Search Documents

By Oda Y, Hashiuchi M

In the smelting section, flexible fuels such as coal or coke are used in place of heavy fuel oil in order to utilize energy sources more efficiently. Heat recovered from the off gas of the furnace has been converted by the waste heat boiler into steam, which is used for self power generation and for heating or maintaining various temperatures. The amount of the recovered steam in the smelter is currently increasing due to maximum utilization of powdered cokes. The heat source required to maintain the temperature of the electrolyte in the tank house is electric power and steam. However until recent year this steam was provided by its own heavy oil combustion type boiler in the tank house since the amount of steam consumed in heating the electrolyte is large. Though experimental work over the last few years has shown the advantages of reducing steam in the tank house by fully covering the cell, the implementation of the full cover can lead to other operating problems. However various improvements, mainly the covering of the cell with a simple device, have led to greatly reduced steam consumption. As a result, steam for the tank house is now provided by the waste heat boiler only bringing more efficient energy usage.

Jan 1, 1987

By D Mukendi-Ngalula, G Hearn

Beach sand minerals from the volcanic rock structures of the Drakensberg, Kwazulu-Natal, (South Africa) have been processed. Screening, flotation, spiral concentration and magnetic separation methods were used either separately or successively in an attempt to concentrate monazite minerals. Products thereof and those from a long time (up to 72 hours) microwaves treatment of the finally produced ilmenite-bearing minerals have been studied using the M÷ssbauer effect spectroscopy. The 57Fe M÷ssbauer effect spectroscopy has demonstrated its versatility and power in monitoring the ilmenite internal reduction mechanism and products and, in characterising the iron-bearing phases contained in different products from the beach sand minerals processing. Microwaves heating of ilmenite for up to 38 hours reduced internally the Fe3+ from the ilmeniteÆs structure. A more prolonged microwaves heating (up to 72 hours) re-oxidised the mineral. 61 per cent natural ilmenite recovery was obtained in the floating products of a spiral concentrated -212+106 ¦m screened and beach sand minerals fraction. A preferential concentration of hematite with a 62 per cent recovery was found in the sinking products while the combination of screening-spiral separation-magnetic separation and flotation yielded a floating product with the highest ilmenite and the highest hematite abundanceÆs (71 per cent, 19 per cent respectively). A natural ilmenite containing 87 per cent ilmenite and 13 per cent hematite could be produced and extracted from the sinking products of the flotation process collected subsequently to the spiral concentration and the initial screening.

Jan 1, 2000

By Heath E, van Calsteren P, Turner S, McDermott F

U-Th isotope studies of recent volcanic rocks may be used to evaluate the depths and rates of melt generation beneath mid- ocean ridges and ocean islands. Island arc rocks exhibit a similar range in Th isotopes to that seen in both MORB and OIB, but while those with high (230Th/232Th) tend to have excess 238U, many of those with low (230Th/232Th) are in isotope equilibrium. The excess 238U is attributed to the preferential mobilisation of U in hydrous fluids from the subducted slab within the last 100,000 years, whereas the low Th isotope ratios in the higher-K arcs are primarily due to the introduction of subducted sediment. Preliminary results from mineral separates from lavas on Soufriere on the island of St. Vincent indicate that some of the minerals crystallised up to 50,000 years prior to eruption.

Jan 1, 1995

By Duncan GR

Having passed through a number of previous phases the best longwall results in Australia have shown a significant increase in the last two years. The results expected from a longwall face can be estimated from the ideal production rate, determined by the capacity of the equipment and the conditions in which it is installed, the utilisation, and the available operating hours. Back analysis of the results achieved suggests that, on average, recent improvements arise from the higher capacity equipment recently installed; the utilisation has in fact reduced slightly. Review of the constraints which limit the longwall results, i.e. shearer speed, AFC capacity, support, advance rate, and man travel speed, shows that little improvement can be expected in the ideal production rate in thinner seams. In thicker seams the AFC often proves the overriding constraint and further increase in equipment size could lead to increased future ideal production rates and is expected. In all cases a concerted effort to increase the utilisation achieved is likely. For deep mines with thin to medium seams this offers the most viable path to improvement; by contrast thick seams with highwall/shallow access may benefit from further increase in equipment size.

Jan 1, 1988

By Kuwasaki N, Mitsune Y

Many activity measurements of components in liquid oxides have been reported in the field of slag chemistry. However, very little is known about the thermodynamic behavior of compo- nents in oxide solid solutions. In the present paper, e.m.fs. of the follow- ing galvanic cells employing solid electrolyte Zr02(CaO) were measured on the entire range of composition of the solid solutions. Pt/Ni-(Mgl-x ix)O/ZrO2(CaO)/Ni-NiO/Pt Pt/Ni-(Mgl-xNix)2SiO./ZrO2(CaO)/Ni-NiO/Pt Pt/Ni-(Mg l-xNix)Si03/ZrO2(CaO)/Ni-NiO/Pt. Activities of NiO in these solid solutions of (Mgl_ Nix)O and (Mgl_ Nix) 2Si0a(where 0

Jan 1, 1980

By R Cannings, J Wallace, M McCamley

The mining industry continues to have major disasters (Bingham Canyon, Pike River, Upper Big Branch, Mount Polley and Samarco), which often have a devastating effect on the enterprise, in terms of personnel deaths and injuries, environmental destruction, and financial and reputational loss. These disasters are not imposed from outside the business or organisation, they are almost always a function of loss of control of the management of the organisation’s critical assets and processes that they contain or to which they are exposed.Asset integrity is discussed as an effective response to business risks in order to mitigate, control and recover from loss scenarios that could expose a mining operation to significant property damage and business interruption, or even total loss. Vital to this process is the identification and control of risks to critical assets. Components of a critical asset assurance program are presented for discussion.Formal risk assessment has a longer history in industries other than mining, eg petrochemical, nuclear, military, aviation and space industries. Risk assessment is a structured, proactive approach to understanding and improving risks, as opposed to a reactive ‘fix-it-when-it-breaks’ mentality. Risk assessment techniques were triggered by major public disasters, such as the Flixborough chemical plant disaster (1973), Three Mile Island nuclear plant event (1979) and others.Today, most industries see risk assessment as an inherent part of their business, but do mining sites capture business risks that are related to major loss scenarios, which could have a significant impact on the operation?Does your risk assessment process:- involve a team having the right skill set so that the discussion is both stimulated and technically sound?- use generic assessment when a site-specific assessment is needed?- fail to consider all possible outcomes, including maximum foreseeable loss (MFL)?- fail to identify all hazards and controls associated with a particular activity?- fail to monitor controls effectively?This paper addresses the issues identified by these questions and provides some direction for developing a risk management process where business risk associated with critical asset integrity is integrated with other business and safety and health risk processes to provide a robust method for managing your business. Case studies and common findings from critical asset failures are used to support the need to include critical asset assessments as part of business risk management processes.CITATION:Wallace, J, McCamley, M and Cannings, R, 2016. How robust are your asset integrity management processes? In Proceedings International Mine Management Conference, pp 53-64 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jun 22, 2016

By Bassett N

The Eneabba deposit, located 280 km north of Perth, Western Australia, and 30 km inland (Fig. 1) is one of the most recently developed deposits of mineral sands in the world. The area has been in production since 1974, while the Associated Minerals Consolidated Limited (AMA) operation commenced production in 1976. Total ore reserves of close to 400 million tonnes contain about 40 million tonnes of heavy minerals (proved and probable).

Jan 1, 1979

The operation of quarries for the production of crushed stone and aggregates, depends heavily on rock blasting efficiency, which usually represents a major share of total production costs. After investigating the causes of this situation, a series of technical aspects have been detected, and they are described for the purpose of contributing to the minimization of costs, which also reduces the effects of blasting on the environment. Utilization of empirical design methods, of inadequate explosive types, and of erroneous drilling pauems with respect to rock properties, are the main factors to be corrected, as a consequence of poor engineering criteria, with scarce use of computational methods and field instrumentation. Several concepts of blasting optimization are pointed out, and their application to industrial operations in a Portuguese limestone quarry indicated clear trends for the reduction of production costs, as well as some of the deleterious consequences of blasting on the environment.

Jan 1, 1990

By Budden J. R, Rhodes M. K

Bacterial oxidation technology was successfully applied in a mine site pilot plant for the treatment of refractory gold concentrates. The bacterial culture was proven capable of selectively breaking down the refractory sulphide minerals to release the gold. Gold extractions greater than 90 per cent were possible when oxidised concentrate was leached with cyanide solution. The pilot plant was designed using data scaled up from laboratory testing and sized for transport by standard vehicles. The bacterial culture used to break down the refractory gold-bearing mineral was a natural mixed culture able to withstand temperatures up to 55¦C, thus making the technology particularly suitable for use in Australian and in some North American gold mining regions. The pilot plant was operated at the mine site over a six month period. Performance of the bacterial oxidation technology under site conditions was as predicted from the laboratory testing. It was demonstrated that the culture was robust under normal site condi- tions and that the culture could withstand wide variations in the feed and the operating conditions, while still achieving satisfactory oxidation levels. The technology was able to be utilised by site operators and supervisors with minimum intervention. Design data for a commercial facility was collected for a number of different concentrate samples and a feasibility study completed. Estimated capital and operating cost have been obtained.

Jan 1, 1991

By Ghose AK

Design and selection of support systems for longwall faces call for in-depth know- ledge of strata mechanics and in particular of strata-support interactions. The paper presents the results of field investigations and analysis of a difficult-to-cave roof using powered supports under a massive dolerite sill in Central India using a state- of-the-art datalogger system. The mechanised long wall face was equipped with 4/680 tons chockshields operated on the IFS mode using a 300 KW DERD shearer. The datalogger system was capable of storing data simulta- neously in 32 channels. The paper describes the monitoring system and the monitoring programme. The system provided useful information on support behaviour, build- up of leg pressures and face convergence during an intense dynamic periodic weighting phenomenon which destroyed the integrity of almost half of the face supports. At this point, the face had advanced by about 197 metres from the barrier. The paper outlines a post-mortem analysis of this dynamic event and provides a critical evaluation of the data collected for understanding strata support interaction and the behaviour of the massive sill in the overburden.

Jan 1, 1992

By D Hume

During 2001 the Ridgeway Gold Mine, driven by company initiatives and recent NSW legislation (General Rule 2000), developed and implemented Major Hazard Management Plans to control significant hazards identified at the underground mine. The paper presents the objectives, issues, outcomes and process involved in the development and implementation of the plans at Ridgeway. The sharing of the experience gained and an overview of the intended way forward will offer a valuable insight for other mines considering embarking on a similar journey.

Jan 1, 2002

There are a number of mineral processing operations which produce at some point a stream of hot particulates. At today's energy prices it becomes important to recover the energy held in the hot particulates. Sometimes it is convenient to use gas, e.g. in air pre- heating, and this will be appropriate in some circumstances. There are cases where it would be very useful if energy in the hot processed particles could be exchanged to the cold feed solids. This can be achieved within appropriate limitations by countercurrent heat exchangers comprised of parallel channels which contain, alternately, fluidized solids of 'hot' and 'cold' streams respectively. A pilot- plant has been built. Some calculations relating to industrial application will be Presented.

Jan 1, 1981

By S S. Kanchibotla, I Brunton

Most blast fragmentation models assume the rock mass properties, explosive properties and blast design variables to be constants and uniformly distributed within a blast. However, in reality all these input variables vary within a blast resulting in variation in the resulting fragmentation size distribution. A stochastic modelling approach is introduced in this paper to quantify this variation. This technique takes the input variables as statistical distributions rather than constants and through several thousand iterations, generates a statistical representation of the expected fragmentation resulting from a production blast. A case study of three production blasts from a large open pit mine are presented and the modelled fragmentation æenvelopeÆ shows good agreement with the fragmentation æenvelopeÆ estimated from Split image analysis. The various blast-related parameters influence different parts of the fragmentation distribution, eg rock strength and explosive velocity of detonation have most impact on the fines. The technique is used to identify the parameters that have the greatest influence on various size fractions. Such an analysis will be useful to direct resources to efficiently minimise the variation.

Jan 1, 2001

By Kesser Z, Vincze T

The Western Mining Corporation mining lease on the Bendigo Goldfield measures 5krri x 18km with more than 20 anticlinal folds parallelling th long north-south boundaries. Numerous closely spaced shafts and extensive underground workings on the reef lines along the folds flooded with groundwater following the progressive abandonment of the field. Preliminary water sampling and assessment demonstrated that a major dewatering programme and acceptable disposal methods were necessary to dewater interconnected old workings in areas of interest prior to any underground work taking place. A field wide geohydolic investigation was undertaken to establish geohydraulic parameters, groundwater recharge rates and water qualities. Data from the field investigation together with estimates of the volume geometry of the submerged workings as obtained from old mine plans, production history, and limited pump testing results were used with an appropriate analytical model to obtain estimates of water discharge rates required to reach various dewatering targets. Water disposal options were limited by relatively high salinities, arsenic levels, contained hydrogen sulphide, and the mine locations within the urban areas surrounding Bendigo. Direct disposal to the surface drainage system could not be considered, treatment to acceptable discharge standards was not economically feasible, and it was necessary to adopt a strategy of collection, containment, and evaporation.

Jan 1, 1988

By Wood P. D, Pettifer G. R

In the upper coal surface in the Latrobe Valley, craters known locally as fireholes have developed due to prehistoric coal fires. They can be several hundred metres across and up to fifty metres deep, and are now filled with overburden materials varying from hard baked clays to very soft lacustrine clays. In addition to reducing coal reserves, continuous mining operations are seriously affected by fireholes. Large undulations in the upper coal surface result in a mixture of coal and overburden on the upper mining levels. The very soft lacustrine clays are unstable in the mine batters and the overburden dump, are difficult to handle on the bucket wheel excavator/conveyer system, and have insufficient bearing capacity for the large bucket wheel excavators. Early identification is essen- tial and both drilling and dynamic core penetrometer have been exten- sively used. However, this has not proved adequate in locating and defining the extent of all fireholes, due largely to their irregular shape. To overcome this a range of geophysical techniques has been trialled with very promising results. A trial area has been covered on a twenty metre grid using gravity and Geonics EM34 conductivity measurements and the same area has been covered at a closer spacing with high resolution magnetics. Image processing of contoured magnetic, EM34 conductivity and residual gravity data has resulted in very good correlation with drilling data.

Jan 1, 1989

By Koppe J. C, Costa J. F C L

This paper compares different results for overburden volume estimation assisted by geoestatistics, particularly using kriging methods. The main goal is to obtain the most reliable digital terrain model for the calculation of the overburden volume. The data was collected on an irregularly spaced grid and interpolated values were calculated to provide a denser, more regular data set before volume estimation. The field work was developed at the Butia-Leste Coal Mine, southern most Brazil, where an accurate survey was done using a total station theodolite with electronic data collector. The study was developed in five main steps: data acquisition, exploratory data analysis, spatial continuity measurements, point and block kriging estimation and verification of the results. Data acquisition was carried out on a 5 x 5 in grid. This dense grid provides an exhaustive data set of the real terrain against which data subsets can be compared for the various interpolation procedures and volume calculation. This provides an interesting insight into the influence of the number of data on the estimation error. Univariate statistics were used to compare each data subset and the exhaustive dataset. Ordinary kriging on the data subsets followed by contouring was carried out using Geoeas and Surfer software respectively. A subroutine written in C provided the link between the files generated in Geoeas and subsequent contouring routines embedded into the Surfer package. Omnidirectional and directional variograms were modelled defining the parameters for kriging estimation using Geoeas. Different variogram models were checked through cross validation prior to kriging. A comparison between the magnitude of the differences in volumes calculated with the different DTMs was attained. These final result indicates the sensitivity of the volume obtained to the number of data points. As the number of data points increases the estimation error decreases, but at some point there is no significant decrease in the final volume with the collection of additional data.

Jan 1, 1995

By M Wortley, J McKay, D La Rosa, O Guyo

It has been a generally held concept that crushing operations were, by their nature, too simple to benefit from the implementation of advanced process control. The commissioning of an OCS¬ expert control system and image-based oversize detection system, VisioRock, at the Pilbara Iron Tom Price facility are dispelling these notions. A constraint-based OCS¬ expert control system has been designed and commissioned on the high-grade crushing and screening plant along with a vision-based oversize detection system functioning on six product conveyor belts. To date, the expert control has demonstrated the ability to increase production by maximising dynamic constraint utilisation. Dynamic constraint utilisation is a concept developed by Rio Tinto Technical Services for effectively evaluating constraint-based control logic performance. The VisioRock system has been installed and configured and has been operating for a period of several months. Currently, Tom Price and Metso personnel are working to define correct oversize detection thresholds. Details of the plant implementation are discussed.

Jan 1, 2006

By S Hanrahan, S McLaughlin

A case study is presented that details the safety journey at a North American project involving two major contracts: a 1000 m shaft recovery and rehabilitation, and the development of a drainage gallery in a large open pit operation. In the early stages of the contracts, there were a number of incidents that created tension between the owner and contractor, which resulted in the contractor being placed on a final warning with almost imminent potential termination. As a result of this, it was agreed to initiate a focused safety recovery plan as a ‘last chance’.Over a period of two years, the engagement and consequent performance of the contractor was turned around, steadily working to set it up for success such that in one of the contract work areas, a record of ‘one year LTI (lost time injury) free’ was achieved. The journey involved the owner and the contractor teams working cohesively to educate all parties in the safety requirements and, most importantly, providing the context and understanding for certain requirements being put in place. Early on in the process, it was recognised that the owner team unknowingly was an impediment in that they did not fully understand the safety requirements and so was not able to lead the way for the contractor effectively. The journey to rectify the situation was supported and followed up by focused engagement with the project team, which generated a progressive improvement in a very challenging environment.In particular, the contractor turnaround was significant and of enough value for the contractor to ultimately export some of the safety systems from this site to other contract sites. This demonstrated the ultimate benefit of the contractor understanding and buying into a safety culture and system.CITATION:Hanrahan, S and McLaughlin, S, 2016. Winning the safety battle, in Proceedings International Mine Management Conference, pp 181-186 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jun 22, 2016

By Reichardt Y

Fine feed fractions in the size range from 1 to 40 ¦m of materials with different hardness as limestone and silicon carbide have been stressed in two different devices. A tungsten-carbide-blodc allows a single stressing with a pressure up to 2000 MPa and a 4-piston-block enables a multiple stressing procedure in which the material bed is stressed in alternating directions with a pressure up to 700 MPa. The experiments show energy absorption as the major factor for the interparticle breakage of hard material, like quartz, zircon silicate, silicon carbide and smelted oonindum, pressure, however, does not influence the results within the investigated range from 100 to 700 MPa and even up to 2000 MPa for corundum. But the breakage of the middle-hard limestone depends on the pressure so far as more fineness can be produced if the same energy is introduced at a lower pressure level. The creation of very fine and microfine fragments decreases strongly with increasing hardness of the feed materiaL The energy consumption for producing microfine material with a multiple stressing procedure on a particle bed is much lower than that one of a usual milling process. But this procedure needs a classification with a seperation cut at a couple of microns, which is not easy to accomplish.

Jan 1, 1993

By Waterhouse J. D, Harris B. M

This paper briefly describes the construction in 1979/80 of a 70m deep trial open pit coal mine near Bowmans S.A. and describes more fully the hydrogeological aspects of the exercise. The primary purpose of the Trial Pit was to provide a large sample (700 tonnes) of coal for combustion tests to be carried out in West Germany and the United States of America. Consideration was given to obtaining the sample of coal by drilling and by shaft sinking as alternatives to open pit methods. It was expected that economic mining of the deposit on an operational scale could only be achieved by open cut methods and it was recognised that major uncertainties existed in planning such a mine in the deep unconsolidated multi-aquifer deposit. It was therefore elected to obtain the bulk sample by constructing a trial open pit, which would be closely monitored to provide as much data as possible for future planning of a full scale mine. The dewatering of the Trial Pit was achieved using 26 deep pumping wells, assisted in the later stages by several hundred well points. This was probably the largest dewatering project currently in operation in Australia.

Jan 1, 1981