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By McDonald K. J, Flann R. C

A liquid phase sintering (LPS) process for preparing basket anodes from nickel powder has been scaled-up and the innuence of compact green density and sulphur content, as well as sintering conditions (period and syngas now.rate) on the perfonnance of anodes has been evaluated. The product anodes have been tested in an industrial electroplating tank. It is concluded that if anode residues are to be minimised, then with a sintering temperature of 960"C, compact green density needs to be as high as economically achievable (85 - 87 per cent density of solid nickel) and the sintering period approximately 40 minutes. With these constraints, if residual sulphur contents of anodes are to be kept as low as those of commercial anodes, then the sulphur content of the green compacts would need to be less than 1670 ppm. At the same time, it is also found that residual sulphur concentrations as high as 2000 ppm are beneficial to anode pcrfonnancc and not detrimental to the quality of the electroplate. The ability of the LPS process to produce marketable nickel anodes for the electroplating industry is clearly demonstrated.

Jan 1, 1993

This paper discusses the implementation and potential limitations of the method for estimating sampling and analytical errors of multiple source mine output blended into a shipping product, described by Everett and Ziegelaar (2010). The practice of quality measurement varies between iron ore miners. The common objective is to monitor effective resource utilisation and control of product quality to customers. A flow diagram is given presenting the various options used by iron ore mine operators and the merits of the different options are discussed.

Mar 1, 2010

Most new engineers in the mining industry do not realise the importance of legal obligations. During investigations the first question you are asked is: Do you have any proof or evidence? The smallest detail in an underground notebook or a diary entry is able to be used as your proof and/or evidence. The importance of a paper trail is often undervalued and overlooked when you first enter the industry. As a new engineer, all too often your legal obligations, including your duty of care are not given enough consideration. Whose job is it to inform you of what your legal obligations are and when do they end? Everyone has legal obligations at every level of the industry, from graduate to mine manager. The level of these responsibilities varies depending on the position that you hold. When you first start in the industry you need to understand what your responsibilities are and how you are expected to discharge them, whether they are memos, databases or senior sign-offs, etc. In order to fulfil your obligations you must first discharge your own obligation, which in turn discharges those of your department and ultimately those of the mine. As a graduate engineer in the mining industry what I have learnt about my own legal obligations has come directly from my own experience, which will form the basis of this paper.

Jan 1, 2007

By M Rafty, C Lane

Managing water is a key aspect of mining, whether a site is in water surplus or water deficit. Water in tailings storage facilities (TSFs) needs to be managed carefully to maximise the density of the solids, maximise the re-use of available water and to minimise the risk of water overtopping the spillway in the event of heavy rainfall. Developing a water balance models is a standard method for monitoring the major flows of water around a site. However, models created by specialist consultants are often overly complex and are not suited to being used by process plant personnel after they have been handed over to the mine operator. Models typically offer information on water management at the time that they are created, but then ‘sit on the shelf’ and offer no further insight or value for operating mines. Advisian has developed a customised water balance model for a mine in Sub-Saharan Africa, which can be adapted to other locations, to assist in managing water at the site and in particular to predict the current and future water level and volume in the TSF under various rainfall scenarios. The model was developed using Microsoft Excel and requires no specialist skills to operate. Site personnel enter in daily production, water transfer and rainfall data and then view the output dashboards to observe the current water level and volume, decant rates, licensed water abstraction and water supply versus demand. The output dashboards were developed in close consultation with the client to ensure that all of the relevant key performance indicators were included, from the perspectives of all the key stakeholders. This modelling approach focusses on the needs of the people who will actually use the model to actively manage TSFs with the need to involve the model developer as part of ongoing operations eliminated. The simplicity of this approach is now being embraced by other mine sites in Africa and Australia. CITATION:Rafty, M and Lane, C, 2018. Water balance management 101, in Proceedings Mine Waste and Tailings Stewardship Conference 2018, pp 485–490 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 23, 2018

The history of the discovery and development of the Kambalda nickel orebody. is reviewed and the decision to process the Kambalda concentrates by the Sherritt-Gordon process at Kwinana is discussed. The Kwinana Nickel Refinery is described and the problems encountered in the first year of operation are Outlined.

Jan 1, 1971

Applications of chlorine metallurgy to the extraction of metals often result in the production of volatile metallic chlorides, most of which condense directly to a solid phase at 1 atm pressure. A stirred-bed condenser suitable for the recovery of these materials is described.The unit, developed from the concept of a fluid bed condenser, has the advantages of versatility of operation and ability to control fog and dust formation. Test work using aluminium chloride vapour (as an example of a volatile chloride) gave recoveries approaching 100 per cent. The yield was dependent upon halide content of the vapour, flowrate, and, to a lesser extent, upon coolant temperature. Analysis of the heat transfer dataindicated condensation side coefficients in the range 10 to 30 B.T.U./hr sq. ft. 0p.

Jan 1, 1971

By C A. Cooper, G A. Suter

The sizing of a starter dam for a Tailings Storage Facility (TSF) involves balancing many competing demands. It should cost as little as possible, be high enough to store tailings until the first raise can be constructed, it must be able to contain water safely, and it must be designed in such a way that the long-term integrity of the higher raises are not compromised, among other things. In addition to these demands there is the complication of the behaviour of the process plant, and the tailings during commissioning. Variations in slurry density, excess water in the TSF, initial settled density of the tailings, reliability issues, and beach slopes above and below water can all impact the way the tailings beaches are developed and ultimately impact the ability of the starter dyke to contain the required volume of tailings and water.The conventional approach to the design of a TSF starter dyke is to begin looking at the elevation required for a set of deterministic design parameters, find ways to reduce the size or volume of it as much as possible to reduce cost, and then possibly look at the sensitivity of some of the input parameters. This paper discusses a stochastic modelling approach for starter dykes that allows a wide range of design inputs to be simulated quickly, with an envelope of possible results produced. The sensitivity to different parameters can also be examined to understand which design inputs have the biggest impact on the required dyke sizing. By integrating the 3D TSF modelling tool Muk3D with GoldSim, it will be demonstrated how a wide range of scenarios can be evaluated and how that information can be used to make better decisions about the selection of design options.CITATION:Cooper, C A and Suter, G A, 2018. Starter dyke optimisation with Muk3D and GoldSim, in Proceedings Mine Waste and Tailings Stewardship Conference 2018, pp 466–475 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 23, 2018

By S Juras

The terms measured resources and proven reserves denote the highest level of estimation confidence in all of the major classification schemes. But what do they really bring to today’s project or mine with respect to production planning and expectations? Initial reserve declaration does not need measured resources, just indicated resources. Economic viability of a project is assessed on total reserves with nary a bonus for the amount of proven reserves. Production plans are based on grade and tonnage goals that may only coincidently correspond to proven reserves. So are the measured and proven categories still relevant? Historically, and almost exclusively in underground mines, companies only allowed mining in areas of proven reserves. Some companies still follow that philosophy. But many others will mine a mixture of probable and proven reserves without hesitation. Also what of the undeveloped project in a new district – what is to be made of their declared measured resources and proven reserves? Measured resources are commonly set either by some type of proximity to data scheme or a matter of ‘feel’ based on the qualified person’s experience. The parameters for reserve conversion focus on the project as a whole and then a portion becomes classified as proven reserves almost solely based on whether the resource category is measured. So should the mining industry continue to use these categories of resource and reserve classification? This paper will present arguments about making these categories once again more relevant. A more disciplined usage of these categories may re-introduce their relevancy in public disclosures of resources and reserves. As well a more consistent usage in operations may lead to increased confidence in managing production targets and costs.

Aug 22, 2011

By R Burke, G Ramage, C Donnelly

Over the decades, Redpath has undertaken a multitude of tunnelling and underground excavation projects for civil and mining clients both domestically and internationally. These projects have been undertaken through varying strata conditions with differing excavation methods in remote locations and in central business districts.With the recent turbulent nature of the global financial environment, project drivers have been challenged with the emphasis being placed on methods to gain early access to orebodies, rapid development techniques, lower capital costs and reduced labour requirements to name a few.A number of mining companies seeking to achieve these objectives have commenced the journey to better understand the operational constraints, challenges and opportunities that may be available with the use of alternative excavation methods.The development of safe and effective alternative excavation methods that comply with both domestic and international mining legislation and regulatory requirements is a challenge the industry needs to embrace. Given the current cost pressures being faced by the Australian mining industry, some alternative excavation methods offer the potential for longer term sustainability and rapid development of resources.More recently work has been undertaken on a project that challenged the norm and implemented an alternative excavation method with the use of an excavator with a rotating drum cutter head.This paper will review this recent project and provide technical and operational insight into some of the challenges faced in implementing an alternative excavation method in the metalliferous industry.CITATION:Donnelly, C, Ramage, G and Burke, R, 2014. Challenging the norm – alternative excavation method in mining, in Proceedings 12th AusIMM Underground Operators’ Conference 2014 , pp 187–190 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Mar 24, 2014

By N Herault

PT Freeport Indonesia recently completed preproduction development and construction of the Big Gossan underground copper and gold mine, located in the Ertsberg mining district of Papua, Indonesia. Production has commenced with an expected ramp-up to full production of 7000 tonnes per day in 2012. The Big Gossan utilises an open stoping mine method with paste backfill.In order to deliver ore to the mill, which sits in a valley above the ore deposit, an underground production shaft and hoisting facility was designed and constructed as the key component of ore haulage. The design and construction of the Big Gossan shaft posed many challenges to the project team. Available shaft design and construction expertise were limited as this was the first shaft of its kind in Indonesia and the project was undertaken during a time of high industry demand for new shaft systems. Construction resources were also limited due to the remote location and competition with existing, producing mines for these resources and skills. The project also taxed the ability of Freeport to provide services and resources to this as well as their other projects.Completion of the Big Gossan shaft was a milestone in PT Freeport Indonesia’s plan to fully transition ore production to the underground environment in this decade.This paper deals with the various challenges faced by PT Freeport Indonesia and shaft contractor, PT Redpath Indonesia, during the construction of the Big Gossan shaft and offers suggestions to improve future shaft projects of a similar nature.

Mar 21, 2011

By D Carroll

Mining of the zinc, lead and silver deposit at the Broken Hill Southern Operations site has been occurring for over 100 years. As a result of this, a significant amount of high-grade ore is now taken from narrow remnant pillars left between old stopes and zones of previously mined ground. Stopes have been filled with either hydraulic fill (also known as ‘sandfill’), cemented hydraulic fill (cemented sandfill), waste rock backfill or a mixture of these fill types.In the last ten years, there has been considerable success mining through narrow pillars where sandfill is exposed in the development face and/or walls using a ‘shell’ support regime, wherein a layer of bolted mesh is sandwiched between two layers of sprayed fibrecrete (25 mm fibrecrete, then mesh and bolt, followed by a final 50 mm layer of fibrecrete). Shell support is also used in very poor, broken, relaxed ground conditions and in areas filled with cemented fill (sandfill with a minimum four per cent cement content).The next stage of innovation has been to develop a technique for mining through old stope voids filled with uncemented sandfill, known locally as ‘contours’ (old cut-and-fill working), an activity where unconsolidated sandfill can run at the face and from the backs. The challenge is to prevent exposed sandfill in the face and the backs from failing before it can be supported.To achieve this, the Southern Operations mine has implemented a technique in which 6 m long spiling bars are used to strengthen and stabilise the sandfill in front of the face. The hollow steel bars are driven in around the heading perimeter in a closely spaced pattern then pumped full of grout. The bars and the grout stabilise the sandfill in front of the face, preventing it from failing into the drive during excavation and prior to further support being installed.A final support system consisting of shotcrete, mesh, bolts and steel girders is installed as excavation progresses. Both the initial and final support systems are essentially passive support systems designed for a low-stress environment (as the stress originates mostly from the mass of unconsolidated sandfill).This process is slow and labour intensive. Fifteen separate cycles of people/machinery are needed to progress one equivalent heading cut (compared to six for a standard fibrecrete- and bolt pattern-supported rock face heading). This slow pace introduces scheduling challenges, but the process opens up parts of the orebody that were previously uneconomical to mine.CITATION:Carroll, D, 2014. Mining through sandfill using spiling bars, in Proceedings AusRock 2014: Third Australasian Ground Control in Mining Conference , pp 95–100 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 5, 2014

By T D. H McGrath, W P. Staunton

Benchmarking, comparing an operation or process with the industry standard, is known to be a useful method for identifying plant optimisation opportunities, and in many cases providing the pathway to realise the benefits. The difficulty is generating the database of plant data necessary for a benchmarking exercise. Larger companies can benchmark internally; this option is not available to smaller companies, and the full value can only be realised with a comprehensive “industry wide” approach.The Gold Technology Group at Curtin University through the AMIRA P420 series of projects has undertaken several comprehensive metallurgical industry surveys in the gold industry over the last two decades. Analysis of these surveys has demonstrated areas where many operations can benefit from re-assessment of their operating practices.This paper will review the work undertaken by the Group in this area, in particular the 1999 surveys of gold companies in the Australasian region, and the 2012 international survey of the industry. The challenges of, and opportunities arising from these surveys will be discussed. Some of the highlights from analysis of these databases will be presented as well as noting changes in processing practices observed by the Group over the last 20 years.CITATION:McGrath, T D H and Staunton, W P, 2018. Keeping up with the Joneses – the value of industry surveys and benchmarking, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 509–516 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

By J Masliyah, Z Xu

The largest oil sand deposit in the world is located in Alberta, Canada, with a total proven reserve of 2.5 trillion barrels of oil. The water based extraction process is currently being used in commercial operations to recover bitumen by flotation from oil sand ores. A recognised challenge in bitumen extraction is the reduced bitumen recovery when processing ores containing high fines content or æweatheredÆ oil sand ores, collectively known as poor processing ores. Inspired by demonstrated success of using kerosene as collectors in coal flotation, an innovative idea of using oily bubbles (air bubbles coated with a thin layer of oil or solvent) was tested to improve bitumen flotation recovery from poor processing ores. In this study, dynamic contact angle of air bubbles or oily bubbles on bitumen and induction time of bitumen-oily bubble attachment in water were measured to justify the use of oily bubbles in bitumen recovery from poor processing ores. The type of oil or solvents, including kerosene, toluene and naphtha, used in generating oily bubbles showed a marginal effect on the contact angle values, similar to the values measured with air bubbles. However, the spreading of an air bubble was found to be much slower than that of oily bubbles on a bitumen surface. The induction time for oily bubble-bitumen attachment was found to be much shorter than that for corresponding air bubble-bitumen attachment in the process water from poor processing ores. The reduced induction time for kerosene-coated air bubble-bitumen attachment correlates well with the improved bitumen recovery from poor processing ores using kerosene-coated oily bubble flotation technology.

Jan 1, 2005

By A Vakili

Dilution is associated with considerable direct and indirect costs in underground open stoping operations. As shown in previous works, an improved ability to predict dilution enables the economic risks associated with unplanned dilution to be reduced. Depending on the width of the orebody and depth of mining, the economic performance of an open stoping operation can become even more sensitive to dilution. It is shown in several well-documented studies that as little as 1 per cent of additional dilution can impose millions of dollars of lost profits per annum. Optimisation of a stoping operation is therefore largely dependent on the ability of the operation to minimise dilution. This can only be achieved through sensible analysis of past and future performance of mined stopes using the most appropriate recent available technologies and tools. This article presents a new design process that utilises advanced geotechnical numerical modelling and various other analytical tools to assist with a more robust mine design of open stoping operations. The focus of this design process is on geotechnical factors affecting dilution during the life-of-mine. A recent application of this optimisation method for a mining operation is presented in this paper as a case study. Through the application of this method and various other operational improvements, the mine was able to deliver more consistent production and lower operating costs over its life-ofmine outlook and was able to reduce dilution by up to 50 per cent and achieve sustainable record high production rates.

Mar 29, 2023

By G P. S Resende, D E. G Oliveira, E A. S Baeta, T F. Bravin

There is currently in the mining industry, as well as in other industries, a movement seeking to increase investments in decarbonisation processes to help combat global warming. Among some initiatives taken is replacing diesel-powered mobile equipment in the mines with electricity-powered equipment, such as electric off-highway trucks or even belt conveyors in the mining operation. Samarco is a Brazilian mining company that since its conception has used a conveyor belt mining system in its mining operation, using only a small number of trucks to complement the mining process. This mining process that combines conveyor belts and trucks has brought environmental gains for the company since the environmental impact of conventional truck-only mining is greater than that of the combined system. To measure these gains, a medium-term mining plan was developed in which two fleet scenarios were detailed. One scenario contemplated a high level of detail of belt mining seeking its maximisation, while the other considered the operation performed 100 per cent by trucks, eliminating the use of conveyor belts. Through the comparison of these two scenarios, it was possible to make an inventory of atmospheric emissions and greenhouse gases for each one of them considering data such as types of equipment, diesel consumption, total distance travelled and energy consumption. The results showed that the fleet scenario with conveyor belts results in periods with up to 15 per cent less greenhouse gas emissions and 37 per cent less total particulates compared with the truck-only scenario. Therefore, the results confirm the environmental benefits of the method and the need to look for ways to even expand it in future operations through a study to identify the potential areas in the long-term mining plan.

Sep 18, 2023

By Parker C. J, Mikula P. A

The excavation for the Sydney Opera House Parking Station comprises a large donut shaped underground cavern with a central sandstone pillar. The maximum effective roof span is about 19 m and the rock cover is between 7 m and 8 m. Permanent support for the roof and the various services tunnels consists of a combination of tensioned anchors, and untensioned dowels, and mesh with shortcrete and fibrecrete as the final lining. Steel sets were installed at main intersections.Fundamental to the design philosophy for excavation of these spans at such shallow rock cover was the use of monitoring to check on the adequacy of the installed support. Prior to excavation, extensometers, inclinometers, piezometers and surface settlement survey stations were installed. Underground survey stations, anchor load cells and shotcrete pressure cells were installed as excavation proceeded. Excavation commenced at the crown using an initial heading and three widening stages. Geological mapping during excavation confirmed borehole expectations, namely sandstone beds 1 to 4 m thick interbedded with thin shale units. Bedding plane contacts varied over short distances from tight partings to thick brecciated seams. Jointing was subvertical and joints tended to be bed-limited.

Jan 1, 1993

By C N. Hatton, K Ward

Tailings operations are inherently reactive as operations personnel continuously contend with a concentrator reject feed (tailings) transient in physical and engineering properties, which places a constant constraint on capital and operational spending. It requires a unique skill set to manage the prescribed distribution of tailings under unenviable conditions. Enter the tailings operator, an oftenundervalued commodity and untapped resource that can provide benefits beyond the rigors of dayto- day operational support. Experience consistently demonstrates that skilled and committed operators can serve a vital function in the safe construction of a tailings storage facility. It takes a village to raise a tailings dam. An important part of this process is establishing a culture of operational accountability and ownership. Operator development training is nothing new. However, we find that many of the intrinsic operator skills are left unexploited, and an operator's experiential knowledge base and creativity are commonly overlooked and underutilized. With proper training and guidance, these skills can be harnessed, contributing to safe dam operations. Operator engagement, when properly facilitated, provides tangible benefits ranging from improved tailings engineering properties to reduced closure costs. One important benefit is helping transitioning tailings management from reactive to proactive. There are many processes involved in the reactive to proactive transition process. One element of that process includes engaging operators in the tailings management process and facilitating legacy ownership. The core of operational legacy ownership is measured and described using five-stage operator engagement rubrics. Levels of operator engagement are presented with a description of the incremental benefits of each stage. An important part of legacy engagement is providing the tools to operators necessary for managing the tailings. Therefore, the approach identifies specific methods used by operations personnel to control tailings distribution and in-place properties. The end goal of leveraging operator engagement is to facilitate committed ownership and transition tailings management from an inefficient, reactive process to an improved, cost-effective, proactive practice.

Jul 1, 2021

By I Grewal, B Klein

The Knelson Continuous Variable Discharge (CVD) is a continuous centrifugal gravity concentrator for high-mass yield recovery applications. It has four operating variables that enable control of mass yield, product grade and recovery namely: fluidisation water, bowl speed, pinch valve open time and pinch valve closed time. Plant testing of a pilot scale Knelson CVD6 was conducted to evaluate the effects of operating variables on mineral separation. The analysis of operating variable effects has provided a framework for the development of operating guidelines for the CVD.

Jan 1, 2001

By C Fricke, R Wood, P Velletri

"In a climate characterised by an ever increasing focus on cost reduction and maximising the utilisation of existing assets and infrastructure, understanding the uncertainty associated with alternative investment and operational choices becomes paramount to minimising the risk of making an ineffective decision. To assist in this process, TSG Consulting has developed an analytic framework to capture the underlying complexity of a mineral supply chain, and then quantify the impact of the uncertainty associated with the key drivers of business productivity. The technical basis of this approach follows three distinct steps: analyse the current system and identify the major factors that drive value build detailed models that can measure the response of the system to potential changes in the factors identified quantify the sensitivity of financial and capacity forecasts to these factors.Each of the above steps draws on a different area from the field of applied analytics, namely: data analytics dynamic modelling and designed experimentation meta-modelling and optimisation.Following the three-step approach described above ensures a rigorous modelling and analysis process is executed to support strategic mine planning decisions. The approach is equally applicable to the analysis of fully integrated system supply chains (pit-to-port), the evaluation of incremental capital investments to targeted areas of a supply chain, or when considering revisions to the operating philosophy of a system in the short term. The basis of each of the three analytic steps is explored in detail in this paper. The result is the definition of a structured mechanism for a business to actively manage risk and drive productivity as a component of the strategic mine planning process.CITATION:Fricke, C, Velletri, P and Wood, R, 2014. Enhancing risk management in strategic mine planning through uncertainty analysis, in Proceedings Orebody Modelling and Strategic Mine Planning Symposium 2014, pp 275–280 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Nov 24, 2014

By D Stow, R Goodridge, K J. Molloy

A range of explosives has been specifically developed for soft ground blasting. These explosives can be used in both wet and dry blasting conditions, range in density from 0.3 - 1.2 g/cc and range in VoD from 2 - 4.5 km/s. This range of explosives has the potential to be tailored to ground type and is predicted to be suitable for a variety of applications which include: blasting in soft to medium overburden, coal blasting, wall control, and low vibration blasting. Trials have been conducted in several applications with encouraging results. Several cast/throw blasts have been conducted with these products partially replacing either ANFO or Heavy ANFO. The results from the blast have been equivalent in cast (per cent) and at reduced cost per unit volume. These products have also been used in presplit blasting and have again achieved equivalent or better results when compared to conventional presplit blasting at a lower cost per unit volume. This product has also been used in a vibration sensitive area replacing traditional explosive products, and generating excellent fragmentation and digging whilst maintaining vibration limits. This new range of products, NOVALITE, has shown great potential in many applications either reducing cost per unit volume, improving wall quality or improving productivity in environmentally sensitive areas.

Jan 1, 2001