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By J Butler, N Patel, S Narendranathan, S Rastogi

The Yallourn Mine (YM) commenced mining of brown coal in the 1920s under operation by the State Electricity Commission of Victoria (SECV), prior to it becoming privatised in 1996. The present owners of the YM, Energy Australia Yallourn (EAY), acquired the site in 2000 and intend to continue operations until scheduled closure in 2028. Brown coal extracted from the YM is fed into the Yallourn Power Station which supplies approximately 22 per cent of Victoria’s electricity. Water within the YM is collected and stored in the Township Field Fire Service Pond. Water levels within the Fire Service Pond (FSP) may fluctuate considerably depending on the requirement for storage at the site. With due consideration to the stability performance of mine batters adjoining the FSP, the authors performed slope stability assessments to evaluate the risk and consequence of batter instability during the potential pond filling as it approaches the ‘critical pool’. The critical pond is defined as the level at which the driving forces (destabilising forces) are at their greatest and the resisting forces (lake forces, friction) are at their lowest. This assessment was undertaken using the Mine Geotechnical Risk Index (MGRI) approach.

Aug 2, 2023

By K B. Quast

During the prefeasibility stage of the mining cycle for a gold deposit, an evaluation of the ore leaching characteristics from various defined areas is essential prior to plant design. There are a number of simple laboratory tests which have proven successful in establishing gold and silver leaching kinetics, carbon adsorption and fouling, as well as elution characteristics. A number of case studies of carbon-in-pulp (CIP) simulation are presented which show excellent agreement between calculated and assayed gold and silver grades in feed and adsorbed on carbon which validate the methods used.

Jan 1, 1998

By C M. Ramotsabi, F Bornman, W Erasmus

Spiral concentrators are gravity based separation devices used for the preparation of coal, iron and heavy mineral ores (Wills, 1992). Gravity concentration remains the main separation method for fine iron ore and is used extensively for treating many minerals. Gravity concentration methods separate minerals of different specific gravity by their relative movement in response to gravity and one or more other forces, the latter often being the resistance to motion offered by a viscous fluid such as water or air (Wills, 2006).The main operating variables for a spiral concentrator are the feed rate, the slurry concentration, the wash water addition and the position of the splitters used to separate the tailings, middlings and concentrate streams (Sadeghi, Bazin and Renaud, 2014). Wash water is an important control variable used to wash away entrapped light minerals from the concentrate stream (Burt, 1984; Bouchard, 2001). Sadeghi et al concluded the spiral operation to be sensitive to the wash water flow addition and resultant economic trade-off. Increasing the wash water flow rate increases the concentrate grade at the expense of the iron recovery.The paper addresses the effects of dripping wash water onto the concentrate stream of a spiral processing fine iron ore. The dripping wash water system offers a low flow alternative and could possibly provide a good balance between grade and recovery of valuable minerals without using excessive water. The Multotec SC20HC/7 WW spiral was used for the experimental test work. The spiral was tested at varying solids concentrations; the wash water rate and the splitter positions were kept constant.The use of wash water at 30 per cent, 35 per cent and 40 per cent solid concentration improved the Fe grade in the concentrate by about 1.5 per cent, six per cent and eight per cent respectively. The additional SiO2 rejected by the wash water is approximately three per cent, nine per cent, and 11 per cent at 30 per cent, 35 per cent and 40 per cent solid concentration respectively. Addition of wash water is shown to have minimum effect on grade at 30 per cent solid concentration, and Fe upgrades obtained with and without wash water were found to be similar. Notable upgrades were observed at 35 and 40 per cent solid concentration with wash water. The results obtained suggest that the additional SiO2 rejection by wash water increases with an increase in solid concentration. This suggests that the benefit of using the drip system is notable at higher solid concentration. It is believed that at lower solid concentration SiO2 particles are reasonably free to move around and are possibly less entrapped than at high solid concentration.The Fe grade/recovery and solid concentration relationship with wash water showed a non-linear correlation. The Fe grade increases with an increase in solid concentration up to a somewhat optimum point and then drops as solid concentration increases further. The recovery of Fe on the other hand follows a converse relationship with solid concentration, the recovery decreases from 30 per cent to 35 per cent solid concentration and then increases again at 40 per cent solid concentration. The increase in recovery at higher solid concentration could possibly be explained by the fact that the mass yield to concentrate also increases with solid concentration. Since recovery is a function of both grade and mass yield, the higher recovery at 40 per cent solid concentration is likely due to the high mass yield obtainable at 40 per cent solid concentration.The drip system could therefore possibly offer a safe guarding against grade and solid concentration variations without using excessive water, and possibly ensure that a product within specification is maintained.CITATION:Ramotsabi, C M, Erasmus, W and Bornman, F, 2015. Optimisation of wash water on an iron ore spiral to improve grade, in Proceedings Iron Ore 2015, pp 175–184 (The Australasian Institute of Mining and Metallurgy: Me

Jul 13, 2015

At Cliffs Natural Resources Ltd (CNR) crushing and shipping sample stations, precisions are estimated for the sampling, preparation and measurement stages of iron ore sampling in accordance with ISO 3085 (2002). In this Standard, gross duplicate samples are prepared at each of the three stages, yielding eight measurement assays. Appropriate calculations of the differences between assay pairs are then made to estimate precision of each stage of sampling. The International Standard for checking precision in iron ore sampling, ISO 3085 (2002) prescribes a method for identifying outliers that is ambiguous and possibly inappropriate. The procedure also makes an unnecessary implicit assumption, that the differences between assay pairs are normally distributed. The Anderson-Darling statistic is used to demonstrate that in some cases the assay pair differences have distributions significantly different from normal. When applied at CNR as specified, the Standard leads to precision estimates well below the expected values, thus overestimating the sampling method's capability and limiting the opportunity for real process improvement. This paper suggests an improved method of estimating sampling, preparation and measurement precision. A bootstrap procedure is used to estimate confidence limits for the calculated precision estimates. The proposed method would be suitable for testing blasthole precision. The discussion is supported by extensive simulation modelling of realistic data.

Mar 1, 2010

By N Ganjian, A Delavar, F Rashidi Nejad

Iran is one of the most seismically active countries in the world, being crossed by several major fault lines that cover at least 90 per cent of the country. As a result, earthquakes in Iran occur often and are destructive. So, it is important to consider the seismic stability and reliability of all structures including tailings dams.In this study, the tailings dam stability of the Sangan Iron Ore Mine in Khorasan Razavi, Iran is considered for the case study. The tailings storage facilities of the mine have three cells with the capacity of 45 million cubic metres. The first cell, which has three stages of dam raising, has been recently brought into operation. This cell has a downstream-raised retaining embankment. As the risk of seismicity in this area is high, seismic response of this dam was evaluated by numerical methods. To do this, appropriate models were developed for materials used in foundation and body of the embankment. Then for seismic stability analysis, Tabas (Iran – 1978) and Chi-Chi (Taiwan – 1999) earthquake acceleration simulations were applied.The results of this study indicated that the upstream portion of Stage 3 of the dam and dam crest did not experience significant horizontal displacements during earthquake period, but the downstream portion of Stage 3 of the dam showed a maximum horizontal displacement of 60 cm at the third stage of dam raising. This is three times more than what was estimated by the designer. Also, the maximum vertical displacement resulting from simulation of the Tabas earthquake was 35 cm. The results of dam response to Tabas and Chi-Chi earthquakes indicate that displacement, shear stress and pore pressure by the Tabas earthquake were higher than the case of Chi-Chi earthquake. The higher energy of Tabas earthquake and the higher frequency near to the natural frequency of Tabas earthquake could be the reasons of this difference. The results of this case study confirm that if the studied tailings dam impacted by an earthquake of a similar magnitude to Tabas, the dam will be seismically stable and the developed strains will not be significant.CITATION:Delavar, A, Rashidi Nejad, F and Ganjian, N, 2015. Seismic stability analysis of Sangan Iron Mine Project tailings dam, in Proceedings Tailings and Mine Waste Management for the 21st Century , pp 173–182 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 27, 2015

By S Watson, L Martinez

Mine projects are complex opportunities that demand a constant assessment of uncertainty, ie risk and upside potential. This is because the value of a mine project is typically influenced by many underlying economic and physical uncertainties, such as metal/mineral prices, metal/mineral grades, costs, schedules, quantities, and environmental issues, amongst others, which are not known with much certainty at the beginning of the project. But, is uncertainty an enemy or an ally of the mine planner/analyst? To answer this question, this paper first assesses and elaborates upon the general concept of uncertainty. It then looks at the different sources of uncertainty in a mining project, such as the orebody, costs and product price uncertainties, and their effect on the final project value. Next, a general?review?of current mine evaluation techniques highlighting their limitations when dealing with uncertainty is made. Finally, an extended evaluation and risk management framework that addresses the existing uncertainty in the (greenfield/brownfield) mine evaluation process is proposed. One important characteristic of this framework is that it uses and manages uncertainty in order to generate additional value to the project; this is done through operational and managerial flexibility, which allow mine planners to minimise/maximise project risk/upside-potential giving a more realistic estimate of the projectÆs market value - this is shown in practical and simple examples occurring at different stages of a mine project, such as exploration and operation. Final conclusions are provided at the end.CITATION:Martinez, L and Watson, S, 2012. Uncertainty - An important source of (additional) value for mine projects, in Proceedings Project Evaluation 2012 , pp 131-140 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 24, 2012

By R O’Sullivan, D Taylor, J G. McLellan, B Miller

The Mount Isa copper deposit is located adjacent to the city of Mount Isa, Queensland, and lies within a series of Palaeoproterozoic to Mesoproterozoic Superbasins. The deposit is hosted almost entirely within the Urquhart Shale (US), a unit of the Mount Isa Group sediments and part of the Isa Superbasin. The copper mineralisation is separated into two distinct orebodies: the X41 mine (1100 and 1900 orebodies) and the Enterprise mine (3000 and 3500 orebodies). The orebodies are situated in the hanging wall of the major controlling structures, the Paroo Fault, which has juxtaposed older basement Eastern Creek Volcanics against the younger Mount Isa Group sediments cf 1655 ± 4 Ma. Conjecture remains over the exact timing of this thrust event. However, it is clear that inflections on the Paroo Fault have a close association with the orebodies and are an important structural feature in the mineralisation of the Mount Isa copper deposit.The life-of-mine is reducing steadily and new geomechanical modelling techniques were employed to target structurally controlled mineralised zones in three dimensions. Following a structural review of the mine using underground mapping, structural data and core shed observations, a conceptual 3D mine model was constructed utilising existing data modelled in MineSight®. This conceptual model included all the main lithological units and structures. The conceptual model aimed to test the effects of deformation on the main lithological and structural components of the system and attempted to highlight areas of anomalous stress and strain that may indicate a higher likelihood of fluid focusing and mineralisation potential. This project was focused on testing the latter stages of a D3 event (NE–SW compression) and D4 event (SE–NW compression), which are considered to be responsible for the current location of the mineralisation.The fully coupled 3D finite element analysis models resulted in highlighting anomalous patterns of stress and strain and subsequent fluid flow as a result of the two deformation events. The NE–SW D3 simulation provided the best correlation with the known distribution of mineralisation. This event also indicated several areas on the Paroo Fault and within the US that have potential to host further areas of mineralisation. The SE–NW D4 simulation provided less of a correlation with known mineralised zones. However, this event may have been responsible for post mineralisation re-mobilisation of copper on a relatively small scale. Areas of maximum shear strain, shear stress, volumetric strain and fluid flow correlated well with areas of minimum principal stress and provided the best overall match with known mineralised zones. Furthermore, several additional highlighted areas provide a high potential for further discovery of copper mineralisation. Recent exploration drilling north of the Enterprise mine 3000 orebody, utilising geomechanical modelling as part of the targeting criteria, intersected copper mineralisation, providing further validation of the modelling results.CITATION:McLellan, J G, O’Sullivan, R, Miller, B and Taylor, D, 2014. Geomechanical modelling of the Mount Isa copper deposit – predicting mineralisation, in Proceedings Ninth International Mining Geology Conference 2014 , pp 197–206 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 18, 2014

By K Williams, T Donohue, W Chen, T Roessler, A Katterfeld

Wet sticky iron ore poses particular difficulties in every aspect of the material handling process. Material hang-ups in bins, pipes and chutes; carry-back and spillage due to insufficient belt cleaning; clogging of screens; malfunctioning of crushers as well as rat holing of gravity reclaimed stockpiles are all predominantly due to the inherent cohesion and adhesion characteristics of the wet, sticky ore (Roberts, 1993). Limited understanding and quantitative measures on the stickiness of such a material significantly lower the mining operation efficiency.This research aims to investigate the cohesion and adhesion characteristics of the wet, sticky ore on physical modelling, experimental techniques and numerical implementation. Initially, the suitable bridging mechanism that contributes to the cohesive and adhesive forces within the iron ore material was identified (Hering, Martin and Stohrer, 1989; Rumpf, 1958). A cohesion/adhesion energy density factor based contact model was then introduced to describe the stickiness of the material. Secondly, an experimental system was proposed to directly test the stickiness of the material. Such a system is able to obtain both the cohesive/adhesive shear force and tensile force of the material at a specific moisture content. Lastly, the implementation of the proposed cohesion/adhesion model into the discrete element modelling (DEM) software was also discussed. A cohesion/adhesion calibration for modelling wet sticky iron ore in DEM was then conducted to ensure the material modelled in the simulation is reflective of the reality.From the study, understanding of the cohesion/adhesion characteristics of the wet iron ore material is significantly enhanced. Experimental and numerical outcomes can be directly applied for better designing or optimising the material handling processes that involve wet sticky iron ore. Consequently, the mining operating costs can be greatly reduced.CITATION:Chen, W, Donohue, T, Williams, K, Katterfeld, A and Roessler, T, 2015. Modelling cohesion and adhesion of wet, sticky iron ores in discrete element modelling for material handling processes, in Proceedings Iron Ore 2015, pp 387–392 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

Development of the Davcra flotation cell has continued over the past seven years. Preliminary testwork on single cells has now been extended to a com- plete Davcra flotation circuit, to cells ranging from 5 to 400 tons per hour capacity and to cells operating on a variety of materials. Operation of both test and production units has shown the Davcra cell to be competitive with conventional flotation machines. It offers a lower capital cost installation than conventional cells and in addition has a number of. operating advantages, particularly in its adaptability to automatic control.'

Jan 1, 1971

By S Harris, A Bossilkov

The Kwinana (Western Australia) and Gladstone (Queensland) industrial areas are among the few dozens of heavy industrial areas globally that demonstrate significant levels of regional resource synergies. Such synergies are also referred to as æindustrial ecologyÆ or æindustrial symbiosisÆ. Fundamentally they involve the exchange of by-products or sharing of utilities between companies in close geographic proximity to achieve competitive advantage and environmental benefit. A concerted research effort is currently underway to foster greater realisation of regional resource synergies in minerals processing intensive regions, in Australia and internationally. This paper summarises current insights from the foundation research into engineering tools and technologies and enabling mechanisms for regional resource synergy developments. Regional resource synergy developments were reviewed for 16 international and two Australian regions. It was found that Kwinana and Gladstone compare favourably with the well-regarded international examples of regional synergy development. Given the fairly strong evidence that self-organisation is critical for regional synergy developments, an implementation model has been proposed that captures entry points for synergy developments at the level of platform (industry collaboration), process (developing synergy opportunities) and project (assessing and implementing specific synergies). It was also found that regional synergies have so far developed in the absence of specific methods for identification and screening of synergy opportunities. Moreover, very limited attention has been paid to the associated technological and engineering challenges. The current technical research effort therefore targets: the development of a toolset for the identification and development of potential synergy opportunities; and assessment of technology needs and opportunities for regional synergies involving water, energy and materials recovery and reuse.

Jan 1, 2006

By J E. Wajon

This paper discusses the background, requirements, need and content of plans for management of drinking water self-supplied to mining-related operations, including construction camps, especially in remote areas of Western Australia. The paper discusses the importance of cooperation between regulators, the mine site operator and the consultant in preparing a plan fully compliant with the Australian Drinking Water Guidelines to protect the quality and safety of drinking water supplied to mine sites. The paper outlines some of the issues that need to be addressed in preparing a drinking water quality management plan, such as hazard identification, risk assessment, the multiple-barrier approach and the concept of critical control points. Data requirements, monitoring, incident management, training and reporting are also covered.CITATION:Wajon, J E, 2013. Drinking water quality management for mining operations in Western Australia, in Proceedings Water in Mining 2013 , pp 321-328 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 26, 2013

By C Hedemann, N Silveste, H Davis, C J. Moran

For nearly two decades water scientists have been debating the need to use appropriate models for the questions being asked and the data available. This paper puts forward a rationale for a hierarchical framework for water balance modelling as it applies to mine sites. The hierarchy is based on the complexity of models and their data requirements. Scientific models are the most complex and require the most data; next is engineering models, then systems models and the simplest representations are given by conceptual models. A position is put forward that systems models have a range of uses that the others do not provide. A systems model, called SiteMiser, is described and its calibration illustrated. The model is applied to seven coal mines from the Northern Bowen Basin in Central Queensland. Currently, there is little relationship between total water use and coal production. This relationship is not any stronger when fresh (raw) water is compared to reused water. Leading practice water use levels are simulated for all sites. The simulation results demonstrate that there is considerable opportunity to reduce water consumption and, in particular, to import less fresh (raw) water to the sites.

Jan 1, 2006

By R Coleman

The flotation mechanism plays a key role in the flotation process. It is used to provide the contact between solid particles and bubbles and also the energy for these particles and bubbles to attach. The mechanism must therefore provide sufficient mixing to keep the solids in suspension so that they can be transported into the froth and recovered to the concentrate. The design of the mechanism is critical and over the past decade Outotec has developed and optimised a new mechanism design to improve metallurgical and energy performance. The FloatForce® mechanism consists of a rotor and stator arrangement and has been specifically designed to provide sustained mixing at higher air flows and lower power inputs.Over 500 FloatForce® mechanisms have been installed in existing and new operations. This paper outlines the technological aspects of the FloatForce® mechanism and provides metallurgical, operational and energy performance results from a number of flotation circuits in which these have been installed.

Aug 8, 2011

By C M. MacRae

The characterisation of high-P iron ores by field emission gun electron probe microanalyser (FEGEPMA) was carried out to determine elemental associations in iron oxides sensus lato and, using this knowledge, to speculate on possible P incorporation mechanisms in goethite. Quantitative data was collected from two goethite-rich bulk ores and results showed that in both samples goethite was the main repository for phosphorus. The P-rich goethite also contained elevated levels of both aluminium and silicon.To understand the mechanism of P incorporation in goethite, high-P grains were located by coarse mapping of polished blocks with the FEG-EPMA. Analysis of element distribution maps collected on the P-rich grains showed that low-P regions within grains were typically associated with low-Al and high-Si, whereas high-P regions were associated with high-Al and low-Si. Based on follow-up quantitative analyses, a coupled substitution mechanism for phosphorus incorporation within goethite was proposed: 2Si4+ = 1P5+ + 1Al3+. Additional quantitative analyses on further examples indicated the mechanism was only valid for Si contents in goethite of <1 wt per cent.Preliminary transmission electron microscope (TEM) studies confirmed the presence of P, Al and Si in goethite.

Jul 11, 2011

By K L. Avarmaa, M A. Rhamdhani, A D. P Putera, H T. B M Petrus, G A. Brooks

Multistage slag treatment was carried out to investigate boron removal from metallurgical grade silicon. Boron is known to be one of the most difficult elements to remove from silicon. Depending on boron initial concentration, boron can be removed from silicon into certain level; most previous studies have attained final 50–100 ppmw (parts per million weight) boron in the silicon using slag treatment. The term ‘multistage’ refers to a process where the resulting silicon from the initial slag treatment is further refined multiple times using a new slag. In this study, an initial slag composition of 45CaO-45SiO2-10Al2O3 (wt per cent) was utilised. Using this technique, boron level in the silicon was expected to be gradually lowered because the new slag will always have more capacity to reach the equilibrium distribution coefficient (LB = (ppmwB)slag/(ppmwB)Si). The current study was carried out through combined thermodynamic calculations (using FactSage™ ver 8.2, by Thermfact Ltd, thermochemical package) and high-temperature experimentation. The thermodynamic calculations were carried out for reactions at 1500, 1550, and 1600°C for three different scenarios: 1. Single stage refining with varied slag to Si ratio. 2. Multistage refining with slag to Si ratio of 1:1. 3. Multistage refining with slag to Si ratio of 2:1. The multistage experimental work was carried out at 1550°C under inert gas atmosphere each time for 2 hrs, with slag to Si ratio of 2:1. The simulation results indicate that the boron distribution coefficient stay essentially constant with varying slag to Si ratio and temperature, around 1.8 to 2, and the experimental results measured LB in the same range, between 1.5 and 2.5. By harnessing this feature, the simulation showed that boron can be removed by approximately 78 per cent in each stage. The experimental result confirmed that the boron concentration in the silicon was reduced by a total of 97.8 per cent from its initial value using four stages of slag treatment, from initial 270 ppmw down to 6 ppmw.

Aug 21, 2024

By A Mehrani, F Zamani, A Dehghani

Vibrating screens play an important role in the dry classification circuit of Gol-e-Gohar iron ore processing plant. This circuit was designed to classify the autogenous mill discharge and produce a suitable feed, with K80 about 450 ¦m, for dry magnetic separators. Three parallel vibrating screens produce more than 50 per cent of the separatorÆs feed. The efficiency of the magnetic separator is greatly affected by feed size distribution. In this work, the JKSimMet 5.1 software was used as an analysing tool to assess the flow rates and USIM PAC3 software as the simulation tool to control and optimise the vibrating screens. Samples were collected and the circuit was mass balanced. Then the vibrating screen was simulated and adjustment parameters such as cut-point, bypass and imperfection factor were determined. The product streams of vibrating screens can also be predicted.

Jan 1, 2007

By E McLean

The decision making check-list and hierarchy of information for process and plant design is generally wide-ranging and complex. The nature of grades, mineralisation and ore types in an ore body, its mine development sequence, and the body of results from metallurgical and physical test work present complex and competing influences on flowsheet development, values for design, equipment selection, plant efficiencies and operating strategy. The challenge is how to manage all these variables, to understand their impacts on performance, and how best to provide a cost-effective plant design and robust process that meets daily/weekly/monthly operating objectives. Throughput, production and grade or product specifications need to be met. The ore body is not average; its range of metallurgical and physical characteristics may be moderately to highly variable. This paper assesses some of the key competing influences and conflicting issues in design and equipment selection, and their effect on production and performance expectations.

Aug 8, 2011

People in economically developed societies demonstrate inherent human care for Earth and want to stop pollution. Yet efforts to clean Earth seem bogged in confusion from wildly contradictory and alarmist predictions of æclimate crisisÆ. Supposed experts openly disagree yet weÆre told thereÆs universal agreement humans are causing æthe end of life as we know itÆ. The turmoil combines with peopleÆs feelings of fear, guilt, anger, hopelessness and even resignation and apathy to trigger æclimate alarmÆ. The paper enables people to rediscover clarity, hope and support for Earth by understanding how climate alarm and confusion were created and how they actually increase pollution. Many people seem to think global warming is as serious as pollution and worry that questioning alarm will enable pollution. Yet theyÆre different. We need be even more concerned about climate alarm because history shows repeatedly that when buried by ignorance and panic real problems grow overwhelming. Environmental credibility is endangered by confused politicians and sensationalist media. When weÆre willing to re-evaluate what weÆve been told we replace fear and confusion with facts and freedom to identify opportunities. Combining this with practical understanding of human behaviour and leadership enables opportunities to be identified and action taken. The paper shows how confident, informed leadership leads and supports higher productivity and effective care for the natural environment.

Jan 1, 2009

By G van Niekerk, M Wortley

Screening is a critical part of many mineral processing circuits and keeping the aperture of the screening media within specification is vital to ensure efficient performance of the processing plant. Typical ways of estimating and/or measuring the wear of the screening media vary from very subjective methods (for instance, using the human eye) to manually checking the width of a few of the more severely worn gaps with a measurement device. Subjective methods can be flawed by human error while manual checking can distort the polyurethane or rubber materials that are used in several types of screening media. All of these errors can cause either premature replacement of panels or, even worse, poor screening of the material.Metso Process Technology and Innovation (PTI) and Metso Screening Media Solutions (SMS) have developed an innovative method that measures screen aperture using advanced image processing techniques. Field trials of the device are presented in this paper, which shows the comparison between the different methods of measuring apertures. Case studies demonstrate how the system, when combined with ScreenTrack, MetsoÆs industry leading maintenance system, and screening media, is providing users with the best possible screening solutions.

Sep 26, 2011

By D Thornton, R Hodson, D Sprott

Blast fragmentation size distribution and thus blast design have been found to have a direct impact on the load and haul cycle through excavator dig time and bucket payload. Previous studies have demonstrated that by reducing the excavator dig time and increasing bucket payload, significant improvements can be made in both productivity and unit cost. Simulation work reported in the literature indicates that a 20 per cent improvement in dig time may result in only a three per cent improvement in load and haul productivity and unit cost. At the same time, a ten per cent improvement in bucket payload will directly translate to a ten per cent improvement in load and haul productivity and unit cost. Based upon these findings, extensive laboratory and field work have been undertaken in the past to correlate blast fragmentation distribution to bucket payload. In contrast, the literature reports limited studies quantifying the impact of blast fragmentation on excavator dig time. Field work was conducted at Placer Dome Asia PacificÆs Granny Smith Mine (Wallaby Pit) in Western Australia, concentrating on quantifying the impact of blast fragmentation on the dig time of a Liebherr 994 hydraulic excavator (shovel attachment with 14 m3 bucket). Fragmentation was assessed for each truck load of material using the Split Desktop system, while the excavator cycle analysis was conducted manually. Measured fragmentation P80 (fragment size at which 80 per cent of material passes) values ranged from 200 mm to 1200 mm. The field study investigated the impact of various fragmentation parameters (P20, P50, P80, cumulative per cent passing 250 mm size fraction, and uniformity index) on the average and total dig times. The results indicate that the fragmentation P80 provides the best correlation to average dig time (total dig time divided by the number of bucket passes to load a truck). The total dig time was found to be dependant upon the fragmentation P80 and the number of bucket passes to fill a truck. Monte Carlo simulation results, based upon these relationships, indicate a 26 per cent improvement in average dig time and a 12 per cent to 46 per cent improvement in total dig time (bucket passes ranging from 4 to 8), with a change in fragmentation P80 from 600 mm to 200 mm.

Jan 1, 2003