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By G Lane, S La Brooy

A century ago, new mines were often accompanied by smelters. In Australia, smelters were built at the Daydream mine near Broken Hill, at Kuridala and Mount Elliott near Mount Isa, Broken Hill, Mount Lyell, Mount Morgan, Mount Isa, and more recently at Tennant Creek, Kalgoorlie and Olympic Dam. Now the big miners eschew site-based processing in favour of shipping concentrate to smelters in Europe and Asia. As Chip Goodyear was in the process of vacating his leadership role at BHP Billiton, he was quoted as saying that BHP should concentrate on mining ore and leave æto others the skill set of processing that materialÆ. Yet there are times when on-site processing clearly makes sense. Few companies ship gold ore or concentrate to China for gold extraction. New smelters are being built in Zambia. Solvent-extraction and electrowinning plants frequently produce copper from oxide ores and concentrates while pressure leaching is increasingly being considered for copper sulfide ores. Some argue that on-site processing is best because the waste products can be returned to the ground from whence they came, avoiding potentially large disposal costs in more-populated areas. Copper treatment and refining charges will not remain at $45 per tonne and 4.5 cents per pound forever. This paper examines when it makes sense to use on-site pyro- or hydrometallurgical processes in todayÆs environment and comments on how current trends might alter the balance in future.

Jan 1, 2008

By Hall G

The Mount Isa silver-lead-,zinc deposit possesses a number of features which sets it apart from usual occurrences of ores containing those metals. The deposit has been described in vario:us papers, but development upon deeper levels during the past two years has, yielded much information not hitherto published. Purpose of the present paper is to furnish a unified and coherent perspective by tracing briefly the full rock deformational and mineralization processes responsible for the ore deposition. The paper represents the outcome of ten years' organized geological effort at Mount Isa. Information contained in it supersedes that previously published.A bibliography of published articles relating to Mount Isa ore deposition is appended. In preparing the present paper previously published data have been drawn upon freely wherever applicable. The authors are especially indebted to the papers by Grondijs and Schouten, and by O'Malley and McGhie, which present results of systematic microscope studies of thin and polished sections from comprehensive suites of Mount Isa ore.

Jan 1, 1942

By J Lapwood, S Pal, M Pascoe

The devastating failure of Dam I at the Corrego do Feijao iron ore mine near Brumadinho in Brazil on 25th January 2019 left at least 270 people dead or missing. In the immediate aftermath of this event, many mining companies commenced reviews of their tailings and water storage facilities (T&WSFs), and Rio Tinto was no exception. Rio Tinto has an interest in over 250 T&WSFs across 47 sites in 13 countries as owner-operator, as managing JV partner, and through non-managed partnerships and other ownership arrangements; T&WSF experts from Rio Tinto’s Surface Mining Centre of Excellence visited the sites in order to complete Technical Risk Reviews of each facility. These reviews looked beyond the day-to-day operational aspects of T&WSF management, and the site’s compliance with local regulations and Rio Tinto’s internal D5 Standard – Management of tailings and water storage facilities, in order to provide a strategic, second line of assurance perspective. The reviews focused on design and construction; operational controls; risk control framework; and competencies and capabilities of personnel involved in the design, operation and closure of the facilities. Additional activities were carried out in parallel with these reviews, including the development of a consistent approach to dam break studies; the public disclosure of information on Rio Tinto’s tailings storage facilities and their management; and contribution to external programs such as the initiatives being co-ordinated by the International Committee on Mining and Metals. This paper provides an overview of the tailings and water storage assurance work undertaken by Rio Tinto’s Surface Mining Centre of Excellence Tailings Validation Taskforce to date; work that will continue to improve governance and assurance for all of Rio Tinto’s T&WSF.

Jul 1, 2021

By P Rubie, J Russell

This paper looks at the past, present and not too distant future of grinding mill relining.Since the adoption of autogenous grinding (AG) mills and semi-autogenous grinding (SAG) mills as the primary ore reducing devices in the comminution circuit, plant shutdown frequency and duration has largely been driven by the liner maintenance requirements of these mills.The past 30 years have seen the introduction of many technologies to reduce relining times and frequencies. Advanced relining systems have been developed which include single and twin Mill Relining Machines, capable of placing large (up to 8000 kg) liners, high energy recoilless THUNDERBOLT Hammers, and high capacity Feed Chute Transporters. Despite these advances, today many of the hazards associated with mill relining remain and reline times still vary considerably between mine sites. A sophisticated discrete event simulation program, designed to analyse the mill relining process, has revealed the dominant influences on reline times of crew performance and of the need for safe access to larger segments of the mill.A new generation of advanced and semi-automated technologies is currently being tested that will address these remaining challenges. These technologies remove people from the hazardous environment inside the mill and will allow techniques used in modern advanced manufacturing to provide a near-future step change in mill relining safety and performance.CITATION:Rubie, P and Russell, J, 2018. 21st century relining – the path to greater mine site profitability, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 621–640 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

This paper describes a mine truck hauling process called "Truck Jigging" which is currently the subject of a process patent application.The investigation explores the production and cost advantages of using the potential energy available in a descending haul truck to assist in elevating an ascending vehicle. Applications are studied for both strip cut mines and open pit operations. Various mechanical connections between the two vehicles are considered, based on a pulley mounted rope system. Fifteen year operating cost estimates show savings of up to 26.5 percent over conventional mine truck operations.

Jan 1, 1989

By A D. Price, W J. Germs, O Patterson, T R. Weaver

"Understanding controls on groundwater and surface water flow and quality at mine sites throughout all mine stages is critical to effectively manage environmental impacts over the entire mine life. Monitoring forms is an essential component of this proof of understanding. Typically, monitoring programs at mine sites have been developed in the framework of existing conditions. However; recognition of the challenges of climate change and the performance of mines during recent extreme events in Australia has highlighted the need to develop monitoring programs that are resilient and responsive to changing environmental conditions. Water monitoring programs need to be effective under a range of environmental conditions, potentially not historically experienced.This emerging challenge requires cross-disciplinary teams to work together to understand issues including: representativeness of background conditions to longer-term conditions at the mine site sensitivity of mine and closure designs to changing climate and hydrologic conditions methods of performance (eg water quality or quantity) failure during extreme climate events such as flood or extended drought.These understandings come together in a detailed conceptual and, in many cases, numerical hydrologic model that considers the mine-water environment under a range of conditions. The groundwater, surface water and water quality monitoring programs that are developed from the conceptual model need to be sufficiently responsive to be effective in the face of such changing conditions, with results in turn informing the conceptual model. Extended drought, major floods and changing weather patterns can alter recharge and discharge areas, oxidation profiles and ultimately, the contaminant flux estimates that would have contributed to mine design parameters and performance. Unless these effects are considered in the spatial and temporal design of the monitoring program and within the parameters monitored, the resultant program may fail to capture data that are critical to evaluating environmental impacts from mine sites.Developing and implementing a water monitoring program that considers these issues can build confidence in mine performance under a range of conditions, leading to increased confidence by all stakeholders in long-term mine performance during and after closure.CITATION:Weaver, T R, Price, A D, Patterson, O and Germs, W J, 2013. Developing resilient water monitoring programs in changing climate conditions, in Proceedings Water in Mining 2013, pp 109-114 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Nov 26, 2013

By Whiteman P. C, Stacey G. S, Hunter G. D

Processing of lead-zinc and copper ores by Mount Isa Mines Limited produces large quantit- ies of concentrator tailings waste which is pumped as a slurry to special dams where the solids are allowed to settle and dry out. These areas are unattractive and show no signs of encroachment by plant life even though the surfaces of some dams have remained undisturbed for more than a decade. During 1970 Mount Isa Mines Limited commenced a long term research program in conjunction with the Department of Agriculture, University of Queensland to deter- mine possible methods of establishing a plant cover on this material. Research has defined the major factors limiting plant growth in the tailings medium. Modification of the edaphic conditions through fertilizer inputs, particularly of phosphorus and nitrogen, and alteration of "soil" physical properties by incorporation of mulching mater- ials, provided conditions which allowed plant growth. The outstanding "soil" amendment treatment was incorporation of fly ash, a waste product of the company's coal fired power stations. A range of crop and pasture species have been selected which have grown well with adequate irrigation under the amended conditions in the field. Further research is assessing a range of native plant species and agronomic techniques to provide a stable plant cover on the tailings dams.

Jan 1, 1974

By Mills KW

Coal mine pillar design formulae available to mine planners are typically based on relationships determined for specific site conditions. Application of these methods is difficult when other factors, relating to mining or geological conditions, not specifically addressed in these relationships are encountered. A review of pillar design methods, coal strength properties and relevant field monitoring of pillar behaviour has shown pillar strength and deformational characteristics are extremely sensitive to in situ behaviour of the rock and other material components that make up the coal pillar system. A method has been developed that has been found to provide excellent correlation between existing field data using the strength and deformational characteristics of materials determined in selected laboratory tests. This method is based on definition of the loading conditions, accurate modelling of the strength, confining conditions and deformation occuring in the roof, floor and coal seam and definition of the in situ strength of coal based on underground monitoring of appropriately sized coal pillar. The design method is considered to provide an accurate and rigorous pillar design method that will give mine planners a more rational mine design capability which is based on the mine geometry and geological setting of the operation. It is envisaged that availability of such a method will allow significant optimisation of pillar layouts and more closely define the geological and mining issues that relate to pillar design optimisation.

Jan 1, 1992

The paper provides an overview of the development and content of APCOM symposia since their inception in 1961. This development is set within the context of the academic environment in which much of the research published at APCOM symposia is conducted. This environment includes rigorous external assessment of research quality at national levels and against international benchmarks, which carries significant consequences for funding and for the continued existence of the academic minerals industry disciplines. Adverse consequences that undermine the academic provision of mining and resource engineering will impact negatively on the minerals industry by reducing the level of research and education resources available to it.The traditional reductionist approach to research is contrasted with the inter-disciplinary approach that is required to address the complex systems problems that the minerals industry will have to address to ensure its technical, economical and environmental sustainability. Such an approach offers a means of raising research profiles, of establishing mutually beneficial academic-industry engagement and provides an opportunity for APCOM to take a lead role in identifying the research and development agenda for the future

Sep 26, 2011

Environmental leaching methods such as the toxicity characteristic leaching procedure (TCLP) test or the ASLP test are used to assess wastes including mining and mineral processing by-products. These tests were initially designed as regulatory tests simulating conditions in a co-disposal municipal landfill waste facility and do not allow leaching performance to be predicted in site specific scenarios. Further, the assumptions underlying these tests tend to define worst-case scenario leaching conditions for by-products from the mineral industry disposed of outside a co-disposal scenario.   Recently some characterisation leaching test methods have been issued as ISO/TS standards (ISO/TS 21268-3:2007 and ISO/TS 21268-4:2007) that aim to define the leaching performance of soil type wastes and to predict the leaching performance of these wastes over long time frames. In this preliminary work these standards are trialled for by-products from the mineral industry and the quality of information that can be obtained from them compared to TCLP/ASLP tests.   Where clear comparisons were possible, the TCLP/ASLP tests were typically found to extract a similar, or often greater, amount of component than (i) tests conducted at the same pH but without the acetate buffer or (ii) for test conditions aimed at simulating long-term leaching in an eluate defined by the waste type. While further work is required, the preliminary results indicated that the tests may provide reliable long-term estimates of leaching performance of wastes in soil types of variable pH and provide a suitable basis for long-term planning for optimal waste handling, treatment or even re-use.

Jun 1, 2010

Contemporary approaches to safety management appear to be failing short of meeting its mark in improving mine safety. This is evidenced by the high workers compensation, high incidence rates and fatalities. Evidence from high-risk and complex organisations points towards safety culture as being important in improving site safety. In more recent years resilience engineering has been touted as a new and innovative way of managing safety. This paper reviews and synthesises previous literature on safety culture and resilience engineering. It then highlights methods that can be used to measure safety culture and resilience engineering, and explores similarities and differences between complex organisations and gold mining to identify opportunities for more innovative approaches to improving safety in gold mining operations through safety culture and resilience engineering.

Aug 1, 2010

The King River Power Development on the West Coast of Tasmania has involved the storage of the waters of the King River in the new Lake Burbury and their diversion through a 7 km tunnel to a 144 MW power station. The last kilometre of this tunnel descends through 160 m under a ridge before emerging from the bank of the King River at the power station site. The decreasing cover over the tunnel as it approaches the power station meant that a steel lining was required in the last few hundred metres of the tunnel. This paper describes the geotechnical investigations which were carried out to establish the necessary length of the steel lining.

Jan 1, 1993

By Yambu J, Titus K

Geotechnical investictations and monitoring have been integral to development of the Porgera Gold Mine. The steep, unstable terrain has required a program for monitoring of slopes and foundations which includes survey stations, borehole inclinometers and piezometers. Case studies of the Maip Pass landslide, Yakatabari land-slide, Anawe Plant Site CIP pond excavation and batter, and a load test study for mine waste dumps are presented.Monitoring is needed to ensure that geotechnical risk is kept to a minimum. A vigilant program will be required for the life of the mine.

Jan 1, 1994

Dartbrook mine is a new greenfields thermal coal longwall mine located n the Upper Hunter Valley ten kilometres north of Muswellbrook Figure 1). Construction began in April 1993 with coal extraction starting n October 1994. Longwall production is scheduled to commence in the first quarter of 1996 with production expected to exceed 3.5 million onnes per annum. The permanent workforce will number 150 full-time ,mployees and productivity rates will be 22 000 per employee per annum m a ROM basis. Being a greenfield site Dartbrook has had the opportunity to develop and operate the mine using the best practices and latest technology available to meet high standards of safety, quality and production.

Jan 1, 1995

Rope guides, consisting of ropes spanning between anchor points at the top and bottom of shafts, have frequently been considered as a viable alternative to fixed guides, comprising buntons and guides. However, their design has generally been based on empirically derived rules, arising from European hoisting practice of 50 to 100 years ago. This paper describes a recent technology development project aimed at defining and quantifying the important forces acting on rope guided conveyances, calculating the resulting displacement of the conveyances and assessing whether the displacements are acceptable or not. The paper describes the derivation of aerodynamic force coefficients based on CFD analyses and other significant forces acting on the conveyance and rope system. The conveyance displacements may be calculated using computer simulation of the mechanical system, or approximately using simplified equations given in the paper. Measurements taken to confirm the suitability of the proposed formulation are described. The combination of displacements and assessment of the rope guide system design are proposed, based on the ratio of design clearances and the predicted displacements.

Jan 1, 2005

By M Aros, L Reilly

Iron ore is normally sold in bulk at certain specifications. These include iron grade and specific contaminant grades, typically silica, alumina, phosphorous and sulfur. These target grades are normally agreed between the mining company (producer) and the steelmaking company (customer).This study presents an alternative to traditional cut-off grade calculation, using linear programming that maximises the total ore inventories within a predefined mining envelope while meeting the specified targets. Providing a feasible mining sequence that maintains the target grade is not covered in this study.The method was applied to Fortescue’s operations. The complexity arising from differing ore quality within each mining horizon, variable yields and upgrades and the need to control iron and contaminant grades provided a good opportunity to test an alternative method of ore selection. The new method significantly reduced the time spent in cut-off selection and sensitivity analysis, and provided an optimised solution.CITATION:Aros, M and Reilly, L, 2014. Ore selection optimisation for an iron ore deposit using linear programming, in Proceedings Orebody Modelling and Strategic Mine Planning Symposium 2014, pp 345–350 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 24, 2014

By Morris B. J

Soil air samples taken from the top one metre of the soil profile, were measured for C02 and 02 using portable field analysers at a number of sites of known sulphide mineralisation in South Australia. Carbon dioxide anomalies were detected over actively oxidising sulphides during autumn and winter following recent rainfall. Anomalies were not detected where no oxidation was occurring, where seasonal conditions had been very dry, or where the sulphur content of the ore was low (

Jan 1, 1993

By P Thwaites

The mining industry uses many types of mineral and metallurgical plants to produce saleable product from ore mined. Plant design history has left current operations with a mixture of manual operation and various forms of automated process controls. Consequently, we typically see high-variability in the continuous operations together with a shortfall in the attainment of full capacity or higher utilisation of consumables.At a level of best practice, ‘operational performance excellence’ focuses on process control, using automation and control systems to deliver process optimisation. This more sophisticated delivery is a great deal more difficult than the first stage of equipment selection/installation. It includes the appropriate selection of the right instrumentation and control system, key process knowledge, individuals with a solid control engineering background/experience and the essential backing/support of the operations management team together leading to higher-value delivery. Robust solutions can be realised, considerably minimising process variation, thus leading to process optimisation. This approach results in an easier, efficient and safer process while providing considerable returns for the plant owners.How variable are your processes, and do you maintain optimised process performance with dedicated resources, modern instrumentation, ‘best practice’ control systems and performance monitoring tools? In this paper, these questions and their possible answers are discussed.I say we can do much more and be ‘more efficient’ in our efforts to remain competitive. This area remains a major opportunity for improved efficiency, minimising tailings losses and other milling costs.CITATION:Thwaites, P, 2014. Manual control, process automation or operational performance excellence – what is the difference?, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 13–40 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

By Sengstock G. W, Spathis A. T

Benchmarks of mine equipment involved in the excavation process of coal mines would suggest that such equipment is not always operating at an optimum level. Dragline operations and truck/shovel operations rely on efficient use of their plant in order to maintain high mine throughput. The first process which affects the material to be excavated is the drilling and blasting process. Drilling and blasting delivers a fragmented material with a given disposition ready for excavation by mine equipment. As mine operators demand more productivity from their major excavating equipment, many sites are considering the use of productivity monitors to measure their outputs. Some of these productivity improvements will be directly related to the drilling and blasting process, so that as the monitoring systems improve, the opportunities to evaluate all drilling and blasting variables will also improve. This paper reviews current and newer methods for monitoring equipment productivity in mines. These include simple time and motion studies obtained by either manual timing of processes or by automated data collection equipment being adopted by the industry. Case studies for truck/shovel operations are discussed and the productivity improvements are compared with typical industry standards. These improvements relate specifically to parts of the load, haul and dump cycle and the potential for significant improvements are identified. Particular opportunities for drilling and blasting improvements are also presented.

Jan 1, 1995

By M Ind, B Usher

Environmental regulators are increasingly adopting risk-based approaches to protect aquatic ecosystems. The Australian and New Zealand Environment and Conservation Council (ANZECC) and the Agriculture and Resource Management Council of Australia and New Zealand (ARMCANZ) (2000) introduced a risk-based approach to water quality guidelines that use decision frameworks to adapt water quality guidelines to local environmental conditions. Environmental quality objectives are no longer a simple ‘pass or fail’ number such as restricting total suspended solids (TSS) concentration to a specified limit for a particular rainfall event. This approach ignores spatial and temporal variability and the complexity of aquatic ecosystems. The risk-based approach establishes levels where adverse effects may occur. If these objectives are not met, further risk-based investigation is undertaken to assess the potential impact to the ecosystem. Klohn Crippen Berger (KCB) developed a dynamic simulation to predict the variability of sediment discharges, which is applicable for risk-based impact assessment of aquatic ecosystems. The application of the methodology over the life of a mine site is illustrated using a proposed South Pacific mine.The site location is in extremely rugged terrain with a high annual rainfall of approximately 4.7 m. There were two major sediment ponds proposed to reduce sediment discharges. A sediment and hydrology model was developed in Goldsim to provide daily estimates of run-off flows and sediment concentrations. A modified algorithm based on the Australian water balance model was created and incorporated into the Goldsim model and calibrated using recorded field data.The sediment module was developed based on a Revised Universal Soil Loss Equation (RUSLE) assessment, an annual prediction of soil loss over a catchment. A land-use type erosion vector was developed for different land-use types and for each of the subcatchments, a subcatchment erodibility vector was calculated. This vector and the daily rainfall erosivity factor were used to estimate the daily soil loss. The estimated soil loss and the modelled run-off yielded predictions of daily sediment concentrations. Finally, a sediment settling module was used to predict the daily efficiency of the sediment ponds and hence discharged sediment concentrations.The results of this modelling form the first part of a quantitative risk-based assessment into suspended solids impacts. The second part is the assessment of the effects of these predicted TSS concentrations on aquatic ecology. As part of the feedback-loop required in a risk management framework, if the environmental quality objectives are not met then further management decisions and actions may be required to reduce the risks presented by suspended solids. This may include modifications to: the mine-development plan; construction techniques and scheduling; processing techniques; rehabilitation strategies; or hard-engineering solutions such as sediment basins or flocculation.The Goldsim water-balance model provides a quick and efficient method of testing potential remedial actions on predicted sediment loads and concentrations. In combination with a cost-benefit assessment, options for reducing sediment releases from the mine site can be effectively and quantitatively compared thereby providing mine operators with a basis for decision-making. Regulators can also be satisfied that potential impacts to aquatic ecology have been comprehensively assessed and the necessary management decisions have been initiated to limit risk to the environment.CITATION:Ind, M and Usher, B, ?2014. A dynamic sediment simulation to predict the variability of suspended solids concentrations over life-of-mine for application to a risk-based environmental assessment, in Proceedings Life-of-Mine 2014 , pp 191–204 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 16, 2014