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By H J. Dalstra

High-grade iron ore may be derived from banded iron formation (BIF) through four fundamentally different processes:1. syngenetic precipitation of chert free BIF,2. residual enrichment by removal of gangue minerals from BIF to form bedded (residual) ironore,3. mechanical erosion of iron oxide and chert from bedded iron ore or BIF and re-deposition andupgrading as detrital iron ore, and4. chemical removal of iron from BIF and precipitation elsewhere as a secondary (channel) irondeposit.Finally, the BIF itself may constitute iron ore if a high-grade concentrate utilised for pellets or sinters can be derived from it through mechanical (industrial) separation of iron oxide by means of crushing/milling and mineral separation.Historically, exploration for high-grade BIF hosted iron ores was focused on the residual (bedded) deposits and driven by supergene concepts. Exploration for detrital and channel type iron ores was mostly secondary to exploration for bedded deposits, but recently, a more focused exploration effort has led to the discovery of enormous moderate to low iron grade deposits in the Pilbara region of Western Australia. Exploration for high-grade iron ores using syngenetic concepts has been limited,but together with exploration using hypogene concepts offers the best hope of fi nding concealed deposits. Exploration for BIF sources suitable for concentrate ores commenced in the ‘old’ iron ore provinces after the high-grade resources were depleted and has only recently gained importance in Australian BIF provinces, mainly as a result of high iron ore prices in the last decade.

Jul 11, 2011

By Hagan T. N

Quite apart from economic considerations, the following performance parameters must be considered when selecting an explosive for a particular blasting operation. 1. total energy yield/kg, and more particularly, strain energy/kg and bubble energy/kg of charge 2. charge weight/m of blasthole 3. sensitivity of the charge 4. water resistance of the charge The effective division of an explosive's total energy into strain energy (SE) and bubble energy (BE) is explained as is the influence of each energy component on blast results. Because some rocks require a high strain energy for effective breakage, while others are most satisfactorily fragmented by bubble energy, values of SE and BE are more meaningful than those of total energy. Unfortunately, our extensive knowledge of the effects of certain variables on total energy has not yet been completely supplanted by the influence of these variables on SE and BE values. Relative SE/kg and BE/kg values are presented for a range of explosives. The 'charge density of ammonium nitrate/ fuel oil (ANFO)-type explosives is essentially constant throughout the length of the charge; because of their compressibility, slurry

Jan 1, 1974

By A R. Penney

Safety management, both personal and that associated with catastrophic hazard, helps to define the success of mining companies. Personal safety management, often categorised by slips, trips and falls, has been widely addressed, with numerous approaches successfully adopted. Catastrophic hazard can lead to a single accident (eg ground collapse, underground fires etc) causing multiple fatalities. Catastrophic hazard management in mining is an emerging discipline, and as such there are various pitfalls to demonstrate its effectiveness and success; it is much more than simply meeting regulatory requirements. Various standards, guidelines, and leading practices are available for reporting key performance indicators. While measuring and reporting safety related key performance indicators (KPIs) such as Total Recordable Injury Frequency Rate (TRIFR), Lost Time Injury Frequency Rate (LTIFR), are important, they often lack detail, and give little insight into the effectiveness of catastrophic hazard management strategies and controls. Catastrophic hazards are low likelihood, high consequence events, and as such demand a different management approach. Companies cannot use the suite of personal safety metrics to help demonstrate management of catastrophic hazards. In-field verifications have revealed that senior management commitment to safety is often clear, well organised, and resourced. However, there are often some inconsistencies between what management promotes and plan, to what the operational teams understand and implement. Communication and clear understanding of expectations were the common themes identified to help empower supervisors to reinforce requirements of catastrophic hazard management. A lack of specific, measurable, and time-sensitive goals and objectives for the short- or medium-term, making it challenging to track progress was another key observation. Development of an integrated, multi-disciplinary auditing process executed by an experienced team of technical subject matter experts, provided an in-depth understanding of the requirements of catastrophic hazard management. Areas such as underground fire prevention, explosive storage, electrical safety, mobile vehicle interactions, ground control, inrush, and shafts and winders management have substantial overlap and intertwined processes, and similar strategies for emergency responses. Auditing of catastrophic hazards and safety management systems compliance is only the first step in safety assurance. Completing operational performance audits in technical areas and benchmarking the site verification of safety management documents and verifications forms a critical part to clearly demonstrate industry leading safety practices. No longer is it the external inspection or regular hazard management plan review requirements that dominate, but rather the culture of continual hazard identification, management, controls verification, underpinned by improvement and follow-up verifications of the corrective actions.

Mar 29, 2023

By J Morgan

Regular monitoring of surface deformation over mine sites is important for providing updated information to managers regarding geotechnical risks related to ground instabilities. This is particularly true in cases where unexpected or accelerating movement patterns are observed, as these trends may have implications related to worker safety within active mining environments, as well as continuity of ongoing operations. InSAR is an active remote sensing technique that uses radar satellite imagery to precisely measure ground movement. This technology has started to become a standard tool for monitoring surface stability in many different sectors, including underground and open pit/cut mining applications. In recent years the launch of satellites that collect radar imagery on a more frequent basis, coupled with advances in InSAR processing techniques, has improved both the extent to which movement patterns typical of mining operations can be characterized and the temporal scale on which results can be reported to geotechnical departments. As a result of these developments, InSAR monitoring can now better meet the operational needs of mine sites. An overview of the more recently launched satellites that have a particular relevance to the monitoring of mines is provided, along with an explanation of the InSAR tools that are the most valuable to mine managers and geotechnical engineers. First, broad differences between high resolution X-band imagery and low resolution (but freely available) Sentinel imagery are discussed. Second, the various InSAR tools and their particular applications for different types of mine sites and operations are covered, which include fast delivery deformation maps for short-term reporting, multi-interferometric algorithms for longer-term analyses and rapid movement tracking (RMT) for emergency monitoring or high-risk situations. The ability of the technology to resolve 2D and 3D movement is also touched upon. Practical examples of InSAR application over a variety of mine sites will be presented, as well as surrounding hazards including landslides, to illustrate how InSAR can help provide geotechnical engineers with a picture of surface stability over the full mine site and surrounding areas to help manage risk. CITATION:Morgan, J, 2018. Wide area mapping of ground instabilities from space: InSAR for geotechnical risk assessment and hazard monitoring, in Proceedings The Fourth Australasian Ground Control in Mining Conference (AusRock), pp 375–382 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 30, 2018

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

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

Aug 21, 2024

By J M. Wallis

Heavy mineral sand exploration drilling prior to the 1970s generally utilised open hole auger and air-blast type drilling. However, mining reconciliations were poor and limitations on accuracy and precision of drilling results were severe.Working with the exploration companies, Wallis Drilling principals designed various systems, including what was termed the ‘Eneabba System’ and then the ‘Capel Twin-Tube System’. Eventually the company with its improvements developed and patented the Aircore Drilling System.Aircore drilling has subsequently become recognised as an excellent drilling system for exploration and mine-sample drilling that gives good precision and accuracy in sampling both above and below water. Its use has also been extended to many other commodities and is used in a number of overseas countries.This paper documents anecdotally the development of the system, identifying problems encountered during the times it was evolving and of the means to overcome the problems as being the documentation of the story by the inventors and developers in Wallis Drilling Company. Aircore drilling system is a Western Australian technological development owing its existence to the designing and incorporation of a number of discrete improvements along the way and recognises the tenacity and inventiveness of all who contributed to the system, in both Wallis and also in a number of companies that gave the impetus to succeed.

Oct 5, 2011

By C T. Senra, A Souza

Increasing fuel prices, unavailabilty and high prices of tyres have imposed tremendous challenges for large open pit operations. Carajßs open pit mines, one of the largest iron ore projects in the world, has been particularly affected due to the high amount of giant trucks operating in this site. On the other hand, environmental constraints push the mining industry towards reductions in fossil fuels, noise and waste generation. As a feasible response to these requirements, an alternative mining method for open pit mining, aiming to reduce or even eliminate the need for trucks has been developed, based primarily on coal opencast continuous operations. This innovative approach for open pits involves the replacement of trucks by fully-mobile crushers, bench conveyors and ramp conveyors. Two different applications have been developed for exploiting waste and ore at Carajßs largest pit, named N4E. To make it possible, mine planning paradigms should be replaced leading to new conceptual design of open pits. This paper shows two case studies (waste and ore conceptual design) carried out at Carajßs mines to anticipate and put forward the future of open pit mining, proving that our industry would be greatly affected by this new way of exploitation, reducing thousands of tons of fossil fuels. Productivities can be enhanced and environmental performance greatly improved. In this approach mine automation can be easily implemented reducing operating costs and man's fatigue.

Jan 1, 2009

By G Capes, L Morizzi, N Mitkas, E Jones, D Grant

This paper describes the mining setting for the sub-level open stoping (SLOS) mining method used at Olympic Dam (OD), and investigates the range of stope performance conditions encountered over 30 years of production, using a qualitative description of the factors influencing performance. Utilising a continuous improvement tool, the Plan-Do-Check-Act (PDCA) process, and a forward-looking rock mechanics program, the intent is to identify the key factors driving productivity and performance to create a stable and achievable long term mine plan.

Mar 15, 2021

By Russell F. M

Following the accident in the Peterson section of Mufulira mine in September, 1970, a method had to be found of extracting up to 300 000 tonnes of ore per month from this area without inducing caving. Sandfill mining methods were chosen, necessitating a plant capable of producing both cemented and uncemented fill on a large scale. The paper covers the design and construction of this sandplant which is thought to be unique for its size, as it incorporates three 3 000 tonne capacity settled storage silos, a 500 tonne capacity cement silo, mixing tanks and a control room situated underground. The plant is designed to handle an aver- age of 440 tonnes per hour with a maximum of 660 tonnes per hour for limited periods, delivering either uncemented fill or cemented fill in proportions varying from 1:6 to 1:30. The instrumentation and equipment necessary to give one man operation of the plant is described and the fill mining methods now in use at Mufulira are briefly outlined.

Jan 1, 1973

By Whiten WJ, Narayanan S

Data from ball mills of a wide range of sizes are analysed using detailed mathematical models and non-linear least squares fitting techniques. This analysis reveals that the relative power inefficiency of large ball mills is due to inefficient grinding of coarse (plus 4 mm) particles in these mills. A qualitative physical hypothesis is proposed to explain this behaviour. The results of the analysis can be used to scale up ball mill behaviour, using the mathematical models and techniques developed. A simpler ball mill scale-up procedure is also proposed, and its limitations stated. Laboratory experiments are being conducted to determine the average size distributions of single particles of different ores after breaKage. These experiments can distinguish between the different ores, and it is hoped to use their results to model and predict the grinding of different ores in ball Mills.

Jan 1, 1978

By A H. Gray

Gekko Systems Pty Ltd engaged in the test work, design, manufacturing and commissioning of the pre-concentration plant at Silver Standard Resources Inc’s Pirquitas mine in the north western Jujuy province of Argentina. Testing of the ore at coarse feeds of between 2 and 12mm returned probable recoveries of up to a total of 95% silver into 50% of the mass fed to the InLine Pressure Jigs (IPJ’s). The plant has been designed and built based on the test results to include a preparation screen to bypass the fines that are naturally higher in grade and repulping of the coarse which is then pumped to three parallel trains of 2-stage IPJ roughing-scavenging. The target 50% yield to concentrate passes over a dewatering screen and the solids are returned back to the mill feed conveyor. The IPJ tails are transferred to a dewatering screen and solid rejects are stockpiled off the end of a transfer conveyor. All dewatered underflow products are processed via hydrocyclones to recover dirty water for use back into the IPJ circuit and return entrained fines to the fines bypass line.With the sulphide orebody being processed, the results from operations to date have shown that plant performance is matching the original laboratory sulphide ore testwork data. The objective of the pre-concentration step is to both reject gangue and achieve grades between 300-400g/t Ag to the float circuit as flotation recoveries are maximised within this range. The plant currently achieves overall upgrades of approximately 150% of feed grade with the IPJ only circuit producing an average 180% increase from calculated feed grade.

Aug 8, 2011

By E Lima, D Gregory, C Faria, A Lapworth

Open pit mine enterprises are complex systems that depend on multiple parameters such as mineral grade distribution, geotechnical characteristics, economic conditions and engineering requirements, all of which vary in time and space with a different degree of uncertainty. The unpredictable nature of these inputs imposes a risk to mine owners and shareholders which in the worst case can lead to highly undesirable financial outcomes.Desktop studies commonly examine a set of scenarios based on adjusting variables such as commodity prices, mining costs, processing costs, and metal recoveries to understand their relative impact on the economics of a project. It is less common to systematically explore and simulate hundreds of alternative physical designs to understand and compare the financial risk associated with one or more mining projects.This paper presents a risk assessment tool set and methodology that uses web based cloud computing to enable multiple simulations of mine designs to be rapidly and efficiently executed. The methodology includes generating random sets of prices and costs values within their respective probability distributions. Pit designs are then created to maximise the profit for each set of input variables. Various approaches to analysing the results are discussed. Use of the same high performance computing environment for understanding the financial risk associated with the variability of the underlying geological resource model is also discussed, with provided examples using case studies from two of the major mineral producers.CITATION:Lima, E, Gregory, D, Lapworth, A and Faria, C, 2014. Simulating extraction shapes to understand financial risk using high performance computing, in Proceedings Orebody Modelling and Strategic Mine Planning Symposium 2014 , pp 351–360 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 24, 2014

By Nguyen T. T, Williams A. M, Siauw T. H

During the last 20 years the CSIRO Division of Manufacturing Technology, through its research and development program, has made a substantial contribution towards understanding the pressure die casting process. Much of this work focused on the hot chamber die casting of zinc, where the importance of achieving optimum flow of metal into the die cavity, combined with the correct thermal balance of the tool, is critical to the production of high quality castings. Having developed a fuller understanding of the heat and fluid flow occurring in the pressure die casting process, CSIRO sought to make this information available to the industry in a form where it could be readily used by die casting engineers. This led to the development of DMT-CASTFLOW and DMT-CASTHERM, two unique, PC-based, die design software packages. DMT-CASTFLOW provides facilities for designing running and gating systems while DMT-CASTHERM enables the die designer to optimise the cooling and/or heating requirements of the die. These two packages are now being sold internationally. This paper will describe some of the major features and benefits that can be derived by using DMT-CASTFLOW and DMT-CASTHERM panicularly in the design of zinc pressure die casting dies.

Jan 1, 1993

By M Habte

This paper presents a simplified method for the assessment of creep deformations in rock masses containing bands of low strength or soil strength rock. The main impetus for this work was the need to assess the impact of distinct bands of clay and/or low strength rock on the long term deformation behaviour of a rock pillar formed as part of a series of proposed tunnelling works. In particular, the authors were interested in being able to provide criterion which could be used by site personnel to assess the encountered rock conditions against design assumptions.Creep deformation versus time plots are presented for a range of material consistencies. These plots were produced using the hyperbolic creep equation proposed by Mesri et al (1981). This empirically based equation was chosen for its simplicity and practicality. Discussion is included regarding typical input parameter values and the sensitivity of the results to these values is explored. Finally, in the soil strength materials, the secondary consolidation equation is used to check the veracity of the results calculated using the hyperbolic creep equation.

Mar 8, 2011

By A Baker

Hail Creek Mine is an open cut coal operation owned by Rio Tinto. It is located 120 km south west of Mackay in the Bowen Basin region of central Queensland. Opened in late 2003, the mine produces two high quality coking coal products that are used in the production of steel in various overseas markets. Hail Creek is a dragline and truck/shovel operation with a capacity to mine eight million tonnes per annum. In 2010, the production was more than seven million tonnes.Traditionally, coal seam edge loss had been minimised on site by the practice of coal edge buffering. Importing buffer material can be quite expensive as it requires a large involvement from the truck and shovel or dozer fleet. In order to minimise this expense, a program of front splitting was introduced on site. Front splitting however involves an additional blast interaction which places added pressure on mining schedules. Both these methods of coal protection demonstrated a significant benefit with coal loss being reduced by approximately seven per cent (absolute) compared to traditional cast blasting.With the application of electronic detonators at Hail Creek the new blasting practice of dynamic buffering is able to be performed on site. Dynamic buffering refers to a blasting practice where two or three separate blasts are initiated during the same blasting event (front-split, cast and at times presplit). The process involves firing a front-split and allowing it to have time to settle and buffer the coal edge prior to the cast blast initiating. This practice is only made possible with the use of electronic detonators and the effective absence of a surface burning front. Current practice at site involves the front-split being fired (occasionally at the same time as the presplit) and the main cast blast being initiated several seconds later. Dynamic buffering is now used for all cast blasts to coal at Hail Creek. Electronic detonators have allowed Hail Creek to achieve reduced coal losses by buffering the coal edge without compromising the mining schedule.

Nov 8, 2011

By L A. Martinez Tipe, J McKibben, S Barry

"Metal prices are central to a mineral investment decision and have a profound impact on the financial performance of companies in the mining industry. At its most basic level, metal prices are influenced by the disequilibrium between international metal volume supply and demand. That is, the commodity price is a regulator that equates international metal supply and demand where inventories act as a buffer between the emergence of this disequilibrium and its dissolution through a price change.From this viewpoint, mining companies are required to forecast metal and bulk commodity prices when evaluating minerals projects through discounted cash flow (DCF) analysis. While supply-demand models are instructive, many companies use historical prices, spot prices, futures/forward pricing and consensus opinion (or a combination of all of these) to develop price forecasts.This paper discusses the definition, fundamentals and differences between futures/forward and consensus pricing and the appropriateness of each in a DCF model for mine project economic evaluation.Our results demonstrate that great care is required when using either futures/forward or consensus pricing and that the decision to use one rather than the other requires consideration of other important elements in the DCF model (ie the risk-adjusted discount rate).CITATION:Martinez Tipe, L A, McKibben, J and Barry, S, 2016. Metal prices and the differences between forward and consensus pricing – which one is better for use in a discounted cash flow model?, in Proceedings Project Evaluation 2016, pp 149–158 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Mar 8, 2016

By C Niemann-Delius

The problem of long-term open pit mine planning is a large combinatorial problem, which canÆt be solved easily by mathematical programming models because of the large problem size. In this paper a new metaheuristic algorithm, which has been developed based on the ant colony optimisation (ACO) and its efficiency, have been discussed. To apply the ACO process to a mine planning problem, a series of variables is considered for each block as the pheromone trails that represent the desirability of the block for being the deepest point of the mine in that column for the given mining period. During implementation several mine schedules are constructed in each iteration. Then the pheromone values of all blocks are reduced to a certain percentage and additionally the pheromone value of those blocks that are used in defining the constructed schedules are increased according to the quality of the generated solutions. By repeated iterations, the pheromone values of those blocks that define the shape of the optimum solution are increased, whereas those of the others have been significantly evaporated. By using this algorithm a high degree of complexities could be considered in objective function and constraints of optimisation model. In addition it can improve the value of the initial mining schedule up to 34 per cent for some cases in a reasonable computational time.

Sep 26, 2011

By Porter I, Singh RN

An advanced elasto-plastic finite element model adopting a modified Von Mises yielding criterion was used to simulate progressive failure of the rock strata surrounding a room and pillar mine structure. The model conformed to the strain-softening behaviour of rock and accounted for post-failure residual strength. The simulation was achieved in such a way that material values were updated after each FE run, according to the stress criterion until the solution reached the final equilibrium steady state of the mine structure. The suggested structural stability analysis approach accounted for the main features of the structure degradations produced during loading through changes in rock material stiffness and subsequent evolution of stresses. Comprehensive parametric analysis was performed and the inevitable effect of interaction of the roof, pillar and floor on the overall mine stability limit was investigated. The numerical results clearly showed that linear models could not realistically represent the true behaviour of the mine structure. The results obtained are in good agreement with that predicted in the field.

Jan 1, 1992

By M K. C Roberts, M G. Magwaza, J W. L Hanekom, P Piper, R Lousteau

Due to the perceived potential to extract the second economic manganese seam at its Black Rock Operations in the Northern Cape Province, South Africa, Assmang commissioned an investigation with respect to mining method and sequencing of the two orebodies in 2007. Based on this initial study into multiseam potential, conditions and impacts, the rock engineering aspect was expanded to determine conceptual rules to govern the extraction of both manganese seams using the normal bord-and-pillar layout implemented at this operation. This work included the theoretical analysis using basic pillar design practices and numerical modelling, including the use of Map3D, UDEC and Phase2 codes.In 2013, Assmang launched a large-scale investigation into the potential to increase mine output from all possible manganese sources at the operation. Included in this investigation was the requirement to confirm or modify the conceptual multiseam extraction rules to implementation. As part of this confirmation process, stress measurements, borehole camera audits and additional numerical modelling were performed at a particular site on the operation where a limited extraction of both seams had been undertaken. The results obtained from this process provided confidence in the conceptual extraction rules and allowed the derivation of final extraction rules that will be implemented at the operation as the multiseam mining process becomes more widespread.CITATION:Hanekom, J W L, Roberts, M K C, Magwaza, M G, Lousteau, R and Piper, P, 2014. Confirmation of multiseam extraction rules for Black Rock Manganese Operations, Assmang, Northern Cape, South Africa, in Proceedings AusRock 2014: Third Australasian Ground Control in Mining Conference , pp 107–116 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 5, 2014

By M Podreka, P Merry, L van den Berg

Anglo Gold AshantiÆs Sunrise Dam operation is located in Western Australia approximately 55 km south of the town of Laverton. Currently, the mine is producing from both its open pit and underground operations and is planning a significant step change in underground production as the pit phases out. The mine ventilation system is arranged in three independent ventilation districts: Astro, GQ and Cosmo. The future ventilation infrastructure requires significant upgrades to keep up with the increased tonnage. In the short term, increased production is planned for the GQ district as well as for Vogue, which is an extension in the Cosmo ventilation district. In the long term, however, Vogue is likely to become the centre of attention for mining activity.This paper explores several ventilation scenarios which include upgrading the existing fan stations, rentals, establishing a common ventilation backbone, and establishing new upcast infrastructure for GQ to support the short-term production increase. These developments were modelled using ventilation network simulation software to determine airflow distribution and fan operating points for each option. For the GQ area, with its short-term increase in production, each option is evaluated for total owning cost by considering capital and operating costs over a three-year period. For Vogue, which is to become the main focus of mining in the future, a different strategy is followed in analysing the ventilation requirements. Instead of considering different short-term options, a number of staged upgrades are considered to achieve the desired production rates.This paper summarises the planning criteria, airflow requirements, ventilation infrastructure requirements, and economic analysis associated with the conceptual ventilation system design. It highlights how the best short-term ventilation infrastructure upgrades can be selected when considered in isolation but highlights that long-term production planning can have an effect on the decisions made in the short-term.CITATION:van den Berg, L, Podreka, M and Merry, P, 2013. Sunrise Dam short- to long-term ventilation planning, in Proceedings The Australian Mine Ventilation Conference , pp 107-114 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 1, 2013