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Sheaves are a critical safety component in a winding system and are expected to survive such extreme loading events as rope break. Sheave designs have often been developed and evolved empirically, consequently many existing sheaves are not necessarily subjected to the detailed analyses that are possible using todayÆs design tools. The design philosophy for sheaves is that the rope should be the weakest link in the system so that associated equipment can function safely for any load up to rope break. A number of failure mechanisms must be considered, but buckling is often prominent. During the course of investigating the feasibility of upgrading the hoisting capacity of a winding system, the capacity of all critical components was reviewed. The sheaves in the system were found to have insufficient spoke buckling capacity for the specified rope. A proposal to increase the spoke buckling capacity by connecting spokes together using a simple tie arrangement was evaluated and found ineffective. An alternative tie arrangement concept was developed and evaluated and shown to be adequate. This paper describes the finite element model, analysis approach and results for the original sheave and the two modifications. The contribution of the sheave rim to the total buckling capacity is evaluated. Some practical issues for spoke tie modifications are discussed.

Jan 1, 2005

By G R. Ballantyne, V Souto, K Bartram

Particle sorting allows partially liberated minerals to be separated prior to energy intensive fine grinding. Sensors select particles for separation and air, water or mechanical ejectors are used to physically deflect those selected. To achieve effective separation there has to be sufficient liberation, accurate detection and presentation of a separated monolayer of particles. These three physical constraints determine the particle size limits, the sorting technology utilised, the separation efficiency, and the throughput that can be achieved. The combination of all these factors controls the effective limits on the degree to which sorting can reduce the specific comminution requirements and increasing energy efficiency. This paper will explore two case studies: the application of sorting in base metal mining and precious metal mining.CITATION:Ballantyne, G R, Hilden, M, Bartram, K and Souto, V, 2018. Characterising energy efficiency of particle sorting, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 531–540 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

By N LaBranche, G Callinan

There has been a reduction in overall workforce in the mining industry during the current downturn; a corresponding reduction in fatalities and high potential incidents (HPIs) has not been observed. The same contributing factors can be seen in the vast majority of these incidents. These include inadequate supervision and lack of adequate risk assessment. How management structures, trains and leads an operation can have a great impact on eliminating these factors and reducing the risk of fatalities and HPIs.Contractors now account for 41 per cent of full-time equivalent employees in the Queensland mining workforce, and are disproportionately represented in the majority of fatalities and HPIs. Having a clear strategy for how contractors are integrated into the workforce is crucial. This talk will include a discussion of the data as collected in the Department of Mines and Natural Resources department database, and offer solutions based on this data.CITATION:LaBranche, N and Callinan, G, 2016. Organisational factors in fatalities and high potential incidents, in Proceedings International Mine Management Conference, pp 201-206 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jun 22, 2016

By H Stedman

Integrating exploration and operational blastholes into one database significantly enhances geological modelling. Benefits include: improved coal predictions, stronger interpretation of structurally complex areas, detailed mapping of heat affected coal aureoles and additional roof accuracy for blast designs that deliver better coal protection.CITATION:Stedman, H, 2014. Integrating blastholes into exploration data to improve coal recovery and modelling, in Proceedings Ninth International Mining Geology Conference 2014 , pp 237–242 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 18, 2014

By R Russell

The relative infrequency of fatalities and other serious events can give them an appearance of being random, of being beyond any reasonable degree of anticipation and prevention. In fact, the vast majority of these events result from exposures that are identifiable, measurable, and manageable. The lessons of prominent incidents, such as the Space Shuttle Columbia, OxyÆs Piper Alpha, Esso Longford, BP Texas City, Massey Mine, as well as lessons from single fatality events, is that alongside the proximate causes of each incident, there also coexisted an underlying fabric of systems, mechanisms, and culture that allowed risk in the workplace to persist and often to become normalised. All of these ingredients of the organisationÆs safety fabric lend themselves to the influence and intervention of senior leaders. The difficulty is that traditional injury prevention paradigms are not sufficient for addressing the precursors that lead up to catastrophic and fatal events. A recent study of such events, led by Dr Thomas Krause concluded that the descriptive aspect of HeinrichÆs safety triangle is useful, but that the predictive aspect is not. The study surfaced reasons why a reduction in less serious injuries does not necessarily correspond to a proportionate reduction in catastrophic and fatal risks. This presentation expands on the findings to include the concept of exposure to the event potential linked to precursor events and the framework for leading an organisation to be both cognisant and effective in eliminating such events.CITATION:Russell, R, 2012. Shifting the cultural paradigm for the prevention of catastrophic and fatal events, in Proceedings International Mine Management 2012, pp 91-96 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 20, 2012

By D Brett

The Paper presents the authors thoughts on how the mining industry should be improving the education of site personnel so they can provide a greater level of effective control of tailings dam safety including empowerment to develop their own documentation, monitoring and surveillance systems and to better liaise with specialist external technical staff or consultants.

Jul 1, 2021

By A Agasty, O Langefeld, MáKellner, E Clausen

The lowering of the pollutant concentration limits at the workplace subjects the mining industry to higher requirements for dilution; this situation is worsened with the current discussions within the European Union (EU) to set new stricter exposure limits for nitrogen oxides in the workplace. This is directly reflected in the performance of the mine ventilation system, which may need to be revised to meet the new standards. The after blast re-entry time, being inversely proportional to the threshold limits, will be higher for a lower limit. This in turn increases the down time for production from the blasted area.Numerical tools have been very useful in predicting the effectiveness of ventilation. This study aims at analysing the dilution time for NOx gases from an ANFO blast in a room and pillar panel. The effect of changing the ventilation on the dilution time is studied next, which helps with the selection of a suitable ventilation system.CITATION:Agasty, A, Clausen, E, Kellner, M and Langefeld, O, 2013. After blast re-entry time for a room and pillar operation, in Proceedings The Australian Mine Ventilation Conference , pp 179-186 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 1, 2013

By M Parcell

"Ventilation risks in an underground mine have essentially remained the same for centuries, yet theevidence suggests that there are many coal mines that have failed to adequately control these risks.The conduit for the knowledge learned by previous generations exists in the mining legislation. In an ideal world, mines would not need legislation to tell them what to do; they would resolve the risks to an acceptable level so as to protect the safety of persons in the mines based on the acquired knowledge. There will be some who have been personally aff ected by a mining disaster but for the majority they will be remembered as a vague recollection of an event from long ago. The mining legislation is the repository for the knowledge and outcomes from inquiries of past disasters. The challenge for the current generation, and the generations to come is to appreciate the legislation that exists, so as to not ælearn the hard wayÆ. In reviewing most disasters there is comment or discussion on the adequacy of the legislation, which ultimately results in some amendment to the law. For each person, there is an increasing responsibility to ensure that the same mistakes are not repeated. Understanding the legislation, its history and its purpose is the fi rst step in ensuring thatventilation risks are eff ectively managed. Failing to do this will be disastrous. This paper discussesthe relevance, importance and potential pitfalls of coal mine ventilation regulation."

Jun 1, 2012

By C Buchanan

For a long time there has been a known relationship between the northern Heavy Mineral (HM) deposits of the Murray Basin to the extensive north east trending ridges in the area. These ridges have been a targeting tool for exploration and have uncovered some significant discoveries, some of which have turned into mining projects. Bemax’s Ginkgo and Snapper deposits are good examples of how the faulting helped create an economic deposit but also result in significant planning issues in the exploitation of these deposits. Material balance, induration and pyrite issues have been made easier to manage through good geological understanding of the deposits.

Aug 22, 2011

By I Gray

This paper examines the effects of the changes in stress that a coal may undergo as part of the drainage process. As a consequence of this, some coal seams will come to the situation that they have zero horizontal stress existing within them at the time of mining. The hypothesis of this paper is that this lack of horizontal confining stress means that on mining, the vertical stresses may be easily raised to a level where failure occurs. This failure may be accompanied by significant energy release from energy stored within the coal as well as that coming from the roof and floor. To determine the state of stress within the coal seam, the concept of the effective stress path that the coal passes through is examined and is found to be very dependent on the shrinkage of the coal with degassing, the Young’s modulus of the coal and its Poisson’s ratio. The Young’s modulus of the coal is important and has been found to be highly dependent on the state of stress within the coal. It may change by more than an order of magnitude.CITATION:Gray, I, 2014. The consequences for pillar stability of zero confining stress brought about by forced or natural drainage, in Proceedings AusRock 2014: Third Australasian Ground Control in Mining Conference , pp 331–336 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 5, 2014

PIP is regularly engaged in businesses where Greenfield Capital Projects are under- delivering on the expected business case. In most of these projects, we can identify that rigorous review has been carried out on the design and financial cost elements and substantial reporting is maintained to Boards on progress versus plan of project completion and cost. However, in all sites of this nature that we have worked at, the planning, design and execution of the operational elements or æwiringÆ of the organisation have fallen short and resulted in significant extra cost or opportunity cost (lost tonnage or quality) during start-up. When compared to the amount of planning and resources that have been poured into the capital side, the ledger on the æwiringÆ side is typically fairly sparse. This presentation outlines the importance of running a disciplined, rigorous process to prepare the human and wiring side of a start-up to ensure rapid start-ups and put the site on the pathway to high performance. It gives an outline of the rigorous process PIP has used with projects to ensure excellent start-ups.

Jan 1, 2006

Underground excavations are subjected to complex stress changes caused by nearby mining, but may also be affected by repeated dynamic loading from blasting and seismic events. In some cases, the combined, cumulative effects can lead to unforeseen damage, displacement and instability. Simulating dynamic loading of an underground excavation is a very complex task. The state of rock mass stress, damage and deformation must first be simulated sufficiently requiring small-scale structures to be explicitly modelled. Supporting elements must be represented with high similitude and then the dynamic event must be applied to the system in the case of blasts, or evolve as a consequence of rock mass instability for seismic events. A special case is for the effect of pit blasting on underground excavations - discontinuous rock phenomena at scales from mine, to bench, to pillar, to tunnel need to be captured and this represents one of the most computationally intensive tasks in mine simulation. Recent advances in computer power allow these tasks to be completed at a mine scale, incorporating discontinuities and geological detail matching the best practice for static Finite Element analyses. The results are a worthwhile contribution to mine decision-making, but require careful interpretation and thoughtful inputs - even more so than quasi-static analysis - as the cumulative effects of unfavourable modeling practices are greater. Some learnings from experiences with mine scale, discontinuum dynamic simulation are summarised, including a discussion of considerations of scale and similitude for this type of analysis.

Nov 25, 2010

Reconciliation involves the collection of tonnage, grade (quality) and contained metal (product) data from disparate and hopefully independent sources. Examples are exploration data, production sampling data from blastholes or drawpoints, and process plant data. These data may be compared by means of ratios (factors). The F1 factor usually relates short-term (ore control) model tonnages, grades and metal content to ore reserves depleted. The F2 factor usually relates received-at-mill tonnages, grades and metal content to delivered-to-mill = production tonnages, grade and metal content. The F3 factor is F1 × F2 and enables a comparison of a mineÆs ability to recover the tonnage, grade and metal content estimated in ore reserves. The F1 factor measures the accuracy of orebody knowledge in the ore reserves to the demarcation of ore and waste by ore control (short-term model). The F1 factor may be used to check and calibrate the selectivity of mineral resource models and/or planned dilution assumed in transfer from mineral resources to ore reserves. The F2 factor enables a check on unplanned dilution entering the ore stream between ore control and the mill. Using the factors it is possible to calculate a monetary value on improvements in the accuracy of orebody knowledge, selectivity and the effects of dilution and ore loss. Reconciliation should be an implicit part of the mining process, and reconciliation targets should be a key performance indicator for well-run mines.

Sep 26, 2011

The MIMDAS geophysical data acquisition system developed and tested by the former MIM Exploration Pty Ltd (MIMEX) is now commercially available worldwide through Geophysical Resources and Services Pty Ltd (GRS). The system implements several new features in its design that give it significant advantages over conventional systems and allows for new approaches to electrical exploration. In particular, the achievable signal to noise levels permit exploration to depths once thought beyond the range of electrical exploration. The flexible multi-channel configuration lends itself to truly 3D surveys in the style of modern seismic techniques. Each of these aspects is illustrated with a number of case histories from both Australia and South America.

Jan 1, 2004

This paper describes modern long-term mine scheduling and gives an example of its application. It then discusses the obstacles to the implementation of such schedules.

Sep 26, 2011

By J Rutter, S Dunham

Technological advances in sensor and material handling technology has enabled a step change in mine operations performance. Sensors capable of monitoring the grade of broken rock mass can be mounted on shovels, truck loading units or conveyors allowing highly precise ore/waste decisions to be made on small parcels of rock, increasing selectivity. This increased selectivity has the potential to remove sub-economic material from the product stream prior to incurring ore treatment costs. Bulk ore sorting is capable of intervening at <10t “pods” on Run Of Mine conveyors, or alternatively at per bucket loading (5-100t) or truck scale (30-350t) parcels of ore. This Grade Engineering technique being developed by CRCORE (Rutter, 2017) can improve mill feed grade, remove deleterious materials and ensure that the high capital intensity ore treatment facility is presented with the best ore feed strategy. While this technology can improve mine economics, estimating the performance of a bulk ore sorting system is challenging. Traditional resource estimation practices such as Ordinary Kriging and Inverse distance weighting (IDW) are based on weighted averages, a process that smooths the grade profile, reducing modelled variance and dispersion. Its purpose is to generate a globally unbiased result but is less suited to generating a model of adequate granularity to enable confidence in local grade heterogeneity. This is an essential component for bulk ore sorting success. Estimating ore sorting performance requires knowledge of the grade-tonnage curve at the scale of the sensor diversion unit (SDU). Evaluation based on an estimator that smooths the SDU distribution will not correctly predict ore/waste separation or economic performance. Alternatives to traditional linear geostatistics have been tested on a variety of mineralisation styles. Additionally, a number of heterogeneity metrics have been developed to assist with evaluation and assessment. The difference between estimation for grade (metal) and modelling for traditional mining block models, versus methods used for predicting heterogeneity and variability are explored.

Nov 10, 2020

By M Yahyaei, F Reyes, R Lage, V Jokovic

Equipment wear is strongly related to the performance of grinding circuits. In particular, SAG mills are subjected to the wear of their shell liners and grates. Changes in lifter height and face angle impact mill performance, while classification at the mill discharge is also affected as grates wear out. Moreover, liner mass loss caused by wear affects how operators interpret readings of sensors such as load cells or bearings pressure. Automating and optimising grinding circuits under these constrain becomes challenging due to the nonlinear and dynamic nature of the system. The operation of SAG mill grinding circuits remains largely dependent on human intervention, which frequently results in inconsistencies in performance across shifts, reflecting the operator’s personal preferences, experience, and other human factors. The influence of human factors can be reduced by careful training of operators as well as by automation using advanced supervisory control. The latter approaches could benefit from the development of dynamic process models that consider the effects of wear on the performance of equipment over time. This paper presents detailed industrial data showing the effects of wear on SAG mill performance. Additionally, a dynamic SAG mill model that accounts for these phenomena is proposed and demonstrated in a simulated environment. This model is shown to mimic the effect of wear on the performance of industrial scale mills and the operational constraints they are subject to, thus extending traditional SAG mill models. Incorporating wear into modelling and simulation platforms can improve the understanding of the effects that wear can have on the performance of key assets in comminution circuits and may allow the development of more robust model-based advanced process control strategies.

Aug 24, 2022

By F Ramos

Conventional techniques for resource estimation generally involve the laborious analysis of variograms and the specification of parameters for covariance functions. In large deposits, construction of resource models and their update require significant amount of manual work, expert knowledge and time. In this paper we take a machine learning view to the problem of resource estimation. This is a non-parametric Bayesian method, leading to automatic parameter estimation (learning). Through Bayesian learning, the parameters of the model can be obtained by optimising a quantity known as the marginal likelihood. The main advantage of this approach over conventional maximum likelihood estimators is that the objective function incorporates the OccamÆs razor principle. This allows the comparison of different statistical models û for example, models designed with different covariance functions û and naturally penalises complexity, thus avoiding overfitting. Our technique presents significant flexibility for the definition of mean and covariance functions and permits the usage of more sophisticated models.The second contribution of this work is the formulation of a data fusion mechanism that continuously updates the resource model. As mining progresses, more information becomes available. For example, the hardness of the rocks can be measured while drilling blast holes, grades of ore and contaminants are obtained from cone logging. This information is in general available at a finer spatial resolution but can be more uncertain. The data fusion mechanism can seamlessly estimate the uncertainties of the different types of information and fuse them as new measurements are acquired. This procedure can significantly improve the quality of the resource model, defining new grounds for stochastic mine planning. We demonstrate the effectiveness of our approach in estimating iron ore deposits by integrating information about different grades.

Sep 26, 2011

By S Mitra, D O’Dea, N Barrett, S, T Honey, M M. Hoque

The steel industry is currently exploring hydrogen-enriched blast furnace operations as a means to reduce the greenhouse gas emissions. However, there is a need to investigate the gas permeability behaviour of mixed burdens comprising of lump and sinter as the current knowledge regarding their behaviour is limited, particularly with regards to hydrogen enrichment. In the present study, a series of interrupted softening and melting (S&M) under load tests were carried out in a hydrogen rich gas environment (~15 per cent) in the temperature range from 1000 to 1300°C by placing different types of ferrous ore layer including Newman Blend Lump (NBLL), sinter and sinter-NBLL mixed burden in between two coke layers. X-ray computed tomography (CT) was then used to scan the interrupted test samples. Scanned images were first analysed using an image processing workflow implemented in ImageJ and the material simulator GeoDict (v2022) to segment different phases such as coke, ferrous and void based on their grey scale values. A quantitative analysis was then performed on the segmented images to estimate the phase volume fraction as well as bed permeability. Bed void fraction thus obtained agreed well with the bed contraction data obtained from the S&M test. It was further noted that both ferrous layer void fraction and bed permeability decreased linearly with increasing temperature for all ore samples. The mixed burden voidage changed in a similar fashion to the sinter, demonstrating a high temperature interaction between the two materials

Sep 18, 2023

By S Viviers, G Ratner

Ventilation is part of all underground mine operations and is undertaken in order to introduce fresh, cool air to the workings and to remove stale, affected air. It is problematic to obtain efficient and accurate estimates of volume flow and static pressure in the installed operational configuration for the auxiliary axial flow fans.An empirical method was developed to estimate the static pressure and volume flow through a calibrated differential pressure port on axial flow fans. Prior to shipping, each fan is performance tested according to BS 848 (ISO 5801) to establish the fan performance curves. In addition to the standard required parameters captured to fully describe the performance, the differential pressure is measured across the fan rotor to enable correlation with the characteristic fan curve.The method was implemented on a ruggedised tablet PC platform. This compact platform is then used to calculate the volume flow rate from the differential pressure sensor measurement input via a USB port. The result is a real-time measurement of volume flow and operating point of the fan system. This can be used effectively in overall modelling of the mine auxiliary ventilation systems and calculation of system resistance could provide a health indication of the fan and duct system.CITATION:Ratner, G and Viviers, S, 2013. Underground auxiliary ventilation monitoring and diagnostic system, in Proceedings The Australian Mine Ventilation Conference , pp 57-62 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 1, 2013