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By O Ishiyama, L Lu

Sintering is the most economic and widely used agglomeration process to prepare iron ore fines for blast furnace use. Due to the depleting reserves of traditional high-grade iron ore, there have been considerable changes in iron ore resources available throughout the world, especially in steel mills in East Asia. Corresponding to the changes in the availability of iron ore resources, the amount of impurities in iron ore has been slowly increasing. Some of these impurities have been found to have deleterious impacts on sinter quality and sintering performance. In the meantime, an increasing number of large blast furnaces with inner volumes of more than 5000 m3 have been built that require more sinter and are often more demanding in terms of the quality requirements of the ferrous materials. Finally, sinter plants are facing increasing pressure due to more stringent regulations regarding their environmental impact. This paper gives an overall review of a variety of technologies developed worldwide to tackle the changing raw material characteristics and mitigate emissions from sintering operations.CITATION:Lu, L and Ishiyama, O, 2015. Recent advances in iron ore sintering, in Proceedings Iron Ore 2015, pp 61–68 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

A simulation model of the load and haul process where the loader cycle has been subdivided into its individual components is used to consider the benefits derived from improved drill and blast methods. Field data from a Hunter Valley mine is u

Jan 1, 1998

By L Hussey

Mt Keith concentrator treats low grade disseminated nickel sulfide ore supplied from the adjoining open pit mine. It is a traditional crushing, two-staged closed circuit grinding circuit (SAG & Ball Mills), followed by a complex split-size rougher, scavenger and cleaner flotation circuit. In 2016, 10.5 Mt was milled, at an average head grade of 0.54% Ni, yielding 35 000 nickel metal tonnes in concentrate.Historical analysis of the plant data indicated that of all the nickel lost in the fines rougher circuit tails stream, 25.6% was recoverable in an eight minute laboratory scale flotation test. These results implied that this fine nickel was readily available for recovery in the plant, either through operational improvements or additional flotation capacity. With operation optimisation ongoing, and capital within the business focused elsewhere, plant personnel were challenged to think differently about improving recovery.In 2012, a separate project to improve plant recovery when treating high talc ore was completed. Amongst other vessels, this project saw the installation of two 150 m3 Outotec Cells to the scavenger section of the fines rougher, middlings and scavengers (RMS 1) circuit. Since installation, the operation of these cells resulted in difficulties immediately upstream with instability in the scavenger cells. It was therefore decided that these cells would be better suited to treating the fines rougher circuit tails.The alterations required to divert these flows were minimal, with the capital project totalling $220 000.In the two years since installation, the fines rougher tailings nickel grade has dropped by 9.9%. The scavenger circuit has also seen a 2.8% reduction in tailings nickel grade, and instability issues were immediately resolved. This project serves as a lesson in how existing plant infrastructure may be better utilised to maximise recovery. Although this is especially applicable when capital constrained, such re-appropriation can be considered at any point to maximise return on existing assets. CITATION:Hussey, L, 2017. Repurposing flotation capacity at Mt Keith nickel concentrator, in Proceedings MetPlant 2017, pp 254–258 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 11, 2017

By Liu Y

Ventilation, air leakage, and various cutting, loading and support movement operations all have a role in dust distribution on longwall faces as shown by the results of a large number of dust measurements on different longwall operations in the Bulli seam on the South Coast. It is concluded that leakage of air on the face has demonstrable mfluence on the exposure of the shearer operator to dust level. It is possible to calculate dust generated by various elements of a rrurung operation on the face from a single point measurement. In the examination of dust deposition from the source of generation as a function of particle size, it is found that respirable dust can remain airborne over long distances without any significant drop in concentration, if unobstructed.

Jan 1, 1995

By H Haghighi

Haul roads are often permanent unsealed access roads used by heavy haul trucks to transfer minerals. These roads can deteriorate rapidly which results in potholes, deformations and dust. Downer EDI Works has successfully provided efficient solutions to the mining industry to maintain their haul roads. HaulPac as a solution package is a process in which a bituminous emulsion is used to create a stable and durable pavement. The emulsion penetrates the road and binds the particles together, creating a stable base. It also seals the surface and prevents water from penetrating the underneath layers. Bituminous emulsion can increase the strength of the pavement material and decrease the road surface degradation which results in dust suppression. However, the everincreasing price of commodities, the necessity of reducing carbon emissions and the increasing use of autonomous haul trucks have made it vital to invest in novel maintenance solutions that can meet the needs of the mining industry in a cost-effective manner. This paper outlines the benefits of bituminous emulsion in terms of productivity, safety and environment followed by Downer’s approach to evaluate the suitability and to optimise the amount of product. The potential for changing the colour of the treated surface is explored and an initiative that incorporates end-of-life tyres of haul trucks into the pavement is introduced. And finally, an innovative method using artificial intelligence to estimate dust emission is presented.

Sep 18, 2023

By T Baumgartl, D Bradshaw, B Forsyth, M Edraki

In a tailings storage facility, the chemistry of pore water is a function of oxidation and dissolution of sulfide minerals, containing metals and metalloids, the neutralising effect of gangue minerals and the geochemical processes controlling solute equilibria such as pH, redox potential, precipitation, ion exchange and adsorption. On the other hand, the changes in geochemical composition of tailings feed over time is a function of spatial variability within the orebody and modifications in processing method. Tailings properties such as pyrite content, pH, concentration of deleterious elements, surface chemistry, pore water chemistry and particle size are already shaped in the dynamic environment of a process plant.To engineer desired environmental outcomes, a new research framework is needed. The new approach should follow the physical and geochemical processes of tailings feed and construct models that can be used for the prediction of seepage water quality and dust propagation and evaluate the potential re-processing of tailings or production of tailings with desirable surface chemistry, particle size and internal structure. The challenge of developing tailings engineering model is not in laboratory techniques, but more of the overall communication of results and establishing the link between disciplines. It requires investigating geochemistry across mining and processing for improved environmental outcomes at tailings storage facilities.The paper reviews the current tailings management practices by comparing the geochemistry and mineralogy of tailings and the chemistry of seepage water from three Australian case studies in the context of geology, mineral processing and climate. Some alternative methods of tailings management are also reviewed and it is concluded that a proactive multi-disciplinary approach is needed with respect to tailings management, based on a novel integrated research framework.CITATION:Edraki, M, Forsyth, B, Baumgartl, T and Bradshaw, D, 2012. Geochemistry of tailings and seepage from three tailings storage facilities in Australia - Uncapped, capped and active tailings, in Proceedings Life-of-Mine 2012 , pp 269-278 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 10, 2012

By J Theiler, B Beamish

Spontaneous combustion hazard assessment from an environmental impact perspective is not well understood and is seldom given due consideration in environmental impact statements. In surface mining operations, self-heating, leading to spontaneous combustion may occur when rock units containing reactive metal sulphides and organic carbon are disturbed by mining operations and exposed to the atmosphere. When these rocks are present self-heating will occur in situations where the rate of heat generated from oxidation reactions exceeds the rate of heat lost to the surroundings. The processes and mechanisms that lead to spontaneous combustion events are varied and generally complex. To effectively manage spontaneous combustion in surface mining operations, it is necessary to characterise the spontaneous combustion propensity of the geological materials involved. Until recently there has been no testing procedure for assessing the propensity of waste rock to spontaneously combust that has been adopted by industry. However, new developments in adiabatic test methods have proven successful in determining the self-heating behaviour of coal (Beamish and Theiler, 2015) and coal containing reactive pyrite (Beamish and Theiler, 2017). These adiabatic test methods have now been modified to assess the incubation behaviour of waste rocks and can be used for their spontaneous combustion characterisation in advance of mining (Beamish and Theiler, 2016). The new method provides a practical means to establish the likelihood of developing a spontaneous combustion event for the specific site conditions. This paper presents examples of the use of a cost effective first pass filter for assessing spontaneous combustion potential of waste rock based on geochemical data from four surface mines. This is supported by adiabatic Incubation Test results for three of the mines and visual examination of cores for one of the mines. CITATION:Theiler, J and Beamish, B, 2018. Valid spontaneous combustion hazard assessment for surface mine environmental impact statements, in Proceedings Life-of-Mine 2018, pp 64–67 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 25, 2018

By S Bhandari

A model for predicting dust plume dispersion from blasting operations using the Eulerian mathematical algorithm has been developed. This model considers atmospheric stability, and wind velocity and direction for computing dust concentrations at different distances from the blast. Software has been developed which simulates the movement of a dust plume at a given horizontal distance from the blast location and time elapsed after the blast. The concentration of dust is also given in vertical planes. It takes into account ground profile and atmospheric conditions such as temperature, pressure, humidity, wind velocity, wind direction and shear. Experiments were carried out in two limestone mines to calibrate the accuracy of the predictions made by such model. High volume dust samplers were used to collect dust samples. Difficulties encountered in satisfactory dust sampling and quantification of results have been described.

Nov 8, 2011

By K Haroon, J D. Speed, S P. Wood

Online analysis of continuous and batch processes has seen a dramatic increase in recent years, with examples ranging from petrochemicals to pharmaceuticals, to industrial biotechnology and food and drink. The particularly challenging environment of alumina processing has meant that instrumentation needs specific features and characteristics to be truly suitable, features such as: robustness, resistance to caustic conditions both in the analyte and the ambient environment, and reliability for long-term continuous use. Here we present the development of a novel FTIR spectrometer that achieves these requirements through the use of a static optics arrangement of mirrors, and stable diamond-tipped light-pipe probe. Firstly we give a very brief explanation of spectroscopic analysis, and the difference between FTIR and other infrared methodologies. Next we outline the novel arrangement of mirrors required to produce an interferogram without moving mirrors, and compare the benefits and drawbacks of this approach instead of conventional designs. We then share the results of laboratory analysis of synthetic Bayer liquors, with detection limits for aluminium hydroxide, sodium hydroxide, sodium carbonate and various sodium salts of organic acids. We then share the results of analysis on production samples, both in idealised laboratory conditions and then online in the process itself. Lastly we present work on in situ ultrasonic descaling solutions to avoid scale build-up and provide continuous cleaning of the probe – preventing the need for probe removal and manual cleaning.

Aug 24, 2022

By P Nissen, T Jenke, M Ralph, M Cattani, M Quinlan

The West Australian Government hold an annual ‘Mines Safety Roadshow’ around the State’s regions and the capital city, Perth. Each year presenters provide an update on legislation and safetyrelated themes. A recurring theme is the mining industry fatality rate. Professor Michael Quinlan’s ‘Ten Pathways to Death and Disaster’ (Quinlan, 2014) has been referenced regularly to assist in structuring workshops and conversations concerning fatality prevention in the mining industry. The ‘Ten Pathways’ are the outcome of an analysis of fatal injuries in the mining industry, which identified a series of common themes to the fatalities: Pathway 1: Design, engineering, technical and maintenance flaws. Pathway 2: Prior warnings or causes for alarm ignored. Pathway 3: Failures in risk assessment. Pathway 4: Failures in management systems and hazard management plans. Pathway 5: Failures in auditing. Pathway 6: Economic pressures compromising safety. Pathway 7: Failures in regulatory oversight and inspection. Pathway 8: Worker and others expressing concern prior to the incident. Pathway 9: Poor management – worker communication and trust. Pathway 10: Emergency and rescue resources and procedures. To determine a fatality risk profile we asked participants at the Mines Safety Roadshows to indicate their perception of their employer’s performance in each of the Ten Pathways. We administered the questionnaire at the Mines Safety Roadshows in 2017, 2018, 2019 and 2023. In this paper, we report on the results of the questionnaires, and suggest how organisations can improve their fatality risk score.

Apr 16, 2024

By W Roy

When it comes to plan implementation and securing success in organisations in the 21st century, if there was such a thing as the secret to success it would be effective communication. Commoditisation brings financial, operational and cultural advantages to organisations that use effective communication. Effective communication tools turn æpeople problemsÆ into system control solutions, removing personality clashes that hide procedural malfunctions. By introducing communications frameworks available in the market place today, and case studies of their use, this paper provides insights into the successes available to organisations courageous enough to redefine their communications for the 21st century.

Jan 1, 2006

Many block caving operations experience difficulties during undercutting, resulting in draw horizon damage, production loss and extensive drift repairs for the life of the block cave. This paper deals specifically with block cave undercut aims strategies, methodologies and management to avoid the problems indicated above.

Jan 1, 2000

By M Edgar, G Pattemore, M Auad, K Job, A Job, S Gale

In recent decades, significant advances have improved the modelling techniques for predicting slope failure. Predicting failures is vital in open pit mining due to the significant risk posed to personnel and equipment from unstable pit walls. Failures not only cause harm and damage to people and equipment but also cause delays to production and subsequently increase operational costs. Coupled with improvements in modelling techniques, utilisation of advanced scanning systems, such as high-definition imagery from UAVs has enabled faster and more precise mapping and modelling. However, one key element required for accurate slope stability modelling and monitoring is the ability for mine geotechnical engineers to have an accurate understanding of the mineralogy and moisture content of slopes, in real-time. To address this challenge, research has been undertaken to utilise hyperspectral imaging across a broad spectrum, combined with high-definition imagery, and LiDAR to scan slopes for minerals and moisture content. In addition to accurately mapping mineralogy and moisture, the data must be collected autonomously and remotely to ensure ongoing safety. The results show that there are many direct and indirect benefits from this new technology, including the ability to monitor slopes at a safe distance and in real-time, improved accuracy of modelling, detection of risks, and improving the automation workflow for geotechnical engineers. The paper presents recommendations for the implementation of the technology in open cut mining environments.

Jun 22, 2022

By D Chalmers

Drill and blast mining techniques are used to mine coal outburst prone and high gas content coals in Australia. As the risk of an outburst is increased in high gas content coal, it is considered that drill and blast is the safest way to mine coals that refuse to yield gas even after considerable gas drainage efforts. The availability of suitable explosives for drill and blast in Australia is dependent on the æBuxtonÆ tests. With the diminished coal operations in England, the type and supply of such explosives is tenuous, causing significant disruption to the production of coal in some mines. In an attempt to free up the availability of explosives a review of the methods used for the testing of coal mine explosives was undertaken to ascertain the scientific basis for these tests. It was hoped that this comparison would allow regulators to have the confidence in explosives that had been tested elsewhere. Although this was not achieved, it has spawned a major research project that aims to better understand the mechanisms involved so that either confirmation of the current testing regime can be achieved or more suitable and scientifically based tests can be adopted. This paper looks at the ongoing research program investigating the parameters that are involved with methane ignitions from explosives. By utilising high-speed data capture and processing the research project is trying to view an ignition as it happens to identify the mechanisms involved so that better explosives can be designed for the coal mining industry.

Jan 1, 2007

By D Xu

BHP Billiton Iron Ore is one of the world’s premier suppliers of iron ore. It currently has operations in Western Australia and Brazil and also has some iron ore interests in West Africa.BHP Billiton’s Optimisation R&D team has developed a proprietary mine planning optimisation tool that uses a mixed integer linear programming (MILP). This tool is called Blasor and it is used to rapidly evaluate the resource development potential (RDP) scenarios for the company’s business development strategy. In addition it generates life of asset (LOA) mine plans for the company’s operations and growth projects. The Blasor optimiser maximises the discounted operating cash fl ow (DCF) as the objective function, subject to mining, processing and transportation capacity constraints and blended product quality constraints. The paper will outline how Blasor has been applied to the resource development potential (RDP) strategy scenario studies, growth project evaluations and LOA mine planning within BHP Billiton Iron Ore.The practical application of Blasor to resource planning optimisation within BHP Billiton Iron Ore has demonstrated the value of such a tool for optimising strategic directions through the evaluation of a number of carefully proposed scenarios and maximisation of operational decisions, such as cut-off grade, open pit development sequence, etc. Particularly for the company’s business development direction studies, Blasor plays the role of a fair valuation tool in that it discovers the most valuable resource development scenario, thus establishing a sound basis for comparing the economic merits of each scenario.

Jul 11, 2011

By D J. Bradshaw, B Lottermoser, A Parbhakar-Fox

"Best practice for acid rock drainage (ARD) risk assessment still relies solely on the geochemical properties of sulfidic rocks and mineral processing products, despite the fact that a rockÆs tendency to produce acid also depends on mineralogy and texture. Consequently, there are a plethora of geochemical tests routinely utilised by the mining industry to predict ARD formation. Due to limitations associated with these tests and their relatively high costs, analysis of recommended best practice sample numbers is rarely achieved, reducing the accuracy of waste management plans. Our research addressed this through examining the application of geometallurgical data for predicting acid formation, and led to the identification of potential environmental geometallurgy indicators.Samples obtained from an iron-oxide copper gold deposit were subjected to the geochemistry-mineralogy-texture (GMT) approach, an improved methodology for classifying acid forming potential. GMT results were compared against geometallurgical and assay data sets to evaluate: relative carbonate content measurements (measured by HyLogger) and identify how these could be used to calculate effective acid neutralising capacity mineral hardness (measured by EQUOtip) to determine application of this data for calculating lag-time to acid formation opportunities to automate the acid rock drainage index (ARDI) using classified images produced by a GEOTEK logger and automated microscopy.Links between the GMT approach and geometallurgical data sets were identified. Classified mineralogy data has application at stage one, HyLogger and EQUOtip at stage two and computer-based ARDI evaluations of classified images at stage three. Through such integration, ARD characterisation costs can be reduced, with value added to geometallurgical data sets. Furthermore, deposit-wide ARD domaining is possible, and acquisition of total-orebody knowledge more likely. Through adoption of this environmental geometallurgy approach, a better informed waste management plan can be formulated, allowing for best practice ARD sampling in a more cost-effective manner.CITATION:Parbhakar-Fox, A, Lottermoser, B and Bradshaw, D J, 2013. Cost-effective means for identifying acid rock drainage risks - integration of the geochemistry-mineralogy-texture approach and geometallurgical techniques, in Proceedings The Second AusIMM International Geometallurgy Conference (GeoMet) 2013, pp 143-154 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Sep 29, 2013

Diamond drilling is a relatively new commodity in terms of drilling. The first known diamond drilling activities were carried out in the Swiss Alps around 1863 when the Swiss engineer M Leschot designed and made a tube with a diamond set face which was used in probing ahead drilling for the Mont Cenis tunnel (Figure 1). Craelius AB which today is a part of the Atlas Copco Group was formed in 1886. The name Craelius is a family name and the founder of the company was Per Anton Craelius (Figure 2). He went to the United States to study this new technology using diamonds to extract core samples and when he returned to Sweden designed his first diamond drilling machine. It was a man-powered drill needing a crew of six men, two to crank the unit, one to feed, two to power the flush pump and a foreman (Figure 3). As time passed through research and development, the original design was improved and manpower was substituted for steam engines and later combustion engines or electric motors (Figure 4). During the 1930s the drills radically changed designs and took the form of the short stroke drills which to a certain extent are still in use today. The original design of these drills have been refined during the years, hydraulic chucks, gear boxes and other improvements have been added.

Jan 1, 1995

By H Indirawati, R Ayres, A Nur Kasnanto, S Konopa

As a project moves through the mine life cycle, the quantity of data available increases and the understanding of the orebody matures. Incorporating new information quickly and efficiently in current 3D models, is essential for adding value across the life-of-mine value chain. At the Martabe Gold Mine, the resource development group manages 14 drill rigs on six resource projects, including three operating mines. The Martabe deposits are geologically complex and the volume of new information that becomes available each day is substantial. It is imperative that new geological and assay information is integrated into the 3D models as soon as possible, so that drill planning and targeting can be modified accordingly. Martabe uses Leapfrog<sup>®</sup> 3D software to update and interrogate the 3D models on a dynamic basis as data becomes available. This results in faster and more effective changes to drill planning and schedules. The impact of this is better drill productivity and cost savings due to optimal drill targeting, and availability of up-to-date models incorporating the most current data. CITATION: Konopa, S, Ayres, R, Nur Kasnanto, A and Indirawati, H, 2018. Optimised drill targeting using dynamic 3D modelling, Martabe Gold Mine, Indonesia, in Proceedings Complex Orebodies Conference 2018, pp 99–101 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 21, 2018

Rifting and transfer faulting in the Late Cretaceous to Early Tertiary resulted in the formation of the Bundaberg Trough and Wallaville Basin and deflected the margin of the Maryborough Basin southwestward between the Kolan and Burnett Rivers. During the Cainozoic, three periods of volcanic activity occurred in the Bundaberg-Gin Gin area. The oldest of these periods, Paleocene to Early Eocene, resulted in the outpouring of tholeiitic lavas. During the Late Miocene to Pliocene, undersaturated alkali basalts generated at depths of from ca. 35 to 55 km were emplaced. These lavas were followed in the Pleistocene by the alkaline Hummock and Berrembea Basalts. The loci of eruption of all of these lavas were controlled by the intersection of the transfer fault system and pre-existing north to northwesterly trending faults in the Bundaberg-Gin Gin area.

Jan 1, 1990

The five main ways in which coal is used are1. for electricity generation,2. as a lump fuel for domestic and industrial purposes,3. for gas making,4. for making carbon for chemical and metallurgicalindustry, and5. as a source of coal tar and coal-tar chemicals.In the past about 80 per cent of Victoria's brown coal has been used for power generation and the rest for making a lump fuel, in the form of briquettes. Some of these briquettes have been used for gas making, and a carbon industry based on them has recently been commenced, and could expand rapidly. However the enormous increases expected in power requirements, approximately a doubling every 10 years, will ensure that even if the manufacture of carbon increases dramatically and a large amount of coal is used for other purposes, the brown coal industry will always be dominated by power generation. As new fuels such as natural gas, oil, and nuclear fuel become available at competitive prices these will take their share of the power generation load.Natural gas or oil, or possibly pumped storage hydro, will almost certainly be used for all future peak-load stations, comprising around 40 per cent of the total installed generating capacity, but new base load stations will continue to be designed for brown coal operation until about the mid-1980s, by which time nuclear power stations will become competitive. By this time Victoria will have installed about 6000 MW capacity of brown coal stations, burning around 50 million tons/year of coal, compared with 18 million tons/year at present, with perhaps 15 million tons/year being used for other purposes.This consumption of 65 million tons/year should then remain fairly stable over the life of the power stations installed, well into the 21st century. Brown coal therefore appears to have an assured place in providinga major part of Victoria's fuel requirements, despite the diversification in fuel usage pattern which appears certain to occur with the recent developments in new fuel resources.

Jan 1, 1971