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Mr. President, Ladies and Gentlemen, it gives me great pleasure to welcome you, on behalf of the Council and Administration, to this University and extend to you our very best wishes for a most successful and stimulating symposium. We as a College of the University of N.S.W. were always proud of the excellent support we received from your Institute members and the close association that existed between our organisations. Now we have matured into the University of Wollongong and have to stand on our own feet, we will need all the support we can get from such bodies as yours to ensure that we are not only producing graduates but are also playing a vital role in the community. Although there is no planning for a school of Mining Engineering in the near future, we do look forward to this being a viable proposition eventually and we will then be able to offer to your Institute wider facilities for your activities and ones which will embrace both the Mining and Metallurgy phases. Thank you Mr. President.

Jan 1, 1975

By A M. Nyembwe, A M. Garbers-Craig, R Cromarty

With the depletion of high-grade lump iron ore, concentrates have been identified as an alternative material for sinter making. Adding concentrates to the sinter mixture reduces sinter bed porosity and gas flow through the sinter bed. This will result in lower sinter strand productivity. A potential solution to this problem is to add concentrate in the form of micropellets. This study investigates the effect of concentrate and micropellet additions on the permeability of the sinter mixture. Permeability was measured on sinter mixtures containing ten to 40 per cent concentrates and micropellets at various moisture contents. The effect of concentrate and micropellet addition on the permeability–moisture relationship was examined. The results confirmed that the addition of concentrates into the sinter mix decreases the maximum permeability of the sinter bed. The incorporation of micropellets into the sinter mix reduced the permeability less than concentrate addition. The study also showed that the maximum permeability of sinter mixes containing concentrate is reached at the same moisture content as the sinter mixture without concentrate addition. For sinter mixes containing micropellets, additional water must be added to obtain maximum permeability. Parameters including the granule size, void fraction and angle of repose were also investigated to evaluate their effects on the sinter bed permeability.CITATION:Nyembwe, A M, Cromarty, R and Garbers-Craig, A M, 2015. Effect of concentrate and micropellet addition on iron ore sinter bed permeability, in Proceedings Iron Ore 2015, pp 69–76 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

I The South Platform of the Gippsland Basin is an extensive area of shallow basement covered by a relatively-thin Late Mesozoic-Cainozoic section. Although the sporadic exploration to-date has not resulted in any hydrocarbon discoveries, the area is under-explored and its taste potential has not yet been fully evaluated. The best potential appears to be in areas underlain by the Golden Beach Megasequence where structures are mainly related to basement fault blocks.

Jan 1, 1992

By S Wellink, D Chalmers, D Adermann, C Martin

The practice of recording blasts for quality control purposes has been conducted for several decades. However, at the low frame rates of a standard video camera, essential data is frequently missed as it occurs when the shutter is closed between frames.The use of high-speed video for the research, development and monitoring of the performance of blasting procedures is a well proven but under-utilised practice.The recent development of low cost, easy to use high-speed digital cameras and user friendly software can deliver a capability into mine management as a day-to-day production tool that can greatly improve blasting performance and reduce costs.Digital high-speed video and image analysis software can accurately quantify each blast. Analysis of the images can facilitate the identification of causes of variance from design, geology changes, errors in blast practice and areas of poor performance. The use of high-speed video greatly enhances the audit and review processes so that future blast design can be quickly and appropriately modified to deliver improved blasting performance and reduced costs.The three videos demonstrate the differences between standard video and high-speed video and the detail that can be obtained from them. These videos of open cut blasts can be used to identify blast performance variances. Capturing images at 1000 frames per second allows the analysis on a millisecond timescale where detonator timings, fragmentation, venting, fume generation and flyrock can be accurately identified.CITATION:Adermann, D, Chalmers, D, Martin, C and Wellink, S, 2015. High-speed video – an essential blasting tool, in Proceedings 11th International Symposium on Rock Fragmentation by Blasting, pp 471–476 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 24, 2015

By B Hawkins, S Durkin, V Lawrence

The requirement for secondary egress from underground workings has long been regulated in Australia. Escape way systems have evolved from simple airleg rising ladders and timber ladders to steel galvanised ladders and more recently fully enclosed polyethylene ladders.The polyethylene ladder, Safescape Laddertube, was introduced to the underground mining industry in 2010. It is an enclosed cylindrical modular plastic ladder designed for use in underground escape ways and access ways. Since its first installation in May 2010, the Laddertube has been installed in 43 mines across four countries, totalling 8800 m of ladders installed to December 2013.The Cracow Gold mine is one operation using Laddertube, located 500 km north-west of Brisbane, Queensland, Australia. Upon discovering and developing both the Empire and Roses Pride orebodies, a safe and economically viable secondary egress system and surface primary ventilation exhaust shafts were necessary to support development and production activities to these workings. The need arose to merge these two critical requirements together between surface and underground mine workings some 200 m and 400 m respectively for each orebody. Neither egress has intermediate access points within their full service length from top to bottom. Several options were considered, the preferable and most feasible method adopted was Laddertube.The longest egress length requiring Laddertube within the two vertical surface exhaust shafts was 400 m long, within a 3.5 m diameter shaft. Due to the length of the vertical Laddertube system in both egresses, personnel are to be assisted by mechanical means using the Extended Ladder Climb Assist system.The Gossan Hill mine also uses Laddertube for their escape ways. Part of the Golden Grove operation, Gossan Hill is an underground sublevel open stoping mine located in the mid-west of Western Australia.With a considerable mine life remaining and a history of acidic water and stress related deterioration in vertical openings, the mine operators sought an escape way solution that would provide for the long-term needs of Gossan Hill. Laddertube was selected due to its non-corrosive properties and the ability to fill in around the ladder way to provide stability to the raise opening.Laddertube is a recent development in escape way systems, and is effectively being applied in a variety of operations, meeting the specific needs of underground mines.CITATION:Durkin, S, Hawkins, B and Lawrence, V, 2014. The application of Safescape Ladders at the Cracow and Golden Grove operations, in Proceedings 12th AusIMM Underground Operators’ Conference 2014 , pp 311–318 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Mar 24, 2014

By B Jones, M Chappell

Installing ground support correctly is not an easy task, whether lack of operator training, poor ground conditions or underperforming equipment. Confirming the quality of installation can help with planning and remedial works and help to maintain a safe working environment. A 2?m bolt with 700?mm of encapsulation will pass a 10?t pull test (assuming ground conditions permit); however, it will not provide any data of the unencapsulated length and thus the ability to withstand corrosion. Complimentary testing in the form of non-destructive testing (NDT) can provide factual data that leads to the assessment of the quality of the encapsulation. By improving the quality of the encapsulation, the risk of corrosion is reduced, the ground support durability is improved and hence the asset life is enhanced.This paper presents a case study of a trial using the NDT system RokTel™. Installations of varying quality were installed and tested. The characteristics tested were corrosion, load and free length. These characteristics can be tested and assessed for cable bolts, thread bar bolts and split sets. The aim of this paper is to present NDT testing as a viable method for assessing installation quality and ongoing performance of the ground support.CITATION:Jones, B and Chappell, M, 2014. A non-destructive testing method for measuring bolt condition, in Proceedings AusRock 2014: Third Australasian Ground Control in Mining Conference , pp 307–314 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 5, 2014

By E Amini, M Scott

Grade Engineering® involves the planning, integration and operation of coarse preconcentration techniques to reject uneconomic material as early as possible in the mining value chain to improve the quality of ore delivered to mineral processing activities. These preconcentration techniques include screening for natural and induced deportment of grade to finer size fractions during blasting and coarse breakage, sensor-based measurements of grade and mechanised sorting at particle or bulk scales and coarse gravity separation. Over the last decade, the Cooperative Research Centre for Optimising Resource Extraction (CRC ORE), with the support of its participants, has developed a framework for the holistic evaluation of economic and production impacts attributable to these preconcentration techniques. The framework combines the characterisation of preconcentration responses, geostatistical modelling, process modelling and simulation of downstream and upstream production impacts and the optimisation of strategic mine plans to quantify changes in net present value due to different preconcentration strategies. This framework has been applied to evaluate preconcentration techniques at numerous metalliferous operations and can also be used to quantify changes in the environmental metrics for energy, water and steel consumption and emission, tailings and waste rock production. This paper collates the results of these Grade Engineering® studies to show the range and magnitude of economic and environmental impacts attributable to preconcentration. The studies have shown that rejection of uneconomic material prior to mineral processing activities can have a pronounced improvement in energy, water and comminution steel productivity, emission intensity and the profitability of metalliferous mining.

Nov 10, 2020

By M Svartsjaern, D Saiang and K Mäkitaavola

The Kiirunavaara mine is a large-scale (28 Mt/a) iron ore mine located in northern Sweden. The mine is owned and operated by Luossavaara-Kiirunavaara Aktiebolag (LKAB) using sublevel caving (SLC). The SLC area underlies an open pit decommissioned in the 1950s, the current main SLC haulage level is situated at an depth of 1100 m. The main orebody dips 60 degrees to the east with a distinct boundary defining the hanging wall to the east and footwall to the west. Since the 1980s damage has been observed both in the footwall rock mass as well as on the footwall crest of the open pit. Recent investigations indicate that the underground footwall damage is primarily controlled by large-scale slope failure mechanisms. Structurally controlled near-vertical planar shear failures in the upper footwall appear to be driven or facilitated by a step-path like curved shear failure situated in a zone starting ca 250 m, and intersecting the SLC about 100 m above the active mining level. To confirm this failure evolution a pilot underground measuring system has been designed and installed to monitor the expected rock mass displacements indicated by numerical models based on the above mechanisms. The systems consists of 50 m time domain reflectometry (TDR) coaxial cables installed in the footwall both across and away from an estimated damage extent boundary to monitor shear movements along natural joint surfaces. The TDR installation is combined with long extensometers to facilitate differentiation between diffuse shear and rock mass normal expansion. Additionally, a low-tech system of tape extensometer lines are installed in drifts and stopes running perpendicular to the ore strike to monitor horizontal displacements in the infrastructure as the footwall ‘slope’ loses confinement during mining advance when the mined out areas are replaced by caved rock from the hanging wall.CITATION:Svartsjaern, M, Saiang, D and Mäkitaavola, K, 2016. Underground footwall monitoring at the sublevel caving mine – Kiirunavaara, Sweden, in Proceedings Seventh International Conference and Exhibition on Mass Mining (MassMin 2016), pp 773–780 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2016

By Morley I. W

In the year 1926, Edie Creek, in the Morobe District of the Mandated Territory of New Guinea, saw the greatest gold rush of recent years. Situated 35 miles inland from the coast, and at an altitude of over 6000 feet, Edie Creek presented to the original prospectors a wet, jungle-clad uninhabited, and inhospitable region. There were no roads; and the only means of approach from the equally inhospitable coast was by an eight to ten days' tramp through coastal swamps and gorge-scarred mountains. All food supplies and equipment had to be carried on the backs of "kanakas," and in many cases through country occupied by hostile natives.Since the first discovery of payable gold at Edie Creek, mining on the Morobe Goldfield has shown remarkable progress, and in spite of the tremendous natural difficulties, the field today ranks as one of the most important in Australasia.Aeroplanes, more than any other factor, have been responsible for this rapid development. They provide the only means of transport from the coast, and at present serve the needs of over 600 Europeans and 3000 indentured native labourers engaged in the industry.

Jan 1, 1933

By D Howe

The Athena gold deposit was discovered in 2007 by Gold Fields Australia Ltd, at the St Ives Gold Mine, 35 km southeast of Kambalda, Western Australia. Gold anomalism was identified in sheared Paringa Basalt as a result of a regional scale aircore drilling program, in association with geophysics. In the 18 months following discovery, the deposit was intensely drilled and by June 2009, it was announced that the Athena deposit contained an ore reserve of 1.7 Mt @ 5.6 g/t for 316 koz. This was followed by a feasibility study, and as a result mine development commenced in November 2009.The Athena mineralisation is hosted in a discrete, north-south striking, steep to moderately dipping shear zone within the southwest dipping Paringa Basalt. Vein intensity has a strong correlation to grade and vein type varies from early thin quartz-albite-sulfide (pyrite and/or pyrrhotite) shear parallel veins to strong brecciation and irregular veining with quartz-albite-actinolite-biotite-pyrrhotite infill. The geology preproduction process developed at the Argo mine was refined and improved following a business improvement project. The aim of the process is to construct detailed geological interpretations prior to development allowing informed mining decisions to be made. The process delivers significant cost savings and revenue enhancements.The development of macroscopic classification scheme was critical to determine ore or waste in the early phases of mining. The Style of Deformation, Alteration and Veining (SAV) Code was the result, and has been enhanced as greater geological knowledge is gained over time.

Aug 22, 2011

By A Purwodihardjo

Evaluation of the construction method used for the pedestrian underpass construction at Ipswich Road, Brisbane, Australia is presented in this paper. The pedestrian underpass was constructed through the existing railway embankment between Harrogate and O’Keefe Streets on the eastern side of Ipswich Road. This underpass construction is part of the CLEM7 tunnel project (formerly known as the North-South Bypass Tunnel) which is the longest toll road in Australia at a total length of 6.8 km. The jacked box construction technique was initially identified as a preferred option during the tender and concept design phases. However at the final design stage, the cut and cover technique was selected as this method can reduce the construction time and cost significantly. The design and construction teams effectively managed the challenges, complexities and risks associated with undertaking cut and cover tunnel through the existing heavily utilised rail embankment. The on-site construction time for the underpass using the cut and cover technique was reduced to less than 42 hours.

Mar 8, 2011

By C Woodall, G Jardine

The Henty Gold Mine, located in Western Tasmania uses innovative solutions to effectively manage a mining operation in an environmentally sensitive setting and has been presented with several environmental awards. Fill is required as part of the mining method to provide passive ground support, minimise rock exposure and ensure maximum recovery of the small but high-grade orebody. The use of the whole portion of leach residue in the backfill reduces the surface tailing disposal requirements. Therefore, High Density Paste Fill (HDPF) has been selected as the most appropriate fill method to meet these objectives. Additional benefits include the minimisation of excess water from fill and the subsequent need for the collection and treatment of water and slimes. There are minimal equipment requirements during placement, thereby optimising mine resources for production. This paper covers the development of a suitable paste fill system to meet the specific needs of the Henty Gold Mine and the successful commissioning of this system for the first time in Australia.

Jan 1, 1998

By J Vann

Mineral Resource and Ore Reserve estimation is a challenging and demanding field, requiring application of professional knowledge, skill and experience of the highest order. If the many potential pitfalls are to be avoided, however, there are two other requirements which are of equal, if not greater, importance:good communication, and common sense. Estimation of Mineral Resources and particularly of Ore Reserves is almost always a team effort, involving a number of disciplines. Good teamwork requires good communication, both between team members and between the team and other parties having an interest in the process. Breakdown in these lines of communication can have far reaching effects on the project under consideration. The need to use common sense during a Resource or Reserve estimation exercise would seem to be self-evident. It is surprising, however, how often rigid adherence to procedures and methods prevails at the expense of clear thinking, usually with adverse and sometimes fatal effects on the project under consideration. This has become increasingly true as computerised methods have assumed a central role in Resource/Reserve estimation. The critical question that estimators should ask themselves at all stages of the process is: æIs what is being done sensible given the data available, what is known of this deposit and the purpose of the exercise?Æ

Jan 1, 1999

By E J. Coyle, L A. Millington

Tailings storage facilities are geotechnically complicated structures that develop heterogeneous strength profiles and varied porewater conditions. The monitoring of porewater pressures is one of the only direct measurements that can be performed to monitor the performance of a facility throughout its life and is of particular importance in upstream facilities. Foundation underdrainage, continuous and staged tailings deposition, climate inputs (rain, snow, humidity, evaporation, etc), and stratified tailings permeabilities can complicate this critical measurement that introduces uncertainty to stability analyses. These difficult conditions manifest in vibrating wire piezometer measurements as very low or negative pressure readings, both of which are within the instrument’s range of accuracy. However, the data can be difficult to interpret, and a range of interpretations are adopted from optimistic low phreatic surfaces to conservative fully saturated tailings. Where tailings are potentially liquefiable, these very low readings introduce further uncertainty regarding the pore space saturation ratio and liquefaction potential above the estimated phreatic surface. This area of uncertainty is the vadose zone, and its affect on tailings behaviour is not well understood. The two facilities analysed in this paper are upstream, raised embankments with tailings classified as clayey, sandy silt that have been found to be potentially liquefiable. The vibrating wire piezometers (VWP) at both sites show very low or negative readings when they are initially installed near the surface and then go through cycles of re-saturation and de-saturation. Eventually the readings settle as the VWPs are buried deeper within the tailings. The instrumented sections within the tailings column do not show consistent readings that would be indicative of a hydrostatic phreatic surface at either site. Rather, they are highly variable and can be interpreted as either representing a high phreatic surface within the tailings or as a ‘perched’ phreatic zone within the tailings layers. How the VWP data is interpreted has a significant impact on how the facilities are raised and operated. The design outcome for Site 1, which adopts a lower phreatic surface, results in an embankment that meets factor of safety (FoS) requirements under residual strength conditions without any buttressing. Conversely, a conservative (high) phreatic surface has been adopted for Site 2 and has resulted in the facility requiring a significant buttress to meet FoS under residual strength conditions.

Jul 1, 2021

By O Joneydi, J Viljoen, R Funnell

Computational Fluid Dynamics (CFD) modelling is a useful tool that can assist engineers in designing effective ventilation systems for the control of airborne dust generated during mining operations. Thistechnology can save time, effort and the costs associated with re-work or the traditional on-site experimental field trials by running desktop 3D simulations of the various proposed scenarios using state-of-the-art CFD analysis tools. Before implementing a dust management system, an understanding of the behaviour of airborne dust particles in the face zone can be achieved, which can improve the confidence in the secondary ventilation and dust management design. Usingadvanced numerical models, suitable dust extraction strategies can be foreseen, and multiple scenarios can be simulated and investigated quickly. As a case study, dry drilling operations in Kimberlite orebodies produce large quantities of fine dust which poses health and safety risks. An effective dust management system is required to achieve acceptable face conditions. A possible practical solution is a ducted exhaust ventilation system with a force fan in the face zone. This paper demonstrates how CFD analysis can be used as a tool to assist the design engineer with validating and optimising the proposed ventilation design by tracking the trajectories of different size dust particles, to determine the best equipment layout and appropriate flow rates which minimises airborne dust.

Oct 12, 2022

By T Medhurst

Recent developments in geophysical borehole log analysis using the Geophysical Strata Rating (GSR) are now routinely used in a number Australian coal mining operations. This allows development of 3D geotechnical strata characterisation models for a range of purposes. The availability of this data provides a means to identify relationships between ground conditions and ground behaviour. As a result, several new design methods have been developed to assist in the strata management process such as roof support, longwall shield design and shaft stability assessment. This paper outlines these methods and provides examples of their application. CITATION:Medhurst, T, 2018. Geotechnical strata characterisation using geophysics and its application for coal mine design, in Proceedings The Fourth Australasian Ground Control in Mining Conference (AusRock), pp 420–433 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 30, 2018

By J Brisebois

The Wisemans Creek derelict mine site is located in native forest approximately 150 km west of Sydney. Mean annual rainfall at Bathurst, 20 km to the north, is 634 mm and reasonably distributed throughout the year, with slightly more rain falling in the summer months. Evaporation is 1350 mm per annum and considerably exceeds rainfall in all but the winter months (May to August). This results in a water deficit for much of the year. Groundwater is relatively deep, as it has not been intercepted in the shallow open cut workings. Investigation of the groundwater regime was beyond the scope of the current study. Mining has taken place on the site for almost 100 years, during which copper, talc and gold have been sequentially extracted from surface and shallow underground workings. The site is now characterised by the presence of small open pits, unprotected shafts and adits, mullock heaps and an unconfined tailing deposit from a small cyanidation plant. From a distance, the mine area is visible because of two distinct steep bare slopes below the relatively small mine workings and mullock heaps. The mining area was characterised in terms of its environmental, safety and heritage issues. Mullock from the early copper mining was found to be acid forming and leachate from this, combined with clearing of timber, has most likely resulted in death of vegetation below the heaps. The mullock also contains elevated concentrations of heavy metals. The gold tailing is apparently benign and not acid forming, although there are indications of oxidation and acid formation in the derelict gold open cut. Oxidation of the acid forming mullock still appears to be taking place even after being exposed to the atmosphere for at least 50 years, resulting in continued contamination of the slopes below the heaps with heavy metals. The concentrations of metals decreases with distance below the mullock heaps and also is confined to the ground surface the further away from the mullock, providing further evidence to support the theory that the mullock is the source of contamination. Despite this continuing contamination, its spread beyond the immediate mining area appears to have been limited because of the relatively dry climate, with only intermittent rainfall and stream flows. Irregular storm flows in the nearby creek could also have washed any contaminated soil some distance from the site and beyond the area investigated in this study. Remediation of the site and restoration of vegetation on the bare slopes will therefore depend on elimination of the source of acid and metals. Options for remediation, focussing on minimising cost by retaining the materials on or close to the site, are identified. The volume of the open cuts would appear to be close to that required for burial of the acid-forming mullock, thereby removing the source of surface contamination while keeping it above the groundwater table. However, implementation of this remediation plan will depend on the availability of funds to undertake the work through the New South Wales GovernmentÆs Derelict Mines Program.

Jan 1, 2003

By J L. Stacey

The diverse priorities, drivers and concerns of multiple stakeholders in the minerals industry complicate the integration of sustainable development considerations into mine design, as well as operational and strategic decisions. The ability of the industry to address all role-playersÆ needs, or indeed, to achieve consensus among all role players on the plethora of sustainable development issues seems a noble yet unattainable goal. One of the difficulties in assessing the relative importance of sustainable development issues across many stakeholders is the inevitable lack of impartiality in valuing these issues. Starting from a premise that transparency and fairness of the process are absolute prerequisites for progress, but that consensus is not, an approach has been developed in which all stakeholders are asked to assess the importance of all other stakeholdersÆ priorities, excluding their own. The approach recognises that stakeholders have different levels of contribution, understanding, vested interests, and perceptions of legitimacy and entitlement, across the diversity of sustainable development issues and decision criteria. Using Triangular Value Analysis, the relative weightings of each of the stakeholderÆs priorities are determined through a regression-like technique. The uniqueness of this approach is the manner in which self-assessment bias and overemphasis of stakeholdersÆ own priorities are avoided. The methodology can be used for both internal and external stakeholders, and in conjunction with other group decision making techniques, such as the nominal group or Delphi techniques. This paper will illustrate how Triangular Value Analysis may be applied in the minerals industry to determine priorities in various decisions relating to potentially conflicting sustainable development priorities within the industry.

Jan 1, 2009

By T Baumgartl, C Gonzales, A Soliman, M Edraki

A soil cover isolates potentially acid-forming (PAF) mine wastes from atmospheric interaction and thereby mitigates acid mine drainage. As a cover that comprises either a single layer or a composite barrier, it essentially manages percolating rain water from flowing into these PAF materials and minimises air flow as oxygen has low diffusivity in saturated soils. However, the availability of suitable soils as cover materials is limited, especially in arid and semi-arid regions where weathering rates are low.This paper investigates the potential use of mine wastes as cover materials in a water-shedding soil cover in north-west Queensland. Four cover trial plots were built using mine wastes as cover materials. Each 2.3 m cover trial plot consisted of a 1.5 m soil cover made up of waste rocks and fines, a 0.5 m drainage layer that consisted of 0.1 m waste rock aggregates and a base layer made up of blended mine tailings. The hydrologic properties of cover materials were determined by in situ measurements and laboratory experiments, which, in turn, were used as input in a numerical model that described the cover’s transient soil moisture profile. The successful performance of the cover is reliant on the long-term stable geochemical behaviour of the substrate used as cover material. Therefore, investigations were carried out to determine the geochemical properties of the cover materials constructed from benign waste rock using static and kinetic tests, with the objective to increase the level of certainty of the material’s benign characteristics. Consequently, the long-term performance of this water-shedding cover design is described in terms of the physico-chemical characteristics of its outflows.CITATION:Gonzales, C, Baumgartl, T, Edraki, M and Soliman, A, ?2014. Mine wastes as cover materials in a water-shedding soil cover in north-west Queensland, in Proceedings Life-of-Mine 2014 , pp 261–270 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 16, 2014

By B L. Coulter, E Wightman, A S. Burrows

With their commitment to sustainable development in an increasingly carbon-constrained world, many resources companies are focused on reducing the energy required to create their final products. In particular, the comminution and smelting of metal-bearing ores are both highly energy-intensive processes. If resource companies can optimise the energy efficiency across these two processing stages, they can directly reduce their overall energy consumption per unit mass of metal produced and thus reduce their greenhouse gas footprint. Traditional grinding and flotation models seek to improve the efficiency of mineral processing, but they do not consider the energy used by downstream metal production, eg smelting and refining. Concentrators and smelters individually may be running efficiently, but are they optimising energy consumption of the overall system? A key step towards answering this question is to understand whether it takes less energy to remove an impurity in the concentrator or the smelter. Analysis of the complete concentrator û smelter process chain may show that there are times when the concentrator should use more energy to reduce the overall energy requirements across the mill and smelter. The new methodology discussed here will integrate downstream processing energy with mineral processing energy, to find the overall most energy efficient circuit design and operating strategy. The proposed methodology includes: determining what grade and recovery positions can be achieved in the concentrator by using different combinations and amounts of grinding and regrinding, thermodynamic calculations of the energy used to process the different concentrate grades to metal, and integrating the concentrating and smelting models to find the lowest total energy for the system. A case study which investigates the effect of increasing regrinding energy on the overall mineral processing û smelting energy consumption is presented. For the copper-nickel sulfide ore investigated the addition of regrinding results in 11 per cent less energy being used in the overall concentrator û smelter process chain per tonne of metal produced. Although regrinding is often seen as an energy-intensive process, in this case study the use of 1 kWh of energy for regrinding reduces the overall energy consumption by 12 kWh. The new mill to melt methodology will allow companies to model energy consumption from mill to smelter with a view to reducing the energy-intensity and greenhouse gas footprint of their processing and smelting operations.

Jan 1, 2009