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By P Thompson, D Rose, S Yu, W Baum, R Zahn, D Meadows, G Hall

Opportunities to improve mill operations are often cited by mining companies and recognised in many concentrators spread throughout the world but are not always followed through. Copper-molybdenum concentrator operations are challenged by a continuously increasing list of detrimental factors. They include deteriorating ore characteristics and poor mineralogical information on deeper ores, water quality and availability, steel wear and increasing power costs. Rapidly declining productivity, sustainability and environmental factors, new taxes, mining industry global skill set shortages, to name but a few, must also be considered. The days of maximising value by just increasing production or simple cost cutting are fading and will not be sufficient for the future of more complex mineral processing operations and larger plants. As a result, FLSmidth’s Global Process Technology Group has launched a plant and process optimisation program based on mineralogical and metallurgical surveys.Copper-molybdenum concentrators of the future need a paradigm shift. Modelling and simulation tools alone are not the answer to complex mineralogical associations and larger scale equipment and operations. Detailed area by area review aimed at identifying process constraints in terms of equipment and operating practice in conjunction with robust diagnostic work, ie mineralogical and metallurgical characterisation, are mandatory for process optimisation. The navigational beacon, for all operations who want to remain competitive, will be ‘process efficiency’. Since the use of automated mineral analysers has become more readily available and reliable, mineralogical-metallurgical plant surveys have proven themselves as the most efficient tool for optimising plant performance.The following paper will illustrate how operations can move toward eliminating under-performing flow sheets, fixing run-away flotation conditions, maximising individual process equipment performance, preventing shortcuts in Bond work index testing which may cause the failure of comminution models and minimising costly and time-consuming ‘debottlenecking’. As previous plant surveys have shown, the net project cash flow can be increased by 50 to 200 per cent if a combination of robust ore characterisation and plant process mineralogy is performed. The combined plant survey approach has been demonstrated successfully in a multitude of operations. This includes the use of key ore types in concert with statistically sampled process streams, bench-scale metallurgical tests and automated mineral analysis on a size-by-size basis.CITATION:Meadows, D, Hall, G, Rose, D, Thompson, P, Baum, W, Zahn, R and Yu, S, 2014. Copper-molybdenum concentrator surveys using mineralogy and process benchmarking tools to improve overall plant performance, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 315–322 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

By Liu Y, Campbell K. R

The paper shows how breakage parameters may he extracted from laboratory batch grinding results and how they may used with reference full-scale hall mill circuit data to estimate the likely size distributions of values and gangue in a full-sca

Jan 1, 1997

By N Clarke, J Hunt, A Barros, L Keeney

The Gramalote orebody is a large low-grade gold deposit situated in the San Roque municipality, 124 km north-east of Medellin in Antioquia, Colombia. It is jointly owned by AngloGold Ashanti (AGA) and B2Gold and is currently in Feasibility Study phase. In 2013 AGA requested CRCORE to undertake a preliminary study of the potential application at Gramalote of pre-concentration by screening, part of the Grade Engineering suite. 160 samples of coarse assay rejects (-3 mm) were tested and showed one of the strongest responses seen worldwide to that time, suggesting that about 70% of the gold could be recovered into 40% of the mass. This was seen as potentially markedly improving the Gramalote economics. A large-scale testing program was implemented on site to follow up these results. A total of 18 samples of 17 t each were mined along a pre-existing exploration adit. A complex test flowsheet allowed size fractions to be generated from the as-received material as well as after crushing to 53, 23 and 3 mm, all from the same head sample. The procedures were designed after carrying out a heterogeneity study to measure sampling errors. The coarser size fractions were designed to study the effect of crushing on upgrade response and predict the response on open-pit run-of-mine ore. The finer size fractions were designed to investigate means of predicting the upgrade response across the orebody. The large-scale testing closely confirmed the average upgrade response as predicted from drill core assay rejects but found that only the -53 mm crushed material accurately predicted the upgrade response of individual samples. Ore geochemistry was able to usefully distinguish samples with good and poor response. A small study on drill core suggested that, for Gramalote, fine crushed material distinguishes vein associated and disseminated values but not other factors that control actual outcomes.

Nov 10, 2020

By Mroczek C. R, Evans D. A

Renison is a world-class ore deposit that has been mined for over 100 years. It currently has reserves of 5.06 Mt @ 1.88 per cent Sn and a projected mine life of 8.5 years. Recent advances in the geological understanding of the deposit have been associated with detailed structural and geophysical investigations accompanied with the discovery and exploitation of the Rendeep orebodies. Mineralisation is linked to the forceful emplacement of the Devonian Pine Hill Granite that resulted in a complex brittle (-ductile) deformation of the Eo-Cambrian host stratigraphy. Dilation jog development on the Federal-Bassett Fault in the Federal and Rendeep areas provided access for cassiterite-rich magmatic hydrothermal fluids responsible for carbonate replacement Mineralisation.

Jan 1, 1997

By D Reid, A Fourie

The in-pipe treatment of slurries with polymer addition shortly prior to deposition is a noteworthy emerging technology of increasing popularity. Although polymer treatment has been shown to substantially modify and improve depositional and dewatering behaviour in a significant number of cases, the impacts of polymer treatment on geotechnical performance of tailings are less well understood. For example, certain combinations of polymer and slurry type have been shown to result in lower final densities at a given vertical effective stress. Despite these lower densities, polymer-treated tailings often exhibit peak undrained shear strengths consistent with untreated material. However, the sensitivity and/or brittleness of the material may be negatively influenced by the looser state created. Although these changes have been studied, most testing available in the literature was undertaken on relatively ‘fresh’ samples of polymer-treated material. However, significant shear may occur following treatment and prior to the commencement of settling and self-weight consolidation as the material moves down the beach.To study the effects of shearing on the subsequent performance of polymer-treated tailings, a test program consisting of consolidation, triaxial and direct simple shear tests was undertaken on presheared polymer-treated material. Materials used were identical to those used in previously published studies on the impacts of polymer treatment in a ‘fresh’ condition. Shearing of the polymer-treated material generally appeared to lessen the impacts of the polymer treatment process. However, the behaviour of the material when sheared indicated that the polymer was still impacting the behaviour of the material in some respects. The results indicate the importance of the consideration of shearing on material behaviour when planning and designing a tailings deposit where polymer treatment is to be implemented.CITATION:Reid, D and Fourie, A, 2015. Effects of shear on the behaviour of polymer-treated slurries, in Proceedings Tailings and Mine Waste Management for the 21st Century , pp 215–224 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 27, 2015

The 1980's have produced an outstanding revival of the Australian gold industry. In contrast to some previous mining booms, the economic aspects of the growth in gold production are soundly based. In general the new developments have been highly profitable and this is beneficial to all parties- whether they be government, shareholders employees or suppliers. Mining companies are showing a large commitment to gold exploration with approximately 50% of Australian exploration budgets now being directed towards gold. An increasing proportion of this expenditure is being channelled towards the eastern States with Queensland 'being the major centre of interest. Further strong growth in production is expected with some 50 projects likely to come on stream before 1990. A very significant aspect of the foundation for this growth is a continuation of the existing tax status of the industry.

Jan 1, 1987

By Z Gao, D Liao, W Sun, S G. Pooley, J Wang, Z Shi, G Jing, S Ren, Q Chen

Yuanjing processing plant is a scheelite and wolframite plant in southern China. Water shortages and recent environmental regulations mean that the plant must reuse the wastewater that comes from the mining operation. This paper describes the efforts to reuse the mining and ore washing wastewater (MOW) in the processing plant. Initial attempts to reuse the MOW in the strong magnetic separation were unsuccessful because the magnetic media pack was seriously fouled by the micro-fine precipitate generated. The focus changed to reuse the MOW in the scheelite flotation circuit, which includes one roughing, one cleaning and three scavenging steps. Laboratory batch tests showed this would likely be successful because using MOW reliably improved the flotation performance in the laboratory tests. Then a 20 day industrial trial was run in the plant. The trial was very successful with the enrichment ratio of WO3 increasing from 17.4 to 23.6, while the recovery remained around 79.2 per cent. The industrial trial was so successful the company immediately adopted the new scheme, which has remained in use ever since. This technical solution not only alleviated serious water shortages, and satisfied environmental regulations but also improved the plant performance.

Aug 24, 2022

By Christie A. B, Swain A, Brathwaite R. L

This study provides quantitative data on vein distributions within seven selected epithermal systems, four deposits hosted predominantly in rhyolitic rocks: Ohui, Wharekirauponga, Neavesville and Komata, and three major deposits mainly hosted in andesite: Martha Hill, Golden Cross and Karangahake. The technique of fractal analysis was used to help quantify vein distribution patterns. The fractal dimensions (D) obtained are related to the number of veins per metre, the degree of vein clustering, and vein thickness. An increase in any of these tends to increase the fractal dimension. It is the relative relationship of these parameters that is important for the characterisation of vein distributions, and the comparison of different deposits. Within the same systems, the rhyolites are characterised by lower vein thickness and vein density, but have a higher degree of vein clustering compared to the andesites. Sections that are deeper and more centrally located within the epithermal system and/or close to major structures, tend to have a greater degree of vein clustering, higher average vein thickness and density, and higher thickness to density ratios. This depth control is most pronounced in epithermal gold-silver systems because they have formed at shallow crustal levels where physico-chemical conditions change drastically both vertically and laterally. In addition to lithological and structural control at vein scale, deposit scale structure is of great importance in the deposition of economic mineralisation. Large open vein structures capable of sustaining high fluxes of hydrothermal fluid, favourable for the formation of large, high-grade gold deposits, are best developed in andesite sequences.

Jan 1, 1995

By Bush P. R, Hale M, Dixon C. J, Wheatley M. R

Barium anomalies in drainage sediments can act as indicators of barite mineralization and path- finders for lead-zinc mineralization. Their detection in an arid climate has been investigated in two areas of Saudi Arabia. At Rabigh, 150 km north of Jeddah, barium anomalies found in wadi sediments reflect barite veins which occupy Tertiary faults in Precambrian metavolcanics and granodiorite. In the Wadi ad Dawasir area, 650 km east of Jeddah, the sediments of wadis draining the Jabal Tuwayq escarpment have been found to contain anomalous concentrations of barium derived from diagenetic barite in the Sudair formation siltstones and shales. Barium dispersion in these wadis is predominantly clastic. Near to the source rocks, barium occurs in relatively coarse grains of barite. Owing to the three well-developed cleavages of barite, its crystals readily break into cleavage flakes during fluvial transport in flash floods; as a result, the longest anomalous dispersion trains are found in the 250 to 600 um fraction. Wadi sediments finer than 250 um have relatively constant and low barium contents, being dominantly composed of windblown sand.

Jan 1, 1988

By Chenggang W, Junhua D

Fragmentation variation laws in loading and non-loading areas are obtained by cement block model blasting experiments under various stemming lengths. A reasonable ratio between loading length and stemming length is worked out according to minimum average fragment size. The present continuous loading structure, for its very long length to be stemmed, leads to insufficient fragmentation in the upper part of bench. So a new loading structure with bottom air cushion is put forward. The author analyzes blasting effects and processes of two loading structures' and proves that there exists a optimal length of air cushion.\

Jan 1, 1990

By Huntington J. F, Green A. A

The quality of a photointerpreter's anno- tation of an image may be displayed by writing maps in which the pixels are shaded according to the number of times a pixel was seen to be on a feature. The map of grey tones is more valuable, if, for each grey level, a measure of quality is determined, which is the probability that a feature exists in a pixel of a given grey tone. From repeated annotations (at least four) of the same image by a single observer, it is possible to formulate a perception model which describes stochastic processes in the observer. From that model, it is possible to assign estimates of data quality for each observer to each grey tone. For two observers on the same scene, the 'mean' method of quantifying the grey levels is to assign a value equal to the mean of the ii,:lities for each of the two observers separately. For this example, the grey tones arr thus quantified at probability levels of 0.70, 0.80, 0.90 and 0.95.

Jan 1, 1977

The investigations described in this paper aim at the development of a new impact mill. The objective is to produce particle size distributions below 10 .tm without using an air classifier. Circumferential rotor speeds of up to 200 m/s are strived for.

Jan 1, 1993

By Blain CF

For all mineral resource-based companies, it is important to reach the right balance of investment between acquisition and exploration to allow the best chance of achieving long-term corporate goals. The Broken Hill Proprietary Company Limited (BHP) provides an excellent example of success from generative exploration and supports the belief that exploration can be justified, not only in terms of investment criteria, but also because it is essential to a company wishing to build a dynamic profitable growth path based on world-class deposits as cheaply as possible. BHP was incorporated in 1885 to mine a lead/zinc/silver discovery at Broken Hill. The Company has since gone through a steel development phase (1911-1965) and is now in a major phase of growth partly based on exploration success. This third phase was marked by decisions taken in the 1950's to search actively for mineral and energy resources above and beyond the requirements of the steel industry. The commercial successes of this period have been Bass Strait oil and gas, Groote Eylandt manganese, Deepdale iron ore, Gregory coal and Carnilya East nickel. In total at least 22 new resource discoveries have been made in the last 25 years, of which 11 have been developed and several are undergoing feasibility studies. A financial analysis shows that the real value of the returns seeded by discovery covers the real exploration cost many times over. Moreover, the major discoveries have had a spectacular impact on the growth and development of the Company. BHP's present exploration effort is directed towards geological targets which most frequently meet attractive financial criteria and also promote diversification from steel-related earnings.

Jan 1, 1986

By Bothe C

Froth flotation processes use different surface properties of the minerals to be sorted. In an aqueous environment the hydrophobic mineral attaches selectively to air bubbles and is lifted to the surface of a separation vessel, while the tailings settle towards its bottom. Besides the surface properties, the hydrodynamic conditions play an important role. With respect to the hydrodynamics the flotation process can be divided, for simplicity, in two sub-processes. The attachment of hydrophobic particles to air bubbles, the so-called mineralisation, demands a large number of collisions and therefore high turbulences. The phase separation however needs a deterministic movement of both the particle-bubbles-aggregates and the tailings particles and therefore a quiescent flow field. The optimisation of the overall process requires a separation of both sub-processes, especially when fine particles have to be sorted. In conventional mechanically agitated flotation cells both sub-processes take place in the same turbulent volume. For this reason they suffer from a decreasing selectivity with decreasing particle size. In flotation columns the mineralisation of air bubbles and the phase separation are performed in a quiescent environment. This results in high concentrate grades and at the same time in a very slow attachment kinetics, which must, especially for fine particles, be counterbalanced by a long residence time of the slurry.

Jan 1, 1993

By D Jeffery, R Whittering, G Lane

Most aspects of process design are best addressed via bench scale or pilot plant scale test work. However, as experience is gained, fundamental or indicative data can provide more than adequate information to manage the risk associated with some process aspects of concentrator design.Historical precedence exists where minimal design test work has resulted in successful projects. On many occasions benchmarking, sometimes supported by fundamental data such as mineralogy, has been used to successfully develop effective process plant outcomes. Of course, this style of approach is most common with æfast trackÆ projects and often comes with the usual surprises that result from inadequate geometallurgy to define the project cash flow.This paper explores the risks and opportunities associated with the various facets of process development and design for a base metals concentrator. The paper is intended to provide guidance to project managers rather than address the technical aspects of process engineering.CITATION:Lane, G, Whittering, R and Jeffery, D, 2012. Benchmarking versus test work - How should you manage process risk?, in Proceedings Project Evaluation 2012 , pp 49-52 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 24, 2012

By D Hillier, A Giblett, K Parker, V Ramsell

Kalgoorlie Consolidation Gold Mines (KCGM) operates the Kalgoorlie Super Pit open cut, Mt Charlotte underground mine, Fimiston process plant and Gidji Roaster facility for joint venture partners Newmont Mining Corporation and Barrick Gold. In 2004, the Fimiston plant was upgraded by the addition of gravity concentration to the Fimiston and Mt Charlotte grinding circuits, including the installation of a central intensive cyanidation reactor to process the gravity concentrates. The gravity project was justified after detailed analysis demonstrating an expected increase in overall gold recovery of approximately one per cent, in addition to reduced elution costs and reduced gold inventory in flotation concentrate stockpiles. The gravity circuits were commissioned in August 2004, and have since consistently recovered 10 to 20 per cent of the gold present in the KCGM ore, delivering a reduction in coarse gold losses equivalent to 0.45 per cent additional metal recovery and contributing to improved metal accountability.CITATION:Giblett, A, Hillier, D, Parker, K and Ramsell, V, 2012. The impact of gravity gold recovery at Kalgoorlie Consolidated Gold Mines, in Proceedings 11th AusIMM Mill OperatorsÆ Conference, pp 199-206 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Oct 29, 2012

By Lu T. K

A new type of rockbolting system, the self drilling rockbolt, has been studied to develop a 'single pass' bolt for use in rockbolt installation in underground engineering. This single pass bolt forms the basis of a Rapid Face Bolting system which will reduce the amount of time spent in securing a roof during the operation of a continuous miner in the development of a panel.The installation efficiency and anchorage tests were performed in the laboratory on the self drilling bolt and the traditional resin anchorage. bolt. The results of both bolts are cmmnared.

Jan 1, 1993

By Stump NW

Until a year ago all isotope on-stream analysis utilised flow cells similar to those designed for conventional X-ray on-stream analysis. These systems incorporated a fairly complex sampling system necessary to present a representa- tive air-free sample of the main process to the flow cell. Maintenance costs and capital costs associated with flow cells and sampling systems have been generally high. Costs can be greatly reduced and reliability greatly increased, by using isotopes incorporated in immersible on-stream analysis probes which actually dip into the main process stream eliminating the need for sampling. A bonus of other advantages associated with immersible probes includes temperature stability and ease of calibration. This paper discusses details and results of the probe systems, justifica- tion for installing on-stream analysis, comparison of conventional X-ray and isotope techniques, and a brief survey of methods of analysis using radio- isotopes in on-stream elemental determinations.

Jan 1, 1971

By R H. Knight

Production mine geology must be accurate and efficient in order to reduce risk and ensure that ore value and mining operation revenue are maximised. Present grade control practices are commonly based on outmoded and inaccurate 2D geological mapping techniques where spatial relationships are estimated by eye, sketched by hand and projected to arbitrary reference planes. The 3D mapping approach outlined in this paper integrates 3D photogrammetric imagery with implicit modelling techniques to enable more accurate grade control and reconciliation in underground mines. High-resolution stereo photographs are taken of daily ore development headings. Ore contacts are traced directly on a 2D face photo using a stylus and rugged tablet. Area-weighted face grades are estimated and calculated on mapped 2D face planes. In the office, a 3D photorealistic mesh is processed and georeferenced. 2D face mapping data is transformed into its actual 3D location and true 3D mine mapping is performed by digitising oriented 3D polylines representing ore contacts and other geological features directly onto the image surface. Three-dimensional spatial relationships are fixed, eliminating the projection error of traditional 2D methods. Ore envelope and waste solids are modelled within the closed, drift-round mesh. Volume-weighted ore envelope and round grades, as well as round volume and tonnage, are calculated. Ore/waste classifications, grade, tonnage and per cent dilution are quantified per round, visually assessed in 3D and reconciled with short- and long-term models on a daily basis. Updated geological continuity models provide geological guidance in development headings under geological control and accurate 3D structural and form-line mapping improves definition drilling and stope planning. Three-dimensional imagery provides a permanent detailed survey and geological record of mine workings that can be revisited virtually to reinterpret geological ore controls in light of new observations and insights. In addition images can be used to monitor daily production performance, create training scenarios for miners, engineers and geologists and prepare management presentations. This approach adds value to underground mines by improving the accuracy and efficiency of mine geology practices. The method is particularly effective in mines with visually distinct and geometrically complex orebodies, such as those in the Balmat zinc mine located in New York State, USA, which are used to illustrate the method.CITATION:Knight, R H, 2017. 3D mine mapping – improving grade control and reconciliation in underground mines using photogrammetric imagery and implicit modelling techniques, in Proceedings Tenth International Mining Geology Conference 2017, pp 203–212 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 20, 2017

By A Boucher, M Baudin, P Androszczuk, I Minniakhmetov, A Rigby, P Machado, M Wright, B Van Dijken

IGO Ltd’s (IGO’s) Nova Operation (Nova), which is 160 km east-north-east of the town of Norseman in Western Australia (WA), mines and processes nickel-copper-cobalt (Ni-Cu-Co) sulfide ore from the magmatic Nova-Bollinger Deposit (Nova-Bollinger), which is hosted by the Mesoproterozoic age high-grade metamorphic rocks of the Albany Fraser Orogen. Over its 56-month life-of-mine (LOM) operations to 31 December 2020, Nova has processed 5.63 Mt of ore grading 2.04 per cent Ni, 0.86 per cent Cu and 0.07 per cent Co from its underground mine. At the end of 2020, both the Nova-Bollinger JORC Code reportable Mineral Resource estimate (MRE) and Ore Reserve estimate (ORE) were >90 per cent classified in the highest JORC Code confidence categories of Measured Mineral Resource and Proved Ore Reserve respectively. The high JORC Code classification confidences assigned to the Nova-Bollinger MRE and ORE results from the 386 km of surface and underground diamond drill testing of the deposit to a nominal 12.5 by 12.5 m pierce point spacing in mineralisation. The close spaced high-quality drilling and bulk mining method employed at Nova has effectively removed the need for any grade control modelling outside of the MRE process. Importantly, having only the one fully drilled out deposit being mined and only the one process plant, Nova’s reconciliation process is in the fortunate situation of not being confounded by issues such as external ore sources and constant updates as new grade control information becomes available. IGO’s Nova reconciliation processes are focused on reconciliation ratios that quantify operational period differences between the MRE and ORE head grade and tonnage forecasts and the process plant head actuals. These metrics have been used to identify key reconciliation issues and have initiated several studies into the causes for specific reconciliation results, which are discussed in the paper. In late 2020, a period of sustained poor reconciliation results led to the recognition that increasing the understanding of risk between the MRE and ORE should be investigated. To assist with modelling stope level risk within the mine plan and subsequent reconciliation, an attempt was made to develop a formula to quantify ‘stope risk’ from MRE metrics such as sample spacing, kriging efficiency and so on

Mar 22, 2022