be able to drill standard patterns through some specially selected void areas, reducing costs and extra time associated with drilling and charging void affected areas. The remote rig is expected to provide a number of benefits, both in the drilling process and in further downstream operations. Costs of drilling in void areas are expected to decrease with standard patterns instead of smaller patterns being drilled. Safety and operator comfort are also expected to increase through removing the operator from the pit floor. Blasting is also expected to see significant improvements through increased ease of charging void areas (because of larger holes and standard patterns), more consistent patterns resulting in less secondary blasting and toe and an overall improvement in the speed and cost of charge-up practices. This more consistent blasting will also improve shovel productivity, crusher performance and overall mine-to-mill efficiency. This paper presents an overview of the development of the remote controlled system, including modifications that have occurred since commissioning. It explains some of the problems encountered and how these have been solved. Key issues for operational success will be identified and explained with a view to making future implementations easier. Factors used to assess the performance of the remote controlled rig will also be explained in further detail and used in a preliminary assessment of the rigÆs feasibility.

Jan 1, 2003

By L Cain, C Every, S Mirlatifi, J Ashley

This paper presents a geographic information system (GIS) based method for the prediction of ground movement and the associated impact on existing buildings and structures due to tunnelling in the North West Rail Link (NWRL) project. The NWRL is a priority rail infrastructure project for the New South Wales (NSW) Government and includes 15 km of twin tunnels between Bella Vista and Epping, which will be Australia’s longest rail tunnels. The NWRL tunnels will be constructed in an urban environment where the prediction of ground movements induced by tunnelling and the associated impacts to existing structures must be assessed in the early design stages of the project. An assessment process was developed using GIS able to respond to design changes.An iterative GIS analysis methodology was developed to generate ground settlement contours and identify impacted buildings and structures in response to multiple changes in tunnel alignment during design development stages. The GIS analysis undertook to rapidly provide detailed and accurate parameter information including tunnel depth from surface, tunnel separation, diameter and sample point proximity to the tunnel and assess ground movement contours along the project alignment. Determination of the ground surface settlements were based on empirical methods proposed by Peck (1969) and Mair (1993). The control parameters and the relationship between damage categories and risk classifications for impact assessment were based on Burland, Broms and de Mello (1977), Rankin (1988) and Boscardin and Cording (1989) methods.The GIS-based ground movement impact assessment approach adopted for the NWRL project demonstrates an efficient, iterative and robust approach and could provide an initial framework for other similar tunnelling projects where rapid design changes and early understanding of tunnelling impacts are required to bring greatest benefit to all stakeholders.CITATION:Mirlatifi, S, Cain, L, Ashley, J and Every, C, 2014. An iterative geographic information system based approach for the assessment of tunnelling impact to existing buildings and structures, in Proceedings 15th Australasian Tunnelling Conference 2014 , pp 647–652 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 17, 2014

By Glastonbury J. R

The kinetics of the direct chlorination of, zircon in the presence of carbon was studied at temperatures between 9000C and 12000 C. From the experimental data it is prop- osed that the most likely mechanism for metal oxide (MeO2) chlorination is as follows: At I Surfaceon zMeO2+ZMeCl - MeOC12 (1) At Carbon MeOC12+C+Cl MeC14+CO (2) Surface It.is envisaged that this type of mechan- ism would occur for both the zirconium and, silicon. constituents of the ore. In the above mechanism; the surface re- actions appear to be fast and not rate controll- ing. In a carbon surface deficient bed the diff- usion of oxychloride intermediate through the boundary layer to the carbon surface becomes the rate controlling step. In a zircon surface deficient bed the diffusion of oxychloride away from the zircon surface controls the reaction. This postulated mechanism can be used to ex-, plain the observed experimental effects.

Jan 1, 1973

The Honourable Neil Pickard has been in Parliament for something like sixteen years. He was Minister for Education in 1976, served as Shadow Minister in a number of portfolio areas while his party was in opposition, and since their return to power in 1988, he has been the Minister for Minerals and Energy. Ladies and gentlemen, I ask you to welcome the Minister, the Honourable Neil Pickard.

Jan 1, 1989

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

The South Wall Base Case Design for Mt Whaleback indicated that along portion of the South Wall a cigar shaped synclinal keel, contain- ing 14 800 m', of Dales Gorge Member ore, would be unkeyed and bed- ding undercut. The dry "ore lobe" slope would be 60m high, unbenched and approximately 170 m long. Stability analyses using specific design parameters established that artificial reinforcement could stabilise the slope and be economically justifiable. To implement the slope design reinforcement for such a complex geo- logical structure it was necessary that all functions pertaining to slope excavation be integrated and co-ordinated within the Mine Geotechnical Section. The objective being to minimise slope damage and thereby optimise the effect of design reinforcement. The successful excavation of the ore lobe in 1988, three years after the introduction of artificial reinforcement, was achieved by strictly main- taining the following parameters. 1. Accurate Geological Model 2. Controlled Perimeter Blasting 3. Controlled Excavation Techniques 4. Quality control -Reinforcement Installation 5. Additional Reinforcement.

Jan 1, 1989

By A Specht, A Müller, V Montenegro, S Winkler, E Klaffenbach, A Schmidt

In the process of primary copper smelting in flash smelting furnace (FSF), the ratio of iron to silica (Fe/SiO2 mass ratio) primarily determines the slag viscosity and magnetite formation. Viscous slag does not only cause difficulties in daily operation, such as in tapping, it also increases the copper losses to slag. Thus, keeping the Fe/SiO2 mass ratio at the desired level is an important aspect of FSF and slag cleaning furnace (SCF) operation. In this study, the improvement of the Fe/SiO2 mass ratio was conducted in two steps: First, the optimal Fe/SiO2 mass ratio was derived based on thermodynamic data. Based on this analysis, appropriate control limits were determined. Second, this range of favourable Fe/SiO2 mass ratios was implemented into operation by an advice-based control system, which suggests the addition of silica based on the analysis of SCF slag. As this approach was successful, the same advice-based control system principle was adapted for the coke addition to the SCF. After testing the new advice-based control for several months, the production data confirm the predictions by thermodynamics: since the prediction was implemented as an advisor, the copper and magnetite content in SCF slag is significantly reduced and viscous slag is reported less often by operations.

Aug 21, 2024

It is well known that the ability to influence project value reduces significantly as planning progresses and decisions regarding project parameters are made. However, at the prefeasibility stage in particular, where one of the main aims should be to evaluate a wide range of options in order to select the best for more detailed further study, there is often a reluctance to spend the time and money needed to do this rigorously. This paper demonstrates, by a number of case study examples, how significant increases in value may be obtained by fully evaluating the combinations of alternatives for various project design parameters, including (though not limited to) mining methods, haulage methods, mining rates, processing methods and rates, sequencing of mining, and cut-off grades, with changes and upgrades over time where applicable. The additional value unlocked is typically orders of magnitude greater than the additional cost of the more comprehensive study. The dangers of misuse of simplistic sensitivity analyses and failure to identify how strategies might change in response to changes in external factors are also illustrated, and the importance of selecting the best ægrade descriptorÆ is discussed.

Jan 1, 2007

By P Gilroy

In recent technical investigations that were triggered from ore for rail shortfalls at Yandi, BHP Iron ore has identified a gap in resource knowledge relating to geo-metallurgical characteristics that predict materials handling performance and throughput. Within these investigations BHP has learnt that this lack of resource knowledge has translated to a lack of predictability associated with mine planning inputs which has resulted in poor compliance to plan and deviation management practices. A business value chain was developed in an attempt to identify the best possible solution to unlock this resource knowledge in the short, medium and long term planning horizons. A fast fail approach was taken with the implementation of hyperspectral blasthole analysis, which was chosen to deliver the best possible value driver for the asset. This report will detail the Yandi journey in expanding the hyperspectral and geo-metallurgical value chain, unlocking resource knowledge along the way. CITATION: Gilroy, P, 2018. Development of an empirical geo-metallurgical model that unlocks value of the mineral resources at Yandi Mine, in Proceedings Complex Orebodies Conference 2018, pp 85–87 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 21, 2018

By D Lucato, B Haase, R Saha, S Limberger-Forte, J Lishman

Cadia East Mining operations have employed geometallurgical techniques to advance the understanding of the in situ rock hardness variability across existing Panel Caves (PC). Geometallurgy advances the understanding of variability across an orebody through the integration of geology, mineralogy and processing response and therefore enhances spatial mapping of comminution or separation properties. Spatially extensive geometallurgical measurements are necessary so that continuous rock properties can be generated and used for the development of comminution and processing domains using geostatistical modelling. Standard testing protocol across geological and mineralogical domains is vital to understand the variability in deposit wide comminution and separation properties. The high cost and large sample requirements associated with metallurgical test work typically results in insufficient data density and distribution, making it difficult to model and map deposit scale variability. Quantitative hardness proxy tools are useful to measure in situ rock hardness, however this data is typically either sparse or missing within advanced mining operations. In recent years, mineralogy and multi-element assay data has often been collected as part of the standard geological data set and is generally coincident with metallurgical test work. In this paper relationships between mineralogy and comminution parameters have been applied to multi-element assay data with coincident measured Bond Work Index (BWi) data to generate a predicted BWi using linear regression. The predicted BWi is intended to supplement existing measured BWi data to enable better extrapolation across the deposit. Geostatistical Conditional Simulation methods have then used the predicted and measured BWi data to produce a BWi variable as a new input to the resource model. The simulated BWi can be used as an input for specific energy models to predict required grinding energy consumption across a deposit.

Mar 22, 2022

By M Akop, G Phillips, L Elliott

An estimation geologist has many tools in their kit and using the correct one for the job is vital for creating a useful model. Reconciliation is a key step to monitor the performance of a resource model and to ensure the correct tools have been selected and appropriate parameters are set. This paper presents an example of refining the estimation methodology for a Channel Iron Deposit (CID), resulting in an improved model. Rio Tinto Iron Ore (RTIO) CIDs are unique iron ore deposits located in the Pilbara region of Western Australia and contribute a significant volume to the world’s seaborne iron ore market. A problematic feature of these deposits is the irregular dispersion of clay pods that cannot be delineated with confidence within the resolution of the exploration drilling. Resource to grade control reconciliation showed an over-prediction of high-grade material in the resource model. A fresh approach was required to improve grade and tonnage predictions. Historically, clay pods were delineated using traditional wireframing techniques and estimated using ordinary kriging with hard boundaries. The new method utilised indicator kriging to estimate the probability of clay. Probabilities generated from the indicator kriging estimate were used as an additional weighting following the ordinary kriging of grades. Results showed indicator kriging improved global high-grade tonnes reconciliation, however, as expected, it did not improve the spatial prediction of clay. Based on improved reconciliation results indicator kriging has now been adopted as a suitable alternative for analogous CIDs at RTIO. These improvements benefit the mine planning process, but do not replace grade control models.

Mar 22, 2022