Search Documents

By T Hausler

The pitfalls, pleasures and management issues associated with international and remote projects are diverse.However, no problem is insurmountable and if an engineering team chooses (by luck or good planning) to push through the difficulties, success can mean an extremely satisfying experience for individuals and a significant, positive result for an organisation.International projects are not for the faint hearted or inflexible. Working in foreign lands with people who may or may not speak English and who may not initially respect you can become mentally and physically tiring.Sometimes the challenges are not fully explained to individuals in advance. Individuals then often learn about the challenges ù and discover solutions ù on the job. While this initially puts great pressure on individuals, matters improve eventually, especially when the locals come to understand that you are on site to make a positive difference.This paper will discuss aspects of a recent international project including meeting international clientsÆ expectations, dealing with cultural differences, social reckoning, environmental issues, and personal challenges. Specifically, it will cover aspects of working within a Russian cultural setting and overcoming social barriers.The paper also presents coping strategies for long periods of time spent away from home in remote places with extremes in weather beyond the normal experience of most Australians. For example, dealing with the effects of the spring thaw and coping with temperature ranges of -45 to +45¦C.Lastly, and possibly most importantly, there will be a focus on the role of translators. They have the power to make an engineer everyoneÆs best friend or, on your behalf, to order cold chicken liver and heart salad for lunch. If an engineering team can establish a working relationship with translators, they can become an invaluable asset and both on and off site.CITATION:Hausler, T, 2013. Achieving success in large-scale, remote area metallurgical plant projects, in Proceedings MetPlant 2013 , pp 539-552 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 15, 2013

In preparation of this Paper, the emphasis has been laid on the commercial rather than on the technical and scientific aspects of coal evaluation. It is intended to describe and comment on the principal factors which currently determine the selection and procurement of coking coal for the steel industry, and is not based on the results of any original research by the author. Evaluation of different coals for strictly thermal uses, for gas production or other chemical applications has not been attempted, and comparisons of coal with other fuels have been excluded: the paper is concerned only with coals for the production of blast furnace coke. The discussion is strongly related to, and illustrated by, British, and to some extent, other Western European practice, but it is hoped that the general conclusions may have a wider application.

Jan 1, 1975

IN any assay office it is of paramount importance to keep the men interested in their work; and in order to do this, men on routine work, such as lead, zinc, and sulphur deterrrrinations, slag analysis, etc, should be changed around monthly. This gives some variety and helps to keep a man's interest on his work, so that better work results. It may be maintained that to keep a man on the same class of work indefinitely makes him more expert at his work. This is certainly true; but in assaying, where accuracy is so essential, it is absolutely necessary for a man to keep his mind on the work, and not 'get' into a mechanical method of working. He is also on the alert to discover means for shortening his analytical methods, and his capacity forwork is increased. Another advantage is that the men get a good all-round training, and one is never at a loss to replace a man on any class of work when he is absent from any cause. This tends to smoother and more efficient running of the assay department. In industrial assaying it is often advantageous to have a result quickly, so that it will be of maximum benefit in the running of some part of the plant, In such a case it pays to sacrifice a little accuracy to speed up a method. The shortest method is less costly, and a quick approximate method is all that is required to give the superintendent the requisite information. Time is thereby saved, and the cost is less. In carrying out assaying for any large industrial plant, such as a smelting works, there is always a tendency for superintendents running the different departments to send in more samples for assay than are absolutely necessary when no system of costing is in operation. Some of these samples may involve a lot of work and heavy expenditure, as, for example, the estimation of only one impurity in a sample of refined lead. If the superintendent knows that the cost of assaying all samples sent in by,him is charged up directly against...

Jan 1, 1922

By Edwards A. B

In their description of the post-mine leaching of galena and marmatite at Broken Hill, Messrs. Garretty and Blanchard1 find themselves unable to account satisfactorily for the fact that the more usual order of solubility of these two minerals is here reversed, and that the galena is leached more rapidly than the marmatite. An explanation of this somewhat unusual phenomena is perhaps provided by the recent work of Garrels.2 Garrels showed that the presence of Cl' ions in Pb-Zn solutions, in concentrations in excess of 0·1 N, rendered the zinc less soluble than the lead. It seems possible that Cl' ions may be present in the underground waters of the North Broken Hill Mine in sufficient concentration to cause such reversal in the relative solubility of the lead and zinc sulphides.Thus the analysis of "water believed to be free from contamination by mine drainage" given by Messrs. Garretty and Blanchard (p. 158 of their paper) is as follows:Total solids in solution 878 grains per gallon...164 grams of Cl per gallon is equivalent to 2· 3394 grams of Cl' per litre, which is equivalent to 0066 N.This concentration is approaching a value sufficient to cause a reversal of the relative solubility of zinc and lead salts; and it seems probable that there will be parts of the ore-body where locally the Cl' concentration will greatly exceed this figure. At such points the lead salts would be more soluble than the zinc salts, so that the galena would be leached more rapidly than the marmatite. With the dilution of such Cl'-rich waters with water containing less Cl', the Cl' concentration would fall below 0·1 N, and the lead would be reprecipitated, while the zinc would stay in solution, as, for example, in the water analysis quoted. The other point on which the authors speculate is the reason why the Northern Ore-body in the mine has undergone greater leaching than the...

Jan 1, 1942

In the Illawarra District of New South Wales, Mines were traditionally developed from the seabord. The advantages were close access to the working faces and a minimal depth of cover. Travelling times to the working faces have become prohibitive in many cases due to progressive westward development of the mines. As a result, additional vent- ilation shafts were sunk to service existing mines and new mines were established west of the Illawarra escarpment. Mining operations west of the escarpment are now being conducted at an increasing depth of cover and can be effected by gas related problems such as high seam gas emission rates and gas outbursts.

Jan 1, 1983

The advent and easy availability of fast and powerful digital computers has marked a transition from one era to another in the field of process control in many industries. Mineral processing is no exception. Aims, practices and problems associated with process control of mineral beneficiation plants in the 'old days' are compared with those available at present. Although basic processes remain generally the same, there have been simultaneous social and economic developments, which directly relate to the development and present value of process control. Lower head grades are now treated, plant capacities have increased, and a large proportion of future capital in the mineral industry will be associated with large capacity plant, treating still lower grades. Environmental considerations have pressurised moves to better control in some areas. With these changes, economic operating incentives have changed, and process control has, in many plants, become more critical. Finally, while computer technology has developed recently at a very rapid rate, developments in the fields of instrumentation, basic on-line measurement and sampling have in general lagged behind, limiting the progress possible in process control. Hence, the benefits of computer control vary depending on

Jan 1, 1977

Anyone who has driven backwards using only their rear view mirrors knows how difficult it is to avoid spinning the steering wheel the wrong way. So why run your mine that way? Traditionally Reconciliation has focused on the past performance of the mine. In this paper we make a case for Prognostication û the act of forecasting or predicting something in the future from present indications or signs. Reconciliation is a common activity carried out at most mines around the world. Countless geologists and engineers spend hours poised in front of spreadsheets diligently comparing how their resource/reserve model, grade control, and survey pick ups compare to what was actually produced. The result is usually a group of factors, which are applied to future estimates in an attempt to better predict how the operation may perform. Unfortunately, if the road ahead isnÆt the same as what you have just been down, youÆll be æoff-roadingÆ in no time! An alternative is to constantly collect and analyse key measurements that are used to calibrate critical estimates in an iterative process. When variations occur, they are analysed and corrective action is taken to ensure the estimates and measurements realign. In this way the estimates become forecasts and can then form the basis for decision making to ensure that what does happen in the future will match the plan or schedule. By automating this process, some mines have been able to be proactive on a daily basis in order to improve the overall performance of the operation. This paper outlines the key estimates and measurements used for reconciliation, details the characteristics of an automated web based information management system to facilitate the process and provides some insights about how mining operations might move beyond reconciliation.

Jan 1, 2003

By Mutton B. K

A systematic approach to the collection, presentation and application of structural geology data is employed in the extraction of narrow en echelon Ag-Pb-Zn orebodies by rut and fill stoping at Mount Isa. The aim is to locate, document and predict areas of adverse ground thereby enabling adequate ground support to be installed in advance of production mining. The important structural features are identified and their relevance illustrated by case histories of previous failures. The methods of collection, documentation and application of data are discussed.

Jan 1, 1977

The face of project evaluation is changing continuously, making it ever more critical to get a clear understanding upfront of the objectives, decision-making processes and criteria of the project proponents. Requirements are usually significantly different for emerging æjuniorsÆ compared with long established major mining houses and companies in developing countries compared with western companies. Requirements are also different for different types of evaluations, such as due diligence studies compared with feasibility studies of æownedÆ projects and there are often key misunderstandings around the use of the term æbankableÆ. Further, it has become increasingly important with increasingly remote and lower quality resources to understand risk relativities such as infrastructure compared with the core processing facilities. This has also driven the need for more trade-off studies to determine the best balance between critical issues, such as optimisation of the interface between mine and processing plant, capital versus operating cost and automation versus labour. In every project evaluation, it is also critical to consider emerging trends and changing requirements and standards such as sustainability and community interface. Finally, the inescapable drive to reduce time to market has driven changes such as increased use of more standardised designs and innovative approaches to the transition from project development to execution. This paper begins with a brief review of the different objectives and risks of each project development stage to establish a framework for subsequent discussion of the different requirements of different types of companies in different locations, different types of evaluations and different types of projects and project components. This is followed by a review of changing requirements and standards and some innovative developments in sustainability and community interface are presented. Finally, the paper outlines a number of developments in the area of operational readiness planning that focus on minimising the time to achieve maximum return on investment.

Jan 1, 2009

By T Hodgkin

The WA Goldfields is a highly productive gold and nickel mining area, but is arid with highly saline groundwater. Groundwater is widely used to supply process water to mines in the region but high groundwater salinity, commonly exceeding 50 000 mg/L TDS, tends to increase processing costs, limit end uses for the water, cause problems with disposal and potentially increase impacts on a sensitive arid environment. The area has low rainfall (200 - 270 mm/year) but run-off, particularly during cyclonic events, is high. Our experience suggests that stream flow from catchments in the area can produce a divertible yield of 8 - 17 ML/km2/year. An evaluation of stream flow harvesting using AnglogoldÆs Jubilee Pit predicted that 1000 ML/year of good quality water could reliably be supplied to the Sunrise Dam Gold Mine. Because of high rainfall variability, it is likely that an alternate source of water supply will be necessary when operating a surface-water harvesting scheme in the WA Goldfields. However, a combination surface/groundwater supply could have substantial cost, operational and environmental benefits compared to traditional supply systems that utilise groundwater only.

Jan 1, 2003

By Sparrow G. J

In a recently completed AMIRA project, 20 samples were searched for gold mineralisation using the automated location facility (ALF) for rare phases on a scanning electron microscope in the CSIRO Division of Mineral Products, Melbourne. The samples were submitted by mining companies in Australia, and Papua New Guinea, and included crushed ore samples, cyclone overflow and underflow products, a flotation concentrate, and 12 tailing samples. Their gold contents ranged from 600 to 0.2 g/t An. Native gold and gold minerals including a gold telluride, gold-silver tellurides, and a gold bismuth mineral, were located in the samples as free grains and associated with other minerals such as pyrite, magnetite, hematite, ankerite, copper sulphides, silicate minerals, and quartz. In the highest grade samples, both micron sized and 200 ¦m grains of gold were found with ALF. It would be difficult to locate such d wide size range of gold in a manual search. Gold mineralisation was located in the tailing samples assaying 0.4 g/t An and higher. In several tailing samples coarse grains of native gold over 40 p.m in size were located. One grain was estimated to have contributed 40 per cent of the gold in the sample. As well as locating gold mineralisation, the ALF examination resulted in the identification of uranium, mercury, and bismuth minerals in the samples. Knowledge of the distribution of these minerals in processing streams could be important in the operation of a concentrator.

Jan 1, 1992

By M Castle, D Mendelawitz

The Marra Mamba iron ore in FortescueÆs Chichester Range project area occurs as a very flat dipping series of waste shale and iron ore beddings. These beddings vary from millimetre thickness to several metres. The ore material generally exhibits a moderate degree of competence when subjected to ultimate compressive strength (UCS) tests, normally failing at up to 60 Mpa. However, the strength of the beddings is markedly less when subjected to the tensile forces imposed by the cutting action of the surface miner. Two surface miners of differing age and sizes were tested over a period of almost three months. These machines produced a product that had not been subjected to dilution by blasting and of such a size that primary crushing is not required. The machines were able to cut all ferrous material presented to them with varying degrees of success. Material containing higher quantities of manganese were broken but caused catastrophic wearing of the picks. During the trial the volume of material produced by the two machines in various strength materials very closely matched the manufacturerÆs estimates. The major impact on costs per tonne related to the wear on bits, which in turn varied with the bit design and composition. Bit design and composition testing is continuing.

Jan 1, 2007

Lithocaps are potentially voluminous zones of advanced argillic and associated argillic alteration located above the subvolcanic intrusive environment. They constitute exploration objectives for epithermal and porphyry-type deposits. High-sulphidation epithermal deposits may be sought within lithocaps, whereas low-sulphidation deposits may exist on their edges. Porphyry Cu-Au/Au deposits may be accessible beneath lithocaps if systems are telescoped sufficiently. Oxidation of the basal, pyritic parts of lithocaps may promote supergene sulphide enrichment under appropriate tectonic and climatic conditions.

Jan 1, 1995

By Doxford CI, Perry AJ

Mining Lease 908, situated on Gorge Creek near its confluence with the present Cape River system, has been subjected to intensive recent exploration for alluvial gold.The gold is hosted by a buried palaeochannel, the Gorge Creek Lead and by an overlying remnant meander of the Cape River. The principal, if not sole, sources of gold within the Gorge Creek Lead are the northwest trending Great Australian Reef and Green's Specimen Reef systems which are situated on adjacent high ground. Lower grade gold bearing eluvial ground separates the reefs from the Gorge Creek Lead. The sources for gold within the old Cape River system channel (Canton Lead) are thought to be situated some distance upstream, one source perhaps being the Lolworth Diggings located 30 kilometres to the northwest.Exploration of previously "heavily dug" ground on both leads consisted of detailed geological mapping followed by the collection and treatment of bulk samples from eight costeans. The wash samples varied in size from 120 to 396 cubic metres. Treatment was undertaken through a commercial sized conventional wet screen and jig plant.

Jan 1, 1986

INDEX OF CONTENTSIntroductionChemical compositionsNormally Cooled MattesPort Kembla mattesMount Lyell matteMount Morgan matteGranulated MattesConclusionsIllustrationsINTRODUCTIONIn a previous paper in these Proceedings(l) an account was given of the composition of some copper-lead mattes from the Port Pirie Smelters. The research programme of the Mineragraphic Section of the Commonwealth Scientific and Industrial Research organization has since been extended to copper-iron mattes from Port Kembla (The Electrolytic Refining ana Smelting Co. of Australia), Mount Lyell (The Mount Lyell Mining and Railway Co.) and Mouilt Morgan (Mount Morga:p. Ltd.).Chemical Composition of the Mattes.The mattes examined have a considerable range in chemical composition, as is shown by their analyses (Table 1).

Jan 1, 1949

By J Rostami, D Tadic

While hard rock tunnel boring machines (TBMs) have an established track record in the tunnelling industry, accurate estimation of TBM performance for each specific project remains critical. Machine performance prediction is required to assist planning activities, including costing and schedule preparation, machine specification and effective planning of maintenance and repairs. In addition, monitoring machine performance during the construction period is required to assess and manage excavation progress, and to achieve optimal advance rates based on specific geotechnical conditions exposed during excavation. TBM performance analysis can also contribute to the development of more accurate performance prediction models for future applications. Rock mass characteristics play a dominant role in machine performance. This paper offers a review of the impact of rock mass characteristics on TBM penetration rates for two specific tunnelling projects. A discussion is provided on the results of statistical analysis of available field data, including geological back mapping, rock properties and measured rates of penetration (ROP). The analysis offers a comparison of the achieved and predicted ROPs to provide a better understanding of the influence of rock mass properties on the performance of hard rock TBMs. A new rock mass adjustment factor is introduced to enhance the accuracy of an existing prognosis model for use in jointed rock masses.

Jan 1, 2008

By Mackenzie J. M W

The mechanism of clay slime flocculation in coal washing circuits is considered and it is concluded that polymer flocculants are most suitable. It was found that the addition of sea water with a polymer flocculant improved flocculation and settling, and it was also found that dilution of a flocculated pulp increased floc size and hence settling rate.In predicting plant consumption of reagent it was found that cylinder tests, or even pilot plant tests, could give erroneous results, particularly on flocculated pulps. Different flocculants may, however, be compared in cylinder tests.For filtration, flocculation with Separan plus sea water was much more beneficial than flocculation with Separan alone.INTRODUCTIONDuring the mining of coal, and its subsequent beneficiation by washing, large quantities of minus 10 mesh material are produced. This fine material, which consists of broken down shales and fine coal, causes difficulties in water clarification circuits, in refuse disposal, and in filtration of fine coal.These difficulties can be largely overcome by flocculation, and this paper discusses the mechanism of flocculation, the methods by which a selection of flocculant may be made from the large number available, and the limitation of the prediction of plant performance from laboratory tests. This work applies particularly to the washeries of The Broken Hill Proprietary Co. Ltd. (B.H.P.) and Australian Iron and Steel Ltd. (A.I. & S.) .

Jan 1, 1962

Segregation of granular material is a very common phenomenon. Realised in a forced manner it is a basis of all separation processes in mineral processing, mainly classification and beneficiation. Spontaneous segregation, occurring under dynamic conditions and making possible mutual translocations of grains, is however an undesired phenomenon as a rule. It decreases the degree of blending of the material which in many cases is an important technological feature of the material. It should be noted that the segregation can be treated as the reverse phenomenon to blending. The importance and frequency of spontaneous segregation has caused many rules and technical solutions to be developed aimed at decreasing the possibility of the spontaneous segregation. However, not enough attention has been focused on an quantitative description of the phenomenon of segregation, either to ways of quantitatively evaluating segregation effects or to explanation of the influence of conditions under which the grained material exists on the occurrence of segregation and its degree. The paper presents the following topics: 1. new numerical indicator for evaluation of the segregation degree (and blending) of material contained in an arbitrary determined region is proposed; it is determined relative to the maximum possible degree of segregation of the given material when taking into account its individual properties; values of the indicator can be calculated effectively for an arbitrary material, also for ulticomponent material. 2. there is proposed a way of evaluating the state of segregation (or blending) of material in an arbitrary part of the region mentioned above, based on investigation of the gradient of distribution of the material features; algorithms of analytical procedures and calculations are presented for typical cases met in mineral processing; 3. results of initial experimental studies, both laboratory and industrial, concerning the effect of the chosen factors occurring in transport and storage of the material on its degree of segregation are presented; and 4. conclusions referring to the fundamental and practical significance of the results are also presented.

Jan 1, 1993

By Dundon P

The Broken Hill Proprietary Company Limited (BHP) is Australia's largest company with widespread commercial interests ranging from steel productin to minerals, oil and gas recovery. While these interests are worldwide, the Company operates or is partner in more than 30 Australian mining ventures. BHP Engineering (BHPE) is the in-house consultant to BHP but is also the largest consultancy in Australia available to general industry. Australian Groundwater Consultants Pty Limited (AGC) is a large, independent consultancy offering specialist services in all aspects of water resources, waste management and environmental engineering, both in Australia and overseas. AGC is particularly well regarded within the mining industry and has a considerable record of providing solutions for mine water related issues. By drawing on the extensive combined experience of AGC and BHP Engineering, this paper will summarize some of the unique ways in which water interacts with and impacts on mining operations in Australia, particularly in matters such as: Slope Stability Drainage and Dewatering Production Cost (Transport, Drilling, Blasting, etc) Water Supply Water Management Tailings and Waste Management Environmental Issues. The paper will also illustrate the cost benefit of providing major engineering works for reduction in total mining cost. It will be shown that, through advance planning and close interaction between outside experts (ie consultants) and on- site personnel, very significant operational cost savings can be made while at the same time achieving a safe and responsible mining environment.

Jan 1, 1988

The Curragh coal mining operation was designed and constructed to produce two coals initially at a rate of 4.3Mtpa. These are a high thermal energy steam coal primarily for domestic electricity generation and a low ash high quality coking product for the export market. Treatment of coals from four seams to achieve this requires a large and complex preparation plant and blending facilities incorporating state of the art technology. This facility was constructed during 1982/83. It has been designed for expansion to 6.8Mtpa capacity. The preparation and handling facilities were built at a cost of approximately A$80 million. Equipment includes 500 plus electric drives with a total capacity of 20 000kw. Commissioning was carried out in three phases : Staging - of the control system Coal Handling Facilities - conveyors, stackers and reclaimers for raw and product coals The Coal Preparation Plant - heavy media cyclones and froth flotation. A period of three months was devoted to the commissioning of the plant before requiring product coal to contract specification. This paper will describe the planning, implementation and results achieved.

Jan 1, 1986