Search Documents

By H S. Pescini

A material aim when feeding ore blends into a processing facility is to reduce the variability of the properties of the feed material and to maximise the output, or throughput. At the Mining Geology conference of 2019, we presented a paper on optimal blending of coking coal given geological variability. The paper introduced integer-programming techniques to both maximise value and minimise feed or product variability. We discussed an application where the geological uncertainty is characterised using a normal distribution and exact solutions are readily obtainable using second order conic constraints in the mathematical model. Geological uncertainty is not always normally distributed, many properties will be characterised as log normal or some other skewed distribution. For example, copper can be some form of lognormal and Fe in Iron ore has a left skewed distribution. In this paper, we discuss some distribution free techniques to optimise the blends of plant feed or output given a quantified geological uncertainty. We discuss the sample average approximation method and how to set-up and apply the method to an ore blending problem. Evaluating a case study demonstrates that the explicit use of non-normally distributed geological uncertainty can better optimise feed into an ore processing facility and potentially add significant value. The approach is equally applicable to all mining and processing operations that blend material into a processing facility or directly into a saleable product.

Mar 22, 2022

By V A. Chanturia, T N. Matveeva, V V. Getman, A Yu Karkeshkina

The development and application of new effective environmentally friendly reagents for the flotation of thin and ultrathin mineral components is an urgent task. The analysis of the nomenclature of chemicals, including flotation reagents and flocculants, showed that water-soluble polymers (WSP) might be used in flotation separation of fine grinding products containing non-ferrous and precious metals. Water-soluble polymers that are responsive to temperature changes are the most attractive as reagents during flotation. These are the thermo-responsive polymers or thermomorphic polymers. The presence of nitrogen and oxygen atoms in the polymer molecule contributes to the formation of a coordination bond with non-ferrous and precious metals. A research conducted at the ICEMR RAS within the framework of the scientific school of Academician of the Russian Academy of Sciences Chanturia helped to develop a method of flotation of finely ground mineral particles containing valuable components using modified thermomorphic polymers. The paper focuses on the experimental study of poly (vinyl caprolactam) (PVC) as a flotation reagent for gold recovery from finely ground mineral products. PVC is a ready-made water-soluble thermosensitive polymer that does not require complex synthesis. PVC has a high ability to form complexes in an aqueous environment when heated. According to experimental data, the polymer interacts with gold nanoparticles, contributing to the extraction of gold from fine mineral products and the tailings that makes it perspective as an additional flotation agent for the processing of gold-containing ores.

Aug 24, 2022

By S Rice, A Midlin

Many of the stacking and reclaiming machines employed in the mining industry today are operating in ways that were never envisaged in the days before they were commissioned, with greater throughput, increased annualised operating hours and load cycles well in excess of their original specification requirements being the norm. In many cases these machines were supplied prior to the widespread use of finite element modelling or, in the era when such software became commercially available, those supplied designed using simplified and/or coarser meshes than would be employed today. With many of these machines being expected to operate for many years to come, it is important that their ongoing reliability be maintained and their operational limits understood. In this paper, a case study is used to outline the method required for estimating the fatigue life already consumed and the likely real life left in a machine. By reference to the machineÆs prior operating history, the use of strain gauges in the field and the development of finely meshed finite element analysis (FEA), a coherent picture of the machineÆs operational state can be generated and then investment/maintenance decisions made to ensure continuity of machine operation.

Jan 1, 2007

By J Lombardi

OZ Minerals' Prominent Hill copper-gold concentrator is located 130 kilometres south east of the town of Coober Pedy in the Gawler Craton of South Australia. The concentrator was built in 2008 and commenced commercial production in early 2009. The Prominent Hill concentrator is comprised of a conventional grinding and flotation processing plant with a 9.6Mtpa ore throughput capacity. The flotation circuit includes six rougher cells, an IsaMill for regrinding the rougher concentrate and a Jameson cell heading up the three stage conventional cell cleaner circuit. In total there are four level controllers in the rougher train and ten level controllers in the cleaning circuit for eighteen cells.Generic proportional – integral and derivative (PID) control used on the level controllers alone propagated any disturbances downstream in the circuit that were generated from the grinding circuit, hoppers, between cells and interconnected banks of cells, having a negative impact on plant performance. To better control such disturbances, FloatStar level stabiliser was selected for installation on the flotation circuit to account for the interaction between the cells. Multivariable control was also installed on the five concentrate hoppers to maintain consistent feed to the cells and to the IsaMill. An additional area identified for optimisation in the flotation circuit was the mass pull rate from the rougher cells. FloatStar flow optimiser was selected to be installed subsequent to the FloatStar level stabiliser. This allowed for a unified, consistent and optimal approach to running the rougher circuit. This paper describes the improvement in the stabilisation of the circuit achieved by the FloatStar level stabiliser by using the interaction matrix between cell level controllers and the results and benefits of implementing the FloatStar flow optimiser on the rougher train.

Aug 8, 2011

By G Sartor, A Rich, D Grimsey, R Forzatti, M White

An in-depth process model was developed for the pyrometallurgical, off-gas systems and water balance of the Kalgoorlie Nickel Smelter. This model was used to assess plant capacity with changing concentrate grades, increased throughput and tighter environmental emissions under a range of potential future operating conditions. Comparison of modelled results allowed for flow sheet optimisation across a range of metrics including sustainability, processing capacity and costs. Process modelling software, METSIM® (ver 2020.06 by METSIM International), was used to simulate the flash furnace, integrated electric slag cleaning furnace, Pierce-Smith converters, matte granulation, waste heat boiler, hot gas handling equipment, wet gas cleaning plant and acid plant. The METSIM® model was divided into three separate, yet interconnected models: metals, off-gas and water balancing. This allowed for improved modelling efficiency and traceability while minimising manual error. The METSIM® model was supported by inputs from other specialised software. Chemical thermodynamics software, FactSage™ (ver 8.2 by GTT Technologies), was used to establish relationships for the flash furnace fluxing strategy and determine the operating temperature. Arena® (ver 16.0 by Rockwell Automation), a discrete event modelling software, was used to simulate material movements within the aisle as well as Pierce-Smith converter operation, allowing for integration with upstream and downstream systems. A dynamic data exchange (DDE) was used to connect the results of each software package, interfacing through Excel® (version 4203 by Microsoft). The integration between models provided a streamlined approach to test capacity, bottlenecks, water consumption and emissions under a range of operating conditions, enabling a more robust process. Further downstream modelling techniques were used to assess mechanical equipment. METSIM® outputs provided key parameters for combustion assessments using computational fluid dynamics and finite element analysis for the furnace mechanical design.

Aug 21, 2024

By Greaves M. C, Amos M. D

A study was made of the instrumentation and technique of atomic absorption spectroscopy developed by Walsh of the Commonwealth Scientific and Industrial Research Organisation (CSIRO), Australia.The method was evaluated for the determination of silver in lead sulphide concentrate. The precision of the procedure developed is equal to that of the uncorrected fire assay method and the accuracy is greater.Brief mention is made of the use of this technique for the determination of silver and other elements in ores and concentrator products.

Jan 1, 1994

By R Benton

Since commencement of underground production in March 2006 the Kencana K1 orebody has delivered over 0.9 Mt of ore containing 1.18 Moz Au until April 2009. The Kencana deposits are part of the Gosowong goldfield located on the island of Halmahera in eastern Indonesia. The district has produced over 2.3 Moz since mining commenced in 1999 with the first two deposits extracted by open pit methods. The K1 deposit is technically challenging being a vein style deposit with poor to very poor ground conditions and a relatively low overall dip of around 45 degrees to mine grid east. It is mined under geological control by underhand cut and fill methods utilising cemented paste backfill aiming for 100 per cent extraction. With these conditions the operation was mine limited in the initial two years of production resulting in low stockpile levels for mill feed blending and hand-to-mouth mine to mill production. Mill feed rates have increased from 30 t/h to 55 t/h over this period following business improvement projects while mine production has escalated to match this increase as deeper levels of the deposit are accessed. The operation has now become mill limited. Monthly mill gold production from Kencana has ranged up to 50 000 oz with head grades ranging between 8 g/t and 122 g/t Au on a daily basis. As individual grade control assays can extend into the per cent Au range there are challenges in sampling, modelling, mining, blending and milling the Kencana orebody. At the time of commencement of ore driving in K1 the national geology team had little prior experience in underground mining and systems were in early development. The variances in feed grade and tonnages have been reduced with time as the operation evolves and business improvement initiatives are undertaken to smooth peaks and troughs in ore supply. Two such initiatives in the geology department have added over US$20 M of additional revenue per annum.

Jan 1, 2009

In many mining operations, the truck and loader equipment represents the bulk of the invested capital and the majority of the mine operating cost. The profitability of these mines is therefore critically linked to the efficiency of the truck and loader operations. The various factors which affect the productivity of trucks and loaders are analysed by computer simulation, and the results presented in a form allowing assessment of the importance of each factor on overall productivity.

Jan 1, 1983

Mining is a high risk, high capital and potentially high reward undertaking. A large proportion of the risk comes from a lack of definition of the orebody (which also provides some of the potential) and the unpredictable nature of the market. This makes the planning process difficult but encourages the development of a robust yet flexible mining system. The system should be capable of absorbing some deviation from the anticipated concept without a significant impact on profitability. The mine planning process tends to consist of a series of related but discrete stages. For instance, the pit shells are designed, a schedule for the pit shells is created, a plant fleet is chosen to achieve the schedule and a financial analysis is carried out on that scenario. It is likely a few iterations are carried out using various mill throughputs to produce a favoured financial result. The problem is that handing results from stage æBÆ for use in æCÆ doesnÆt encourage a flexible system. æCÆ is likely to be built for exactly æBÆ. Unfortunately, in mining, æAÆ (the orebody) has the highest potential for variability and impacts everything else downstream. æDÆ the market also has high potential for unplanned variability. These variations can spread and æreverberateÆ through the whole mine process. For example an unexpected increase in ore oversize impacts all downstream mine processes to the primary crusher which may in turn create problems back æupstreamÆ by restricting throughput rate. Also an unexpected drop in demand or price could require modifications to the planned production rates. This paper looks at how mining process simulation can be used to support the development of strategies to counteract unforseen circumstances or alter production to match fluctuations in demand and price.

Jan 1, 2003

By Glenn R. J

Treatment processes are outlined for the recovery of rutile and zircon from the heavy mineral-bearing sands on the east coast of Australia. With the exhaustion of the higher grade deposits and the imposition of more rigid specifications for the finished products, strict metallurgical control has become necessary.A description is given of the methods used by The Titanium Alloy Manufacturing Co. Pty. Limited to control the operation of suction dredging, of wet concentration using fans and spirals, and of dry separation using high tension and electromagnetic processes. By applying these methods a plant designed for an output of 15,000 tons of rutile per year has been tuned to produce over 20,000 tons of rutile and a corresponding amount of zircon.Details are given of (a) the method of drilling to determine the extent and grade of the ore bodies, (b) a simple electrically-timed pneumatic automatic sampler, and (c) the methods developed for the physical estimation of quartz, rutile, zircon, ilmenite and "others" in the products of plant operation.The method used for calculating the metallurgical balance and the forms used for the reporting of production results are presented.Examples are given which show the value of this detailed production and metallurgical control of plant operation.INTRODUCTIONThe organization which is now known as "The Titanium Alloy Manufacturing Co. Pty. Limited" (T.A.M.Co.)-a subsidiary of National Lead Company-commenced operating at Yamba, N.S.W., in 1935. A mixed natural concentrate was at first simply dried and bagged and later was upgraded by the removal of silica and the lighter heavy minerals on shaking tables and, after air-drying, was bagged for export. At that time zircon was the most wanted constituent.

Jan 1, 1960

By L McCarthy, B W. Cuffley, O K. Thomas an

The Central Victorian Goldfield is a world-class field located in Victoria, Australia. It is currently undergoing a revival through activities in the Bendigo, Ballarat, Tarnagulla, Maldon, Castlemaine and other fields. Sediment-hosted auriferous gold-quartz reefs that are structurally and geometrically complex dominate the region. To date, no remote methods have been developed to assist in the targeting of the discrete high-grade oreshoots that characterise the mineralisation. An understanding of the structural setting and controls, and thus likely frequency of repetition of oreshoots remains the main exploration tool. Gold within the reefs is generally characterised by both its coarse nature (>100 up to 10 000 microns) and erratic distribution; as a result, most of the Victorian deposits are classed as high- to extreme-nugget effect systems. This characteristic ensures that mineralisation is very challenging to explore, evaluate and exploit. The key issues facing the explorer and miner are related to effective sampling, and definition of geological and grade continuity, and ultimately grade and tonnage. Tonnage can often be estimated to a reasonable level of confidence, whereas the grade estimate generally carries a medium- to high-level of uncertainty. In these deposits, surface diamond drilling alone is generally only able to define an Inferred Mineral Resource, with underground development, closely spaced in-fill drilling and bulk sampling/trial mining required to define Ore Reserves. The extraction of gold from ores is relatively simple, based on the coarse nature and hence amenability to gravity recovery. Ground conditions and the need for in-stope grade control (eg mapping, sampling etc), generally point toward mechanised cut-and-fill as the primary stoping method in the region. To potential investors this style of mineralisation has been viewed as high risk, because of the associated low confidence in the grade estimate, general paucity of Ore Reserves at mining start-up and need for underground development at the Feasibility Stage.

Jan 1, 2004

By Wilson AC

Permian coal from Western Australia's only producing coalfield at Collie is the dominant fuel used in generating electricity for the State's interconnected grid. Collie coal is sub-bituminous, non-coking and has a low ash, medium volatiles and high moisture content. The seams were laid down in a fluvial basin which extended beyond the Collie Basin and included the Wilga and Boyup Brook Basins at least. Adjacent parts of the southwest Yilgarn Block are prospective for Collie-type basins. In the past few years significant deposits have been delineated within the Perth Basin, specifically on the Vasse Shelf and in the Hill River area. In the former area high quality steaming coals are correlated with the lowest coal bearing member at Collie. The seams are amenable to underground mining and because of their high quality, the coal may have export potential. Sub-bituminous coal deposits of Jurassic age are present in the Hill River area. Exploration has down-graded the prospectivity of the Carnarvon and Canning Basins for sub-bituminous near-surface coal deposits. Tertiary lignite deposits are present in palaeo-drainage systems in the southern part of the State and their potential for development is being evaluated.

Jan 1, 1986

By M Dean, M Nehring, P Knights, M S. Kizil

Integrated continuous mining techniques such as fully mobile in-pit crusher and conveyor (FMIPCC) systems offer inherent labour, energy and environmental benefits to deep pit metalliferous mines. However, before such systems become commonplace, a number of barriers must be overcome.This paper outlines a number of commonly perceived barriers to FMIPCC application, together with a number of suggested solutions. The paper advances a design approach for specifying FMIPCC systems for deep pit metalliferous applications. A novel FMIPCC configuration is advanced using a hydraulic excavator in backhoe configuration. Because of the requirement to minimise belt extensions, a mine planning approach is presented based on a series of parallel and radial belt conveyor moves.The FMIPCC system does not fully replace truck-shovel systems. In the proposed mine plan, sinking is undertaken with truck-shovel systems using a series of box cuts, whereas pit ‘widening’ activities are accomplished via the FMIPCC system. Because of inherent differences in mine sequencing, the net present value derived from the FMIPCC mine will differ markedly from that derived from traditional, nested-pit, truck-shovel mining approaches. Therefore, any comparison of the FMIPCC and truck-shovel approaches must take into account radically different mine planning approaches.CITATION:Dean, M, Knights, P, Kizil, M S and Nehring, M, 2015. Selection and planning of fully mobile in-pit crusher and conveyor systems for deep open pit metalliferous applications, in Proceedings Third International Future Mining Conference, pp 219–226 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 4, 2015

**Add abstract here**

Jun 1, 2010

Longwall mining operations have been in place in Australia since the early 1960s. This mining method is currently used to extract the bulk of coal obtained from underground mines in Australia (CSIRO, 2010). Despite the high tonnages extracted the expected utilisation of much equipment remains relatively low. To some extent this level of utilisation is influenced by the variability in conditions inherent in the mining process. This variability in production rates presents challenges to those attempting to design a coal clearance system. The difficulty is to design a system that has sufficient capacity to support production, without over capitalising or incurring high operating costs. The need to allow for a series of largely unplanned events in the design of a coal clearance system makes simulation modelling an ideal technology to employ. Simulation modelling is a methodology that allows a system with interacting components to be modelled over time, while explicitly taking into account unplanned events that may disrupt operations.This paper discusses how dynamic simulation models have been used to assist in the design of coal clearance systems. Typically this type of modelling has been used to look at the likely profile of production rates from the Longwall shearer and to determine how well various proposed combinations of belts, bins and stockpiles would support production.

Sep 26, 2011

By S M. Arndt, D Tyler, F Reusch

Although significant advances have been made in understanding the mechanics of pit slopes, numerical modelling hasnÆt significantly impacted on the reliability of the design process. It is well known that legacy modelling approaches donÆt simulate large slopes well. In recent times, the emergence of very large finite element (FE) models with more than ten million degrees of freedom and the ability to simulate a large number of discrete structures, has allowed a step change in the simulation precision for slopes. The model size allows global and local effects to be realistically simulated in one model for the first time and the process can be better integrated into normal open pit slope engineering processes. Some examples of simulation of very large open pits are shown that demonstrate the challenges and some recent advances in modelling large slope behaviour. Significant limitations in the current measurement and observation regimes of open pits have been identified.

Jan 1, 2007

Mount Isa Mines Limited has been mining copper ore for 50 years. In recent years, this production has been entirely by open stoping methods with cemented backfill, mostly in the large 1100 orebody.This has been the major ore source for 20 years, with smaller amounts coming from the 400, 500, 650 and 1900 orebodies. At present, the 1100 orebody is the only source, and this situation will continue until the deep 3000 and 3500 orebodies begin producing in late 1992/93. Production rates have increased to almost 6 Mt/yr, and are planned to rise to 7 Mt/yr by 1995/96. In the future, there will be a move towards variations of the open stoping system as production moves to more lensy zones of the southern 1100 orebody and to the deeper 3000 and 3500 orebodies. This paper describes current operations in the 1100 Orebody, with some indications of future directions.

Jan 1, 1993

A simple method of designing effective fill drainage systems for slurry backfill is presented. By using the proposed method, it is easy to calculate and predict the expected fill drainage rates or to provide additional drainage systems to accelerate the fill drainage. The fundamentals of hydraulic fill and an efficient method to determine its permeability is also explained. The safety in hydraulic filling and bulkhead stability depends totally on achieving effective drainage regime for the fill. This paper provides the basis for creating such efficient drainage regimes. The recent fatal fill bulkhead failures in Australia were the result of poor drainage from the respective fill masses, and therefore it is more important to provide suitable drainage arrangements to continue using hydraulic fill to the benefit of the mining industry. At present there is no procedure available to mine operators to estimate the expected bulkhead pressures to design a satisfactory bulkhead. Some mines are constructing bulkheads after their initial investigations carried out years ago. Other mines have simply borrowed the ideas from the pioneer mines and using in their areas. It is high time that we develop a rational approach to estimate the expected bulkhead pressures for the design of bulkheads. We need a simple model that could be understood and used by the mine operators on a day-to-day basis. This paper also presents a model to predict the bulkhead pressures for designing safe bulkheads.

Jan 1, 2002

By G Davison, C Rossimel, M Bouazza

Expanding rock bolts anchor within a rock mass more efficiently than non-expanding varieties. This is of great importance in weak ground conditions, where grouted friction bolts perform less efficiently than in good ground conditions. Filling a Split Set with demolition concrete has been shown to double the load-carrying capacity when compared to conventional use of Split Sets. This report details verification of these results by installing and pull-testing 14 Split Sets of varying grout conditions within in a fault zone. These Expanding Split Sets achieved loads double and triple that of ungrouted and normally grouted conventional Split Sets. A literature review and chemical analysis were conducted to understand the expansion process better. It was found that 20 per cent more calcium is included in expanding cement, which is responsible for its growth. Factors most affecting the expansion process were identified. Furthermore, the expansion rate of a bolt outside a borehole was measured and 6 mm of expansion across its diameter was found. The compressive properties of the cement were compared with other types, due to expanding cement becoming uncohesive after the expansion process is complete. When confined within a Split Set, compression testing demonstrated that this grout is just as strong and rigid as normal grout. Finally, the bolts were tested by shear and it was found that the Expanding Split Set (ESS) has a similar shear capacity to grouted Split Sets, which is 70 per cent higher than that of ungrouted Split Sets. These results enabled the mechanism for improved performance in weak ground conditions to be verified. Expanding grout will expand the Split Set into its borehole of varying diameter and lock it into place, creating increased friction and resistance to pull-out. This paper shows that ESSs can be a useful reinforcement technique in weak ground conditions.CITATION:Rossimel, C, Davison, G and Bouazza, M, 2014. An investigation of expanding split sets in weak ground, in Proceedings 12th AusIMM Underground Operators’ Conference 2014 , pp 159–170 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Mar 24, 2014

By Weller K. R, Trahar W. J

The Mount Lyell Company treats some 2.3 million tonnes of ore annually, mined from a number of orebodies on the field. Blended ore is essentially a quartz-sericite schist containing about eight per cent of pyrite and three per cent of chalcopyrite. Four-stage crushing and two-stage ball milling are followe by selective flotation for copper. Pyrite is recovered from the coarse fraction of dopper circuit tailings. A detailed survey involving examination. of 82 samples provided information on the size- by-size behaviour of the principal ore constituents throughout the grinding, copper flotation and pyrite flotation sections of the circuit. Results for the copper and pyrite flotation sections are presented in the paper, and it is shown that over half the copper reporting to the final tailing (5% of copper in the feed) is plus 100 microns and that the major pyrite loss is in the desliming cyclone overflow. These data proVide a basis for assessing potential methods of circuit optimisation.

Jan 1, 1977