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By S A. McManus

With the advances in software speed and capability, many of us now are running multiple scenarios on entire models rather than just testing small areas or a few blocks. In the authors experience both the geological and geostatistical academic theory and our rules of thumb, often prove un-useable or incorrect in the real world we work in. The only way to truly validate and tune our models is to complete the entire model and ‘see if it works’. If it lacks some property we were expecting, then we need to find out why and/or run different scenarios to see what changes. This is not always possible with tight project timelines but we find ourselves doing more and more of this sort of thing, and in so doing, understand that every deposit is different and requires its own ‘rules’ to get valid and useful results. For the purposes of this paper, this process is termed Empirical Geostatistics. Take Clayton Deutsch’s ‘all realisations all of the time’ concept a step back. Before you even think of simulating, test the alternate realisations generated by alternate parameters such as different domaining, varying search neighbourhood parameters etc.

Mar 22, 2022

The object of this paper is to give an insight into various metallurgical operations involved in the making and shaping of steel for shipbuilding at the Newcastle plants of the Broken Hill Proprietary Co. Ltd., Commonwealth Steel Co. Ltd. and the Port Kembla plant of Australian Iron and Steel Ltd. Whilst not steelmakers, inasmuch as their processes start with semi-finished. steel supplied by the Steelmaker, the plants of Stewarts and Lloyds (Aust.) Pty. Ltd. and their associate company, British Tube Mills, Rylands Bros. (Aust.) Pty. Ltd. and the Newcastle and Kembla plants of John Lysaghts (Aust.) Pty. Ltd. make substantial contributions to the Australian shipbuilding industry, principally by way of boiler tubing and wires for welding rods and sheet steel, including special silicon lamination sheet for electrical motors.THE MAKING OF STEELThe making of iron and steel began as an accident, slowly developed as an art and has not yet become an exact science. The iron age dawned on the day when, by chance, man's primitive ancestor built up the wall of his fire with ironstone. In the ashes of the fire he found pieces of sponge iron from which he hammered out the first sample' of wrought iron. For many centuries iron ·was manufactured in bloomeries and occasionally, when the temperature was excessive, the iron combined with some carbon and steel was produced. But it was not till '1740 that steel was manufactured under controlled conditions. In that year Huntsman invented the crucible process which held undisputed sway for over a 100 years until in 1856 the invention of the Bessemer process revolutionised the whole industry.From then on, rapid progress was made. The Siemens...

Jan 1, 1951

By R Barritt, P Scott

Across the globe, it is a common scenario that tailings storage facilities (TSFs) are being decommissioned; however, their subsequent impact on the local environment and landscape can often be overlooked during the mine planning process. In addition, the requirement of a cover system for a facilities closure may not be a priority until the latter stages of the mine/mill operation when potential cover materials may have been utilised elsewhere or, worse, buried. Developing a conceptual design and closure plan for a TSF early in a mining venture is fundamental to its success once operations have ceased. If a cover system is a planned component for rehabilitation of a TSF, it is vital that its design is appropriate to the facility and any local site constraints, such as climate and cover system material availability. It is also strongly recommended that various cover system options are physically trialled at the site by using performance-monitoring instrumentation. Through this process, an informed decision can be made regarding the most appropriate cover system design to meet any regulatory and stakeholder closure objectives and criteria specific to the site in question; however, in order for the cover system’s performance to be determined through on-site trials, it is essential that an appropriate instrumentation design is utilised. Often, little attention is paid to the data that is being obtained, and its importance may only become apparent after several years of monitoring at an expense to the venture. This should not be the case. Many sites have used an appropriate initial planning stage to understand what is required for the successful closure of a TSF, how it can be achieved and how monitoring data can be utilised to prove, or otherwise, that a cover system design will be a success.CITATION:Barritt, R and Scott, P, 2015. Cover system performance monitoring for tailings – are we doing it correctly?, in Proceedings Tailings and Mine Waste Management for the 21st Century , pp 283–288 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 27, 2015

By I Grewal, B Klein

The Knelson Continuous Variable Discharge (CVD) is a continuous centrifugal gravity concentrator for high-mass yield recovery applications. It has four operating variables that enable control of mass yield, product grade and recovery namely: fluidisation water, bowl speed, pinch valve open time and pinch valve closed time. Plant testing of a pilot scale Knelson CVD6 was conducted to evaluate the effects of operating variables on mineral separation. The analysis of operating variable effects has provided a framework for the development of operating guidelines for the CVD.

Jan 1, 2001

By G Zhang, I Glacken

Multiple indicator kriging (MIK) has been used in the minerals industry for some decades. As one of the non-linear estimation methodologies, MIK has advantages related to resolving multiple or mixed populations, high variability data and strongly skewed distributions. Applying the MIK methodology requires a lot more effort when compared to other non-linear methodologies, for example localised uniform conditioning. This is due not only to the variogram modelling for multiple indicators, but the validation is also very important because the panel model is fundamental for follow-up work, including the generation of recoverable resources at the local or SMU scale. Apart from this, only a few reported case studies of MIK have documented post-processing of the estimated modelled distribution, representing the probability distribution at point scale at un-sampled locations. The MIK post processing should include the change of support from the point scale to the panel scale, and then the extraction of quantile values from the panel conditional cumulative distribution function (CCDF) for localisation of grades into the SMUs within each panel, based on a ranking estimate marking the SMUs from high to low. In this paper, we present a case study on a gold deposit with the MIK method with full-post processing implemented for recoverable resources. The MIK point estimate was carried out with an indirect lognormal change of support from point to panel scale, and localisation was done with a custom script. The localised uniform conditioning (LUC) method was also applied for comparison purposes. The comparison shows that MIK has advantages compared to LUC when comes to capturing the high-grades, especially when mixed or varying anisotropy is present within the mineralisation.

May 24, 2023

By K Devencorn

The development of robust, economical transport infrastructure has been identified as a key driver to sovereign economic growth. Notwithstanding the value of undeveloped mineral resources, unless they can be brought to market they are of little value. Within a global context, the continent of Africa probably faces one of the most significant transport driven economic development programs as countries strive to unlock their much sought after resources.The UN’s Africa Review Report on Transport (United Nations Economic and Social Council, 2009) provides an excellent context for the issue facing African countries and the potential for investment in transport to solve many of the intrinsic problems they are confronted with. With little exception, economic development in Africa is very likely to be driven ‘off the back’ of transport development – and more specifically from heavy-haul rail as a means by which economic wealth can be derived from export of the continent’s vast natural and mineral resources to the world. The report found:transport is a key driver of economic development and poverty reduction;road transport is the most dominant mode in Africa;the ‘Cost to Market’ of African goods is hampered by the reliance upon road transport;the cost of road transport is not just economic – 19 per cent of the world’s road fatalities were recorded on African roads;African railways are seen to be disjointed and under-utilised;Africa’s ports are key to export trade - yet only six ports (three in Egypt, and three in South Africa) handle about 50 per cent of the continent’s total container traffic;the cost of transport is increasing making African trade even less competitive; andsignificant negative impacts of Africa’s reliance on road transport – health, and greenhouse emissions.We understand that mining the resource is only part of the solution – it has to be put to market at a competitive landed cost.Most African countries face huge costs associated with transport development and ongoing operation – in many cases beyond their available resources.The Australian rail industry has faced and solved many of these challenges.

Nov 22, 2011

By V Lawson

Vale’s Sudbury Clarabelle Mill processes Cu/Ni ores from a number of mines in the Sudbury basin in Ontario, Canada. Bulk sulphide flotation produces a copper-nickel concentrate with pyrrhotite as the major diluent. After successful commissioning of the Voisey’s Bay Cu/Ni Mill (VBN) in Labrador, a miniplant campaign on Clarabelle ore with the VBN flow sheet produced a significant recovery improvement over current performance. In 2001, the Mill Redesign Project moved grinding energy into rock/sulphide and pentlandite/pyrrhotite separation and in 2006 Cu/Ni separation was re-introduced to Clarabelle Mill to produce a saleable Cu concentrate. The projects were a great success. What remained was to simplify the Clarabelle flow sheet by introducing the missing components found in the VBN flow sheet. This project known as CORe has evolved through many stages including the mining boom and surviving the 2008 economic downturn and it is scheduled for completion in mid 2013. This paper outlines some of the challenges faced in this major brownfields project – organizational, technical, financial and operational.

Aug 8, 2011

By C Hamilton

Stawell Gold Mines (SGM) is an underground mining operation located in Victoria, Australia. The mining method employed is long hole retreat stoping, utilising up and downholes and artificial concrete pillars. Stawell is currently mining the Golden Gift and Magdala orebodies.Access to the Magdala and Golden Gift deposits is via 6.0 m wide by 5.5 m high declines developed at a gradient of one in eight to one in seven from the surface to a depth of 1500 m, with a planned depth of 1650 m. From the declines, cross cutting drives are developed to intersect the orebodies. Orebodies in the Gift system are discrete lodes which are generally mined from a bottom up centre retreat to minimise geotechnical stresses.Ore development fronts are currently located between 1000 m and 1500 m below surface, with all ore being hauled to the surface using a fleet of 60 tonne underground trucks. With the use of conventional pyrotechnic long period (LP) delays, broken rock of combined ore and waste is thrown 10 m from the face and the materials hauled to the surface. The majority of the mullock from development is consumed in the underground as backfill.With the use of Orica Mining Services eDev™ Electronic Blasting System for Tunnelling, the waste is thrown up to 40 m from the face, while majority of the ore is left 5 - 10 m from the face, effectively segregating ore and waste. This enables significant recovery of gold values with minimal loss and significantly reduced dilution. By using this technique in ore drives with a 30:70 waste to ore ratio, SGM is able to haul 24 000 tonnes less mullock to the surface annually. Resue mining is applied to narrow vein headings and gives a 40 per cent grade increase at the faces as well as increasing the economic footprint of development. This will also contribute to an improved grade profile for the year from 3.98 - 4.16 g/t Au and allow extra capacity for ore haulage from stoping and for milling.This paper describes the application and the successful blast outcomes achieved using the eDev™ Electronic Blasting Systems for resue mining at SGM. Results to date, since commencement in March 2010, have been achieving significant benefits in terms of ore grade as confirmed by geologists grab sample grades. Face advance have also shown improvement with better breakage of perimeter holes giving improved face profile. These benefits are delivering increased productivity and safety performance when compared to other resue firing techniques.

Mar 21, 2011

By W Malone, J Garrett

FLSmidth (FLS) has spent the last 15 years, working with customers and engineering houses to deliver innovative improvements in crusher safety, coupled with the latest, maintenance friendly, crusher design. The key focus being to prevent service personnel from working underneath the crusher during maintenance and obviate the need for personnel to be exposed to suspended loads when performing tasks such as, main shaft installation, for example. Improvements include: full top-service capability to ensure the safest and fastest way to disassemble the crusher for maintenance purposes, which also removes the requirement for a service cart; a selfaligning main shaft which ensures remote assembly is now possible, keeping service personnel well out of harm’s way; And rotable shells, or the ability to perform relines off-station, allows for quick shell ‘swap-over’ without the downtime associated with removing, refitting and curing time associated with epoxy backing. The high flow spider improves large material entry into the crusher, reducing blockages and downtime and therefore maintains crusher capacity. Each size of crusher in the range comes with an option to increase the standard feed opening to a larger one if desired to compensate for ‘blocky’ or ‘elongated’ feed material, a common problem for Pilbara hematite iron ores. Power capability has also been increased with a maximum of 1500 kW, to match the higher throughput capacities being achieved. This due to uprated eccentric speeds and larger discharge annulus. Increased eccentric throws and mantle diameters are also now a reality, when compared to more traditional designed gyratory crushers. To keep up with the improved design features of the Mk V, digitalisation has also been upgraded to maximise performance capabilities to ensure that the most efficient reduction and throughput capacities are achieved, whilst utilising the higher powers now available as standard. Condition monitoring ensures that the crusher is at its optimum operating capability by monitoring and adjusting the crusher settings via feedback from additional sensors, ie main shaft spin, temperature and vibration. Camera monitoring capabilities are available as is an advanced oil contamination monitoring system. As a result of the above design improvements, it will be shown that the Mk V range offers benefits such as: enhanced safety features, increased availability, faster maintenance turnarounds, higher power utilisation, equivalent product size at higher throughput capacities and with Remote operation capabilities. All of which result in a gyratory crusher with higher levels of safety and a lower per tonne operating cost.

Sep 18, 2023

By N J. Potter, N W. Brand, J M. F Clout

The increasing demand for iron ore with low concentrations of trace elements, puts increasing pressure on iron ore producers for high-quality material. Understanding the mineralogy, petrography, chemistry, and mineral association of iron ore deposits is becoming increasingly important to provide iron ore products that meet the ever-increasing standards of steel mills. Limited attention has been paid to documenting new orebodies beyond bulk RC drill chip assays and product specification data. Therefore, limited information is known about the spatial distribution of minor and trace elements at the hand specimen scale, and elemental deportment within different ore and gangue minerals. In this study, samples from high-grade microplaty hematite, supergene-enriched martite-goethite and hematite iron ores are examined for their elemental and mineral associations. These samples contain distinctive minor and trace element distributions, with the mapping of deleterious elements (eg Zn, As, Cu) enabling the deportment and abundance within the ore and gangue minerals to be assessed. Results from this study show a diverse range of minor and trace mineralogy that are present in typical iron ore samples, in abundances below the detection limit of routine XRD scans, that host the deleterious elements, including but not limited to, sphalerite (Zn and S), chalcopyrite (Cu and S), xenotime (P and Y), apatite (P and Ca), cryptomelane (K and Mn), barite (Ba and S), alkaline feldspar (K, Al and Si) zircon (Zr and Si) and chromite (Cr and Al). The presence of these minerals and associated deleterious elements, even at low concentrations, has implications for producers, with the ongoing restrictions and tightening of environmental constraints in shipped iron ore products. By understanding the distribution and location of these elements within the iron ore, steps can be considered to maintain increasingly higher quality iron ore supply around the world.

Nov 8, 2021

By R Goddard

An alternative stoping method has been adopted for narrow vein stoping at the Tasmania Mine in Northern Tasmania. Colloquially described as ‘Radial-in-Reef’ (RiR) stoping, the method employs the drilling of radial rings in the plane of the Reef from a drill stub located at the geographic centre of the proposed stope panel.Production from the Western Zone of the Tasmania Reef has been undertaken remotely from the Reef since 2007, after a detailed geotechnical engineering analysis indicated that the integrity of the sill drives could not guarantee an acceptable level of confidence should an anticipated seismic event occur within a radius of 10 m. The key tenet of the remote mining approach was the exclusion of personnel from sill drives once stoping had commenced. The remote mining method had to be ‘retrofitted’ to four existing stoping blocks totalling 11 sill drives which totalled 160 m vertically. The remote mining method proved to be complex, cumbersome and very expensive. However, the ore was extracted successfully.By early 2010, previously developed ore had largely been exhausted and the future development with an orebody open at depth presented the opportunity to review the current extraction method. However, the new extraction method needed to maintain the tenet of excluding personnel from sill drives of active stoping blocks, but seek opportunities to reduce the difficult and costly aspects of the previous method. The new ‘Radial-in-Reef’ stoping reduced the development requirement from six to two drives per ore block. Cost implications aside, the significant reduction in prestoping extraction ratio was expected to also reduce the likelihood of seismicity. Transverse production rings were designed to be drilled radially from a drill stub mined from a mid-stope footwall drive. Stopes totalling up to 7000 tonnes were planned be fired in a single electronic blast. Extraction was designed to take place from a basal sill drive under teleremote operation. At the time of writing, the method was under trial.

Mar 21, 2011

By B J. Monaghan, R J. Longbottom, D J. Pinson, S J. Chew

Recycling steel plant by-products is a critical issue for achieving both environmental and economic sustainability of integrated steel plants. A key steel plant by-product stream is dust from basic oxygen steelmaking (BOS), which can be recycled back to the BOS vessel as iron units and to aid slag formation. The major limitations for its recycling are zinc and the uncertainty in zinc speciation of the dust. This uncertainty affects the amount of dust recycled and how it interacts with the slag during processing. BOS dust in stockpiles can undergo self-sintering reactions that oxidise the iron-bearing components. As this occurs, zinc (or oxide) may combine with iron oxides to form a zinc-iron spinel solid solution phase. Knowing which zinc-bearing species are present in the BOS dust is a key aspect in understanding and developing an efficient recycling process for the dust. To overcome difficulties associated with phase identification in the BOS dust (both fresh and selfsintered), particularly the magnetite-zinc ferrite spinel solid solution using X-ray diffraction (XRD) / scanning electron microscopy (SEM) / energy dispersive spectroscopy (EDS), high end characterisation tools, transmission electron microscopy (TEM) and Mössbauer spectroscopy, were also used. Such an approach allowed improved phase identification of key zinc- and iron-bearing phases that were not previously resolvable. The zinc in fresh BOS dust was mostly present as extremely fine separate particles of zinc oxide, attached to the iron particles. These extremely fine particles were <10 nm in size. Additionally, a small amount of zinc ferrite was also identified within the sample (most likely contained within a magnetite-zinc ferrite spinel solid solution). However, the zinc in the self-sintered BOS dust, was found to be present entirely in a magnetite-zinc ferrite spinel solid solution. While this spinel phase had been previously identified by XRD, it was not clear that it contained zinc. The Mössbauer results provided definitive evidence of zinc within the spinel phase.

Jun 19, 2024

By G Guy, J Summerville

Over the past five years in coalmine slope evaluation the application of 3D modelling has increased significantly as software has become more user friendly but also areas requiring evaluation have become increasingly complex. Often simplistic 2D Limit Equilibrium modelling and analysis has been poorly used to solve slope stability issues by back analysis and subsequent forward predictive analysis. A plane strain condition with slope movement perpendicular to the slope strike is assumed where in reality the problem is more complex. This often leads to a misinterpretation of the failure mechanism because the failure mechanism being modelled in 2D does not generally represent the actual failure mechanism observed in the pit, with 2D modelling often oversimplifying a slope. This paper presents a case study where the initial slope assessment and remedial design evaluation was undertaken as a 2D Limit Equilibrium model which led to an overly conservative and costly remedial solution being implemented. Subsequent modelling of the slope using both 3D Limit Equilibrium and Finite Element methods were able to provide a better understanding of the structural complexities associated and correlate well with slope monitoring data to create a more realistic outcome.

Nov 29, 2022

By A Fern, A Hawkes, o

This presentation will cover: the importance of high-quality safety leadership; insights from a Safety Climate Survey that includes responses from 7903 employees working at 19 Australian mining organisations; the results of a critical control verification (CCV) coaching intervention; and recommendations for improving safety leadership in high-risk work settings. Safety climate is a representation of the deeper culture that exists in an organisation. Safety climate is predictive of behaviour, performance and reporting in organisations. Leaders play an important role in the establishment and maintenance of culture. Perceptions of safety climate were collected from 19 Australian mines (n = 7903 employees). These results indicate that the Australian mining sector is doing well in team support for safety and supervisor safety commitment. There were negative perceptions of willingness to report errors, employee involvement in safety initiatives, psychological safety and emergency readiness. Perceptions of safety leadership were in the fair range, with recognising behaviours perceived lowest, falling in the poor range. The underreporting rate was at 25 per cent indicating that 1 in 4 incidents are not being reported. Analyses exploring climate, leadership, safety behaviour and well-being will also be discussed. The integrity and success of critical risk management systems is often determined by the quality of safety leadership. Leaders need a mix of technical safety knowledge and interpersonal skills to be able to support the workforce to build critical control knowledge that invites open and collaborative discussions to find new or improved solutions. Forty leaders at a major mining operation completed training and 5-weeks of coaching focused on developing critical control verification competencies. The follow-up evaluation demonstrated significant improvements in relationship building, observation of controls and overall capability. Overall, insights from multi-organisation climate data and a prepost coaching intervention will be discussed and recommendations and practical guidance for leaders will be provided.

Apr 16, 2024

By M Qiao, A Sugden, W Zong, J Hines, J Roberts, T Ren

Long-term exposure to respirable dust continues to present an occupational health and safety hazard to mine workers in underground mines. Workers who are exposed to mine dust can develop occupational lung diseases including coal workers’ pneumoconiosis (CWP) or ‘black lung’, progressive massive fibrosis (PMF) and chronic obstructive pulmonary disease (COPD). To demonstrate the exposure impact of certain working conditions and improve dust management in longwall development panels, this paper details the development of a computational fluid dynamicsvirtual reality (CFD-VR) based training tool. The tool has been developed as an educational platform to facilitate the effective communication of workplace health and safety (WH&S) dust control measures for continuous miner operators and engineers. The study introduces a promising approach to model ventilation and dust flow patterns based on site-specific data, employing computational fluid dynamics (CFD) for a detailed analysis and visualisation of these mechanisms. Additionally, an algorithm has been developed for processing the large and complex CFD data sets into a form amenable for visualisation within a virtual reality (VR) environment using standalone VR headsets with limited processing power. This training tool has been deployed to mine sites with the specific purpose of educating users on the hazards of dust emissions and the best practices for control.

Apr 16, 2024

By J H. Zietsman

The transition to more sustainable metal production is receiving much attention at present, and the iron and steel industry is at the centre of the conversation. New, more environmentally friendly production technologies, such as direct reduced iron (DRI) smelting furnaces, need to be developed in a short period of time. This necessitates increased use of computational modelling that incorporates more accurate material descriptions. The combination of large-scale multiphysics models of high-temperature processes with CALPHAD material descriptions leads to infeasible computation times. This can be resolved with the previously reported RapidThermo framework, which has been demonstrated to make equilibrium calculations orders of magnitude faster, within controllable limits of accuracy. In this paper, we explain how further material properties, which are important to modelling hightemperature reactors, can be added to the RapidThermo framework. This can improve the accuracy and usefulness of process and multiphysics models in the development of new technologies, which can significantly accelerate development cycles.

Aug 21, 2024

By S J. Clarke, G Sieders

Double corrosion protection (DCP) rock bolts have evolved to become complicated assemblies comprising numerous components. This complexity is mainly associated with durability considerations including potential exposure to adverse groundwater conditions and ensuring separation of dissimilar metals within the bolt assembly itself.Recent progress in the construction of glass-fibre reinforced polymer (GRP) rock bolts have the potential to provide a viable alternative to conventional steel rock bolts in civil tunnelling applications. The durability of the material results in a much simpler bolt detail and permits the use of resin rather than solely cement based grouts.This paper presents the findings of the comparative structural testing of GRP bolts with conventional DCP steel bolts. The axial load performance, including stiffness, ultimate capacity and ductility of bolts are compared. Shear behaviour of bolts is considered, including durability issues associated with damage to the plastic sleeve used in DCP bolts.The paper also considers other issues which are relevant to the design of temporary and permanent rock bolts used in tunnel support, such as initial tensioning and grouting. Long-term performance, including durability and creep are also reviewed.CITATION:Clarke, S J and Sieders, G, 2014. Comparison of glass-fibre reinforced polymer rock bolts with double corrosion protection steel rock bolts for use in tunnel applications, in Proceedings 15th Australasian Tunnelling Conference 2014 , pp 237–246 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 17, 2014

By T Burns, P Savory

In 2013, Rio Tinto Iron Ore (RTIO) produced 251 Mt from 15 mines in Western Australia. Throughout the mines, Ore Reserve models are used for long-term and medium-term mine planning. Grade control data aids the accuracy of short-term planning. Reconciliation of models with grade control data is important for maintaining confidence in predictions from the models, understanding the limitations of the models, and identifying issues that may require further work.There are a large number of sites and models, with more than 200 professionals involved in different parts of the reconciliation process. Regular meetings of all involved and enabling effective communication are important in the reconciliation process.Reconciliation data is gathered and processed through a web-based system; Grade Block Reconciliation System. This system cuts each grade block against the required model, stores the results, and allows users to view and analyse the data. Development of this system has occurred over a number of years and all Rio Tinto Iron Ore mine geologists and resource geologists now use it as standard to report reconciliation results. The results can be viewed in many ways including by different time periods or benches. Graphing the results assists identification of trends. Centralising and standardising reconciliation has allowed easier comparison between sites. Flexibility in the system allows users to customise reports to manage issues unique to their particular site.In parallel with system development, substantial effort has been put into ensuring mining professionals get together to discuss and understand reconciliation issues. To facilitate this there are now regular sessions, including site visits. Issues are assessed on a case-by-case basis and decisions on how best to address the issues are made by the relevant stakeholders. Reconciliation reports and action plans are revised each quarter.CITATION:Burns, T and Savory, P, 2014. Reconciliation of orebody model predictions – system and people, in Proceedings Ninth International Mining Geology Conference 2014 , pp 367–376 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 18, 2014

By D Luppnow, H Rourke

Recent disasters such as the failure of the Mount Polley tailings embankment remind us of the risks that tailings facilities pose. It is widely recognised that dam-break assessments are a vital tool in identifying the consequences of the failure of a facility, which in turn can be used to develop emergency action plans. A typical assessment includes an estimation of breach parameters and outflow volume, followed by the preparation of an inundation map to illustrate potential flow extents and downstream impacts. This paper focuses on the estimation of outflow volumes, which is an area that the authors feel can be improved. Presently, many types of analyses assume that the volume of tailings released is only a function of the storage volume and dam height. After a review of several documented tailings failures, it has been found that the extent and depth of the supernatant pond needs to be considered as it is just as important, if not more so, as the storage volume and dam height. Tailings facilities with excess water storage have a higher risk of failure as they are more susceptible to overtopping, piping and liquefaction failures. In addition, they pose greater failure consequences as the saturated conditions will lead to more material being mobilised.This paper has reviewed available information on a number of tailings dam failures and proposes an alternative estimation of potential tailings release volumes as a function of supernatant water stored on the facility for use in dam-break analyses. In a broader sense, the paper seeks to shift the current risk paradigm from tailings dam heights to volumes of water stored and provides a basis for continuing research and discussion.CITATION:Rourke, H and Luppnow, D, 2015. The risks of excess water on tailings facilities and its application to dam-break studies, in Proceedings Tailings and Mine Waste Management for the 21st Century , pp 225–230 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 27, 2015

By A Millar, B Wraith

Process plants are characterised by variability of performance over a wide range of time-scales; reflected in fluctuations in metal recovery, concentrate grade, plant throughput and reagent costs. In turn, these fluctuations impact financial metrics such as operating costs and revenue. The primary cause of plant variability is variation in the physical, lithological and mineralogical characteristics of the ore fed to the plant. The variability of the ore is driven by the intrinsic heterogeneity of the geology and mineralogy of the orebody, the mining method and mine production plan, the capacity to stockpile and blend, as well as the plant flow sheet and the level of plant automation. Whilst the impact of ore variability on process plants is universally recognised, it is rarely quantified in financial terms. Consequently, opportunities to reduce its impact are often overlooked due to the lack of a basis for a quantifiable cost-benefit analysis to justify improvement initiatives. This paper will present case studies using production data from the Renison tin concentrator and a zinc concentrator. These case studies demonstrate that as the standard deviation of plant head grade increases (as a proxy for ore variability), plant metal recovery subsequently reduces. The metal recovery is then converted into plant revenue losses, to quantify the economic impact of ore variability. The Renison case study demonstrated that whilst a very rare occurrence, revenue losses were as high as 34 per cent (relative to the baseline) when standard deviation was at its highest. The zinc concentrator case study demonstrated that revenue losses were as high as 6 per cent (relative to the baseline) when standard deviation was at its highest. Options are available for reducing and managing ore variability in the process plant. These options include changing mining practices so that the ore is fed to the plant with less variability, more advanced process plant control systems and the use of predictive geometallurgical models.

Aug 24, 2022