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By M I. Pownceby, M A. Rhamdhani, S Palanisamy, D Fellicia, B Satritama, G A. Brooks, A Ang

Metal production have long been using carbon sources as both reducing agents and energy sources. Consequently, the global extractive metal sector contributes significantly to greenhouse gas emissions, accounting for approximately 9.5 per cent. Hydrogen gas offers as a promising ecofriendly alternative to carbon in metallurgical processes, serving as both a reductant and energy supplier with a by-product being only water vapour. However, the implementation of molecular hydrogen faces certain challenges related to the thermodynamics and kinetics of metal oxide reduction. In addressing these challenges, researchers have explored the application of hydrogen plasma, generated by subjecting molecular hydrogen to high energy to produce atomic, ionic and excited hydrogen species. Hydrogen plasma offers thermodynamic and kinetic advantages over molecular hydrogen and carbon-based reductants, exhibiting lower standard Gibbs free energy of reaction and activation energy. Therefore, hydrogen plasma can produce metal in fewer steps, process any oxide feed and feed size and even be used to refine metals. Despite these advantages, challenges exist in utilising hydrogen plasma in extractive metallurgy, including electricity costs, potential reverse reactions and industrial-scale implementation. This study provides a mini review of prior research on hydrogen plasma for metal oxides reduction, particularly iron oxide, as well as state-of-the-art techniques for its use in extractive metallurgy applications by mentioning several reactor types. Future prospects and scale-up possibilities of the hydrogen plasma in extractive metallurgy will also be presented.

Aug 21, 2024

By F Faraj, M Pal, M Haest, M Bradshaw, H Lang, K Hume

MineSense Technologies Ltd. is revolutionising grade control at mining operations by installing ShovelSense® sensors on buckets that measure the grade of every load before it is dumped in the truck. This allows the mine to exploit grade variations at a resolution that was not available before, reducing the amount of ore loss to the waste stream and removing waste from material destined for processing. These changes dramatically improve the profitability and sustainability of mining operations. ShovelSense relies on X-ray fluorescence analysis of the rocks as they flow in the bucket and is integrated with fleet management to direct the trucks to the right destination. Lab simulations of ShovelSense measurements on porphyry copper ores show correlations between predictions and lab measurements at 0.98 r-squared with a coefficient of variation of 10 per cent. Visualisation of copper grade predictions in three dimensions shows a reasonable match with the dig plan, but with local changes in the ore-waste contact due to more accurate contact identification, related to blast movement and other mining factors. Correct delineation of these contacts ensures ore trucks are not sent to the waste dump and waste trucks are diverted from the crusher, creating enormous value for the operation and the environment.

Mar 22, 2022

By L Klemettinen, J Biswas, W Malan, D Sukhomlinov, D Lindberg

In order to mitigate the effects of climate change, our society must be able to drastically reduce its CO2 emissions. As the metallurgical industry is a considerable contributor to these emissions, new greener technologies must be invented and developed. One option could be the direct production of metals from oxides using renewable electricity. The aim of this study was to investigate the possibility of using high-temperature molten oxide electrolysis (MOE) for iron and ferrochrome production. FactSage™, ver 8.2 (by Thermfact Ltd and GTT-Technologies) was utilised for estimating a feasible equilibrium electrolyte composition, and the experiments were conducted at 1550–1580°C in conical alumina crucibles with iridium wire as the cathode and platinum wire as the anode. The sources of iron and chromium were either pure FeO powder or industrial chromite pellets. Voltage was applied to the electrolysis cell for 6 hrs and the resulting current was measured, along with oxygen concentration in the off-gas line. The electrolyte comprised of SiO2, Al2O3, MgO and CaO. First, the effect of FeO concentration on iron reduction efficiency was investigated using only pure oxide powders as starting materials. The results indicated that 10 wt per cent FeO mixed with the electrolyte resulted in more efficient iron reduction compared to 20 wt per cent. In further experiments, industrial chromite pellets were ground and mixed with the CaO-free electrolyte. Iron and chromium reduction efficiencies were higher when approximately 19 wt per cent of the total sample mass consisted of pellets compared to increasing the pellet amount to 37 wt per cent. Generally, the chromium solubility in the liquid electrolyte was relatively low, and most of the chromium was confined to the spinel solid solution, from where its dissolution to the liquid electrolyte was very slow, resulting in slow reduction kinetics. For larger scale applications, economically more viable electrode materials should be investigated.

Jun 19, 2024

Topography, location of coal bearing land and existing built-up areas severely restrict locations for overburden disposal and dumping sites north of the Latrobe River clear of the coalfields are assumed until internal dumping areas can be established.

Jan 1, 1982

By A Smith

Rock masses usually exhibit scale dependent mechanical properties primarily due to presence of discontinuities and their inhomogeneous nature. One of the essential preconditions for selection of appropriate strength and deformation parameters of a rock mass in relation to tunnel design is assessment of the scale of the joint network relative to the scale of excavation. In tunnel design practice, scale effects are estimated indirectly using small-scale unconfined compressive strength (UCS) tests and rock mass classification based empirical correlations. Large-scale UCS tests have the benefit of direct assessment of anisotropic and scale dependent properties of a rock mass.This paper presents results of a large-scale UCS test on a jointed siltstone. A 450 mm diameter sample with inclined bedding planes was cored and tested in uniaxial compression until failure with load and displacement measurements. The aim of the test is to determine strength and deformation parameters and correlate them with results of small-scale UCS tests of the same sample. The relationships between the small-scale and large-scale rock mass parameters were validated against published correlations from the literature.

Mar 8, 2011

By Grey D, Turner R, Capsanis J

Coal fines are recognised to have a major impact on the cost and efficiency of the recovery of saleable coal. Fines affect the productivity of the whole mining cycle because of the low yields obtained in washing this material as well as affecting the moisture content and handling characteristics of the final product.In 1990, Coal and Allied Hunter Valley Mine initiated an internal study into coal fines based on the assumption that a reduction in fine coal in ROM material will lead to increase yields in the preparation plant. The initial results of this study indicated that the level of fines in the ROM coal can be reduced by more than 40 per cent by simple changes in blast design and implementation.

Jan 1, 1992

By J Liu

In situ coal gasification is a method of extracting a high proportion of the energy value from coal without the need for mining. In situ conversion of coal to combustible gases is achieved by drilling wells into the seam, injecting gasification agents and initiating combustion. The product gases are then extracted to surface using production wells. These gases are clean energy sources for power generation, heating or synthetic fuel production. In situ coal gasification is of particular interest with respect to its lower environmental impact, potential application to otherwise inaccessible energy resources (ie offshore, deep deposits or beneath protected lands) and low capital intensity. Practical application of this clean technology is restricted primarily by lack of satisfactory quantitative descriptions of the processes involved, in particular the hydromechanical processes.In this study, three characteristic physical zones of an in situ gasifier are identified as the rubble zone, combustion front and virgin coal zone. Coupled mechanical processes of coal consumption and overburden collapse are used to describe the permeability profile in the rubble zone. Additionally, the redistribution of overburden load associated with coal consumption is accounted for with the formulation of a stress (compressive) dependent permeability profile, which is applied to the virgin coal zone. The model was implemented into and solved by FEMLAB, an advanced computer simulation tool. The flow process, according to DarcyÆs Law, is subsequently described in terms of permeability dependent injectivity. Injectivity is an indicator of flow velocity, which has been identified as a crucial factor in determining the commercial value of product gases from in situ coal gasification. The stress alteration to coal permeability was found to have a dominating influence on the flow process. This finding implies that a greater understanding of the in situ coal burning induced deformation of surrounding rocks would be of significant value in assessing the economic viability of applying this clean technology to potential sites.

Jan 1, 2004

By Guarascio M, Massacci P

In process simulation, more reliable prediction of industrial results and evaluation of data for design purposes and process optimisation may be attained by the combined use of: the modelling and simulation of ore characteristics, and 2. the modelling and simulation of the process. It is well known that geostatistical methods allow the defining of models of orebodies in which the variables considered are the grades of the valuable components. These models are proper for reserve estimation, geostatistical contouring, design and simulation of the exploitation method, and, in addition, for evaluating the variability of the ROM which is expected to be fed to the processing plant. However, no data are normally incorporated in the orebody model in order to evaluate the ore characteristics relevant for a reliable process simulation. The procedure for process simulation aimed at predicting plant results normally used so far consists in collecting samples from different orebody sites and building up a so-called 'representative sample'. On this sample, the ore characteristics (eg liberation, washability, grindability, etc) and the processing tests are referred to as the 'average behaviour in the orebody', assumed constant. A more reliable methodology consists in collecting samples from different orebody sites, in performing tests to characterise the samples from the point of view of the process (ore patterns), and in using synthetic parameters (process features). The values of the parameters are processed using geostatistical methods in order to develop a model for simulating the feed to the process. The estimation may thus be referred to the amount of recoverable minerals instead of to the existing minerals. Furthermore, the selection of the processes, the sizing of equipment and the design of control devices, as well as the prediction of results, become more accurate and reliable.

Jan 1, 1993

Remote sensing techniques can be used to map joint sets in a rock mass for the estimation of in situ block size distribution and improved optimisation of blasting. This paper reviews remote sensing using photogrammetry and laser mapping for mapping rock masses and presents elements of the analyses applied to data acquired with these mapping technologies. These techniques enable a user to map areas of hundreds of square metres rapidly with high precision. Using this data computer programs such as Sirojoint can provide estimates of joint position and orientation with orientation measurement accuracies better than one degree. The paper describes the use of remote mapping and provides potential users with a description of some of the advantages and limitations of the mapping techniques and the data they produce. Mapping of lithology and structure of rock masses is an important task required in many areas of mining and construction. It is a complex task routinely performed using established techniques developed to provide consistent results under a wide range of conditions. The techniques for data acquisition and analysis described in this paper enable more accurate mapping to be performed rapidly and enable mapping of inaccessible sections of a rock mass. These techniques will provide geologists and geotechnical engineers with more detailed, accurate data than previously available.

Jan 1, 2001

By J Heyes, G A. Maddocks, R J. Stewart, G D. Corder

Mining is an international business and vital contributor to national and global economies. It depends on the trust and confidence of investors and stakeholders for its financial and operational well-being (Committee for Mineral Reserves International Reporting Standards (CRIRSCO), 2016). The Social Licence to Operate (SLTO) is an increasingly multifaceted and multistakeholder risk that can impact investment decisions. Community challenges to broader political and economic decisions have given rise to protest delaying or stopping projects or closing mines and has led to loss of life (Ernst and Young, 2016). Some governments are now giving greater powers to stakeholders to make the final decision on approving mining and metals activities (EY, 2016). With billions of dollars in project investment at stake, ongoing engagement, collaboration and effective communication with stakeholders is crucial and mutually beneficial solutions are increasingly expected (EY, 2016). It is therefore essential that the industry communicates the risks (and opportunities) associated with investment effectively and transparently in order to earn the necessary level of trust with investors and stakeholders to underpin its activities (CRIRSCO, 2016). Despite this need, investor and stakeholder trust in the sector has eroded in recent years.CITATION:Maddocks, G A, Corder, G D, Heyes, J and Stewart, R J, 2016. The social licence to operate and drivers for change – resource reporting and mine material characterisation, in Proceedings Life-of-Mine 2016 Conference, pp 183–187 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jun 28, 2016

By M N. Mian

The Cayeli volcanogenic massive sulphide deposit is located in Black Sea region of Turkey. Cayeli Bakir Isletmeleri (CBI) was formed as a joint venture between Inmet (Canada) and Eti Holding (Turkey). CBI is processing complex copper/zinc sulphide ores. The Cayeli concentrator was commissioned in 1994, with a design capacity of 600 000 tonnes/year. The grinding circuit was a classical rod mill/ball mill combination. The rod mill was converted to a primary ball mill in May 1997. The reasons for conversion were to use mill power more efficiently and eliminate feed interruptions during rod charging. The grinding circuit now has a primary ball mill in open circuit, and a secondary ball mill in closed circuit with hydrocyclones. Classification was originally done in two stages with hydrocyclones. Both mill discharges were combined and pumped to a primary cyclopack having two, 500 mm diameter cyclones. Primary cyclone overflow was pumped to a secondary cyclopack for further classification. The secondary cyclopack had ten, 200 mm cyclones. Both unit underflows were fed to a secondary ball mill by gravity. The secondary cyclone overflow, typically 62-64 per cent passing 36 ¦m, at around 42 per cent solids (w/w) was fed to flotation circuit. In order to increase circuit capacity to 1 000 000 tonnes/year and to improve control over the grinding circuit, it was decided to convert the classification circuit from two stage to one stage. For this purpose, six Warman Cavex cyclones having 400 mm diameter were installed. Now, the combined primary and secondary ball mill discharge was classified in single stage with the Warman cyclones in closed circuit with the secondary ball mill. The cyclone overflow goes directly to the copper rougher circuit as flotation feed. The grinding circuit is producing a flotation feed of 70 per cent passing 36 ¦m. The change over to single stage classification at Cayeli was successful. A mill throughput of 1 000 000 tonne/year is being achieved with better control over classification, and improved grind size. Results and comparison between the two classification circuits are presented in the paper.

Jan 1, 2003

By K Aikawa, M Ito, K Mitsuhashi, Y Ebisu, J V. Satur, I Park, N Hiroyoshi, T Suto

Copper concentration using flotation is becoming more difficult, because of an increase in ore complexity accompanied by smaller grain sizes of copper minerals than usual, requiring finer grinding in order to liberate them. Project Arqueros, located at the mid northern part of Chile, is a copper mine project with an orebody consisting of various sulfides such as chalcopyrite, chalcocite, and bornite. Some of the copper minerals in Arqueros show low floatability mainly because of their fine grain size and resulted fine grinding size, and also because of the complex mineralogical composition. For example, chalcopyrite in Arqueros floats less than the other copper sulfide minerals. In this study we carried out some kinetic flotation tests with the Arqueros ore using a laboratory-scale forced air type flotation machine by varying the regrinding size. The products were assayed and mineralogically analysed to compare the minerals in their flotation behaviour with respect to size classes and liberation classes. The results were compared with a model calculation according to bubble size measurement. From the flotation testing and mineralogical analysis, it was found that copper minerals of the same size and liberation class floated at the same rate even with different regrinding size. At the same time the comparison between experiment and calculation showed that the fine particles of less than 5 µm size floated faster in actual than in the model applied. These results suggested that interactions among minerals of different species and of different sizes had positive impacts on the flotation rate of the fine particles. It indicates that this phenomenon can be applied to improve copper recovery in the project.

Aug 24, 2022

By K Osten, N Scagliotta, G Lane

Oceana Gold (New Zealand) Limited operates the Macraes Gold Mine near Dunedin on the South Island of New Zealand. The orebody is mineralogically complex and comparatively low grade requiring a series of unit processes and resulting in a relatively complex plant. As part of Oceana GoldÆs ongoing Business Improvement program, a concerted effort has been made to focus on operational efficiency. One aspect of this has been the efficient use of energy in the gold recovery process. A benchmarking process has been developed for the Macraes operation that includes comparison with other operating mines and theoretical design. Criteria for determining operational efficiency have been developed. While benchmarking is, in theory, a simple process, this paper looks at putting benchmarking into practice by catering for variability in ore and associate processing methods. The unit processes discussed include the comminution circuit, flotation plant, pressure oxidation plant and gold recovery circuits.

Jan 1, 2004

By C Vejrazka

Northparkes is located 27 km north of the township of Parkes in central New South Wales, Australia. The operations consist of underground block cave mines and an ore processing plant that produces high-grade copper and gold concentrate. Production is currently sourced from the E48 Lift 1 block cave mine and open cut stockpiles. Mining commenced at Northparkes in 1994 as an open cut operation. Underground block cave mining began in 1997. Northparkes was the first mine in Australia to use the highly efficient block cave mining method, which relies on gravity and natural rock stresses to fragment the ore.The occurrence of air blasts is one of the principal mining hazards in block caving operations between the time of first undercutting and breakthrough of the cave to surface. As such, it needs to be managed continuously, and risk assessments need to be reviewed on a regular basis for applicability to changing conditions. Unfortunately, there is little literature on how to practically approach air blast risk assessments in a way that can be incorporated in the day-to-day operation of a mine. Previous methods of assessing air blast risk were tedious and results were often unrepeatable.With the extension of the E48 Lift 1 extraction level, it was necessary to assess the air blast risk for the extension drives and develop operational guidelines for production from the extension. A review of the methodology for assessing air blast risks revealed substantial improvement opportunities.This paper outlines the principles used for air blast risk assessments at Northparkes Mines and the methodology employed to achieve efficient, repeatable and auditable results.CITATION:Vejrazka, C, 2016. Northparkes Mines’ current air blast risk assessment practices for block caving operations, in Proceedings Seventh International Conference and Exhibition on Mass Mining (MassMin 2016), pp 257–264 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2016

By P B. Card

"The website www.economicevaluation.com.au, which had its origins at the Project Evaluation Conference 2009, provides a free way for industry professionals to teach themselves economic evaluation. At its core is a set of fast-moving modules and three worked examples.The website recognises that economic evaluation is a discipline with a hierarchy of three levels:decision-makingevaluating the project/businesshands-on modelling.There are a set of modules for each level that describe the concepts and activities in detail. These emphasise that the most important and rewarding work is the evaluation of Level 2. The economic model created in Level 3 is merely a working tool and should not become a sophisticated ‘trophy’ in Excel that only one or two people can comfortably use.Hands-on modelling contains three sets of practices designed to make any model rigorous and intuitive so that it can be easily understood and used by others in the project team. Even if the model develops into a long, detailed and complex workbook, it should remain easy to follow and be intuitive. The website advocates freedom to devise any architecture that best suits the project under study, but promotes rigour through the following practices:four cash streams and graphsthree architectures – concept, prefeasibility and feasibilitysix principles.The modules in the Level 2 evaluation use conversational language to describe in detail the broad range of activities needed to properly understand and characterise a project/business. It stresses that net present value is nothing more than the mathematical treatment of a whole set of opinions, is not an absolute truth and is only a fraction of the evaluation process. The modules describe in detail the range of economic metrics that should be computed and the full spectrum of equally important characterisations required to make the decision in Level 3.CITATION:Card, P B, 2016. Teach yourself economic evaluation, in Proceedings Project Evaluation 2016, pp 160–171 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Mar 8, 2016

By A G. Guinea

If you were reading this article in a newspaper or similar in the 1800s, you would know that the world was firmly in the grip of the Industrial Revolution. You might have been one of the families that decided that an agriculturally based existence was no longer for you, and that the promise of a factory job was more appealing and more secure. And it was. Financially at least. Not so much from a workplace safety perspective.

May 5, 2022

By P Audet, D R. Mulligan, D Doley

This analysis attempts to reconcile existing ecological theories, rehabilitation planning goals and implementation constraints in the form of a rehabilitation paradigm that considers potential and pragmatic ecosystem transformation pathways. The framework prioritises multiple developmental scenarios for post-disturbed landscapes within a continuum of ecological outcomes. A feature of the framework is that ænovelÆ ecosystems and agro-ecosystems, having a range of commercial and societal values, are valid outcomes spanning the conceptual divide between the ecological functions of under-rehabilitated versus re-instated ænaturalÆ landscapes, especially in a changing environment. Landscape suitability analyses are considered to be fundamental to the incorporation of regional landscape and climate in the implementation of land rehabilitation and management strategies. Altogether, the paradigm could facilitate the identification of widely pertinent rehabilitation goals having direct implications at the regional scale of restoration ecology and acceptance of the need for ongoing commitment to the management of disturbed environments.CITATION:Audet, P, Doley, D and Mulligan, D R, 2012. Can ænovelÆ ecosystems offer suitable rehabilitation alternatives for post-mined landscapes?, in Proceedings Life-of-Mine 2012 , pp 135-142 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 10, 2012

By M Grigorescu, S Crimp, J H. Hodgkinson, P Kokic, W Jin

Mines are typically located in remote, inhospitable locations and movement of materials between site, processor and port are often at risk from extreme weather events. Mining companies have recorded multiple supply chain, production and logistics delays caused by climatic events. Recent analyses of extreme temperature and rainfall events (90th and 99th percentile values) for 1960 to 1985 and 1986 highlighted regionalised increases in the frequency and intensity of extremes. The trajectory of this change is likely to be maintained (IPCC, 2014) in regions where increases have occurred historically, suggesting that some parts of the industry may be faced with management challenges beyond current experience (Hodgkinson et al, 2010; Loechel, Hodgkinson and Moffat, 2012). Reliance on historical data to plan for extremes (such as scheduling production downtime to reduce impact) will become increasingly ineffective as the data become less representative of future conditions. Importantly, mine site remediation and closure management need to consider the future climate to ensure rehabilitation is sustainable under changing conditions.Vulnerability assessments and risk-reducing adaptation will become more common as the industry reaches to secure both a mine’s longevity and the industry’s reputation as shareholders and clients become less tolerant of repeated or prolonged interruptions (Hodgkinson, Hobday and Pinkard, 2014). Climate-resilient new mines may be planned using site planning tools combined with knowledge of future climate scenarios. Scenario tools are valuable for developing a gated risk management approach to reducing climate-risk during a mine’s life, through to the rehabilitation process and for managing care and maintenance or closed mines.CITATION:Hodgkinson, J H, Crimp, S, Jin, W, Kokic, P and Grigorescu, M, 2016. Life-of-mine planning tools for a changing climate – intuitive, interrogative, iterative, in Proceedings Life-of-Mine 2016 Conference, pp 71–74 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jun 28, 2016

By P Waters, S Miller

BHPBilliton operates the Mt Whaleback Mine located in the semi-arid Pilbara Region of Western Australia. Approximately 200 Mt of net acid generating (NAG) material still remains to be mined. Acid Rock Drainage (ARD) was first identified at the site in 1995 following cyclonic storms. This resulted in the development of strategies that have allowed the mine to successfully manage ARD whilst continuing to operate. BHPBilliton Iron Ore is working toward prevention of ARD in its operations, however, historical practices have left residual areas that must be considered. Three significant sources of ARD have been identified that must be managed: stormwater run-off from exposed pyritic shales in pit surfaces; basal flows beneath overburden storage areas following rainfall events; and contaminated water from pit dewatering. The mine contains all ARD water onsite. This is achieved by: storage of all affected water in the ARD dam; evaporation of affected water from the ARD dam and the adjacent evaporation ponds; pumping from upstream dams to prevent stormwater from being affected; and emergency storage and treatment in-pit as a contingency. The site ARD management strategy is approved by senior management and endorsed by State Government regulatory authorities and relevant external stakeholders. Additional strategies are also under evaluation to effect long-term closure of the operation. Record rainfalls from 1998 - 2001 have tested the capabilities of the ARD strategy and management plan. Learnings from these events, coupled with recommendations from an extensive technical audit in 2000, have been incorporated into the strategy for ARD management. This paper presents the strategy and an overview of the ARD management plan that can be considered and applied by other affected sites in the management of ARD.

Jan 1, 2003

The Closure Risk model was developed as a new tool to aid decision makers in the complex area of mine closure. It uses a simple analytical technique that allows the decision maker to simplify what is often a complex mine closure process into more easily managed sub components. This systematic approach ensures that critical factors in the closure process are not overlooked. It also allows the most important issues to be highlighted. The model can also be used to produce quantitative estimates of risk by weighting and prioritising the issues to produce the Closure Risk Factor (CRF). Field trials at several mine sites in the Northern Territory of Australia in 2001 tested the model. The trials confirmed that the model has significant potential as a tool for decision-makers to assess in a structured, systematic manner, the major closure risks at individual mine sites. The risks include not only environmental impacts but safety and health, community, legal, financial, technical and other issues. The trials confirmed the value of a team-based approach and the inputs of key staff including environmental, production, mine planning, and community liaison personnel as well as mine management. Although the usefulness of the qualitative component of the model was established, it was found that, due to the influence of subjectivity, the utility of the prototype model to determine quantitative risk was of limited value. Using a continuous improvement approach, improvements to the model were sought. A refined model, incorporating the Australian Standard 4360 definition of risk and facilitated in-house risk assessment sessions was developed and tested against the data obtained in the field trial. This model, while maintaining the qualitative strengths of the original, allows more accurate absolute and relative quantitative scores to be calculated. This in turn facilitates comparisons between the issues at a single site as well as between different mines.

Jan 1, 2003