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By T Nassis, P Louw, M R. Fry, T du Toit

Business intelligence (BI) and business analytics (BA) are established IT technologies that are used extensively in the business environment. This paper discusses the use of these technologies in production environments and beneficiation plants.Assmang’s Khumani mine is an iron ore operation located in the Northern Cape, South Africa. Assmang Limited is jointly owned by African Rainbow Minerals Limited and Assore Limited. This paper presents a case study of a BI solution applied to this plant, which is used by metallurgists, supervisors and all levels of operations and management to extract and analyse data to control and optimise the operation of the plant.The main advantage of adopting an established BI solution is the ease with which production personnel can extract and analyse data. The data is easily presented in familiar spreadsheets and no IT staff or specific training is required to achieve this.The solution adopted at Khumani mine uses a data mart with a multidimensional model (called an online analytical processing (OLAP) cube) acting as the main repository and source of data. The OLAP cube simplifies the access and analysis of plant data.The OLAP cube stores data in a specifically-designed way, which allows extraction and analysis to be performed quickly. It is designed to hold large amounts of data on a long-term basis, which could be for the life of the plant. It also performs automatic aggregations over many dimensions on a background process.A major benefit in adopting such a BI solution is that it allows common BA methods to be applied. This is due to both the efficient long-term storage of data and the availability of standard BA tools. BA tools are now able to perform data mining, predictive analytics, forecasting and other machine-learning algorithms. This paper presents the possible use of such advanced data analysis methods in a beneficiation plant.CITATION:Fry, M R, Nassis, T, Louw, P and du Toit, T, 2015. The use of common business intelligence and analytics tools in the operation and optimisation of iron ore process plants, in Proceedings Iron Ore 2015, pp 129–138 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

There is a difference in design aspects between steel linings and rubber linings for grinding mills. The basic design rules for rub- ber are described as well as the liner designs for different applications.

Jan 1, 1978

By Hatherly P, Holt GE, McNally G

The current methodology for delineating and subsequently evaluating coal reserves is based on the use of vertical drill holes and surface based geophysics/geology. These techniques have three major problems, these being respectively:-a) Vertical drill holes can only provide a small sample of the coal seam and stratigraphy. Therefore the planar variation in coal reserve and environment parameters can only be approximated.b) Although surface based geophysics has had its fair share of success in recent years, there are still environments which have masked the finding of major structures.c) Access to drill sites is difficult at some locations due to mountaineous terrain, standing water and environmental impact.

Jan 1, 1985

By Singh RN

Monolithic packing systems have gained in popularity as a gate side packing method. However, there has been no detailed investigation to assess their underground strength behaviour. This work includes the laboratory and in situ investigation for strength behaviour determined on various monolithic packing materials namely Tekpak-XX, Hydropak-20, Hydropak-30, Astrapak-3R, Flashpak, Thyssen pack and Aquablends. A simple technique for assessing the pack strength was developed at the laboratory by using a penetrometer, of which penetration resistance can be directly correlated with the uniaxial strength of the pack. The in situ strength investigations were made on core samples obtained from three pipes inserted inside the pack, while the penetration test were made on the pack surface. The in situ results indicated that the packing material develops an inconsistent strength on various part of the pack which was mainly related to an inadequate mixing of grouts inside the pack.

Jan 1, 1992

By J B Tucker, A T. McGrath

Situated in north-west Queensland, Australia, the Ernest Henry Mine (EHM) has been producing copper and gold since 1996. Owned and operated by Glencore Xstrata, ore is currently sourced from a newly developed underground sublevel cave (SLC) mine below the old EHM open pit (the pit). Ore feed to the concentrator is supplemented by satellite open pits comprising the Mount Margaret operation.The transition from open pit to a producing underground mine involved a complex extraction sequence for the first two production sublevels on RL1650 and RL1625. Underground mining during cave initiation was further complicated when south wall instability prevented completion of the final open pit shell. The transition mining phase included mass firing of an inclined crown pillar between the initial SLC void and the pit followed by a combination of transverse and longitudinal SLC mining.The inclined crown pillar mass firing was the first significant milestone in the extraction of the transition ore block. Comprising approximately 890 000 t of in situ material; 70 000 m of drilling was charged with 351 t of emulsion and 6026 electronic detonators to initiate the single mass firing. The firing contained five direction changes over 19 seconds making it one of the largest and most complex underground blasts ever conducted in Australia.Risk management was integrated into every facet of the technical and operational planning and execution of the transition mining phase, whilst maintaining daily mine construction and production commitments. This paper provides a detailed overview of the transition objectives and constraints, mining method selection, post mass blast outcomes and the journey ahead.CITATION:McGrath, A T, Campbell, A D and Tucker, J B, 2014. Transition of the Ernest Henry Mine from open pit to an underground sublevel cave, in Proceedings 12th AusIMM Underground Operators’ Conference 2014 , pp 297–308 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Mar 24, 2014

By J Player, G Sweby

The material properties and hence performance of saturated alluvial sediments slope can be incorrectly forecast if the water content is not preserved, and materials properties not correctly determined. The occurrence of saturated sediments in the Western Australia (WA) Goldfields, while not common, should be a significant investigation focus. Geotechnical engineers new to the area may be unaware of this and hence the importance of correct testing and determination of the material strength. Application of appropriate analysis to determine stable pit slopes to an acceptable level of risk, is not possible unless the appropriate strength and hydrogeological parameters have been established at the outset. A back analysis is presented of a pit that had extensive slope failures in alluvial clay-rich sediments with discussion on the approach adopted by the original design engineers to assess pit wall stability and consequent poor slope performance. Learnings from a full pit 3D back analysis are presented, with an approach to geotechnical and hydrogeological investigations and analysis for slopes in similar materials.

Jun 22, 2022

By Dight P. M

The challenge of narrow vein mining is to produce ore with as little dilution as possible, at the least cost -commensurate with the increasing degrees of safety being demanded for mine workers by the modem 'duty of care' legislation. Geotechnical factors play an important, if not overriding, role in these areas. The geotechnical factors cover the complex interaction over a period of time, between the in situ and induced rock stresses, rock structures, rock mass strength and the cable, rock bolt and other ground support members. In the Archaean schist belt areas where many of our narrow vein mines occur the pre-mining in situ rock stresses are commonly significantly higher than the overburden stresses. These are concentrated in areas beneath previous open pits and may be highly concentrated in the pillars and abutments of stopes on narrow veins. The presence of high in situ stresses may be suspected from the appearance of drill cores and underground development long before they become sufficiently concentrated by mining to cause damage or bursts. These initial indications are discussed and modem low cost methods of stress measurement are described. Practical and quick methods of analysing the stress redistribution around scopes and other underground excavations are now available and guidelines for interpreting them in terms of rockmass characteristics, stope stability and support requirements are developed with the object of increasing safety, whilst reducing overall costs and dilution.

Jan 1, 1993

By P A. Montoya

La Colosa is a world-class porphyry Au project located in Colombia, currently undergoing prefeasibility analysis. As part of collaboration between AngloGold Ashanti and the AMIRA P843A GeMIII Project, the application of emerging geometallurgical characterisation testing and modelling tools has been incorporated in early stages of project development. The aim of the geometallurgical study is to map inherent comminution variability across the La Colosa deposit providing information critical for mine/mill design and optimisation. In this study, site-based data incorporating multi-element assays, quantitative analyse X-ray difraction QXRD bulk mineralogy measurements, EQUOtip rebound hardness data, and routine geological logging information from 59 diamond drill holes has been integrated with a range of geometallurgically specific comminution test (ie GeMCi, A × b, BMWi). The work in this paper demonstrates the integration techniques used at La Colosa to link routine data acquisition methods with comminution test results through the development of proxy support models. The integration incorporates a range of statistical techniques including principal component analysis and regression modelling. By creating proxy models, comminution index estimates can be propagated into the geological database enabling comminution processing domains to be defined. These domains provide the first spatial representation of comminution performance and variability at La Colosa and can be compared against traditional geological domains. This study provides the foundation for ongoing comminution characterisation as the La Colosa project evolves through project cycles into an operational mine.

Sep 5, 2011

By I Cameron

Simulation is increasingly being used to analyse mineral processing operations and explore efficiency options. Engineers that use simulation are rightly concerned with the quality and applicability of the underlying models. However, many of these models have a significant empirical component, and the best structure for this component may not be apparent. There is an opportunity to improve the quality and application range of these models by exploring potential structures for this empirical element. One approach to this problem is the use of structural optimisation, which is a formalisation of the model development process. This method searches through a family or hyper-structure of candidate models for a model that is optimal with respect to some measure of model quality. This method has been applied to the modelling of an industrial flotation circuit. The result was a model that was a significant improvement over a number of standard models reported in the literature. Structural optimisation provides a method to compare potential models in a systematic and efficient way, and hence to improve the structure of process models.

Jan 1, 1998

By Hoberg H, Schneider FU

The stability of suspensions can frequently be controlled only by the use of supplementary polymeric agents. Such methods date back to the time of the ancient Egyptians, who used natural rubber as a deflocculant for carbon black in the manufacture of ink (Anon, EncyclopediaBritannica, 1968). Since the development of synthetic polymers in the 1950s they have been deployed in all manner of applications. Indeed the mining and paper industries as well as industrial or communal waste water treatment plants are largely dependent on flocculants which make a major contribution to the relief of the environment. As some of the polymers used are carried out from the process via purified water, problems can emanate from the application itself as long as no reliable data is available as to the exact whereabouts of the polymers and their impact on the biosphere. In order not to invade other systems, they would have to be biologically degradable which has not, until now, been confirmed (Blockhaus, Sequaris and Schwuger, 1991; Schumann, 1991). It has, however, previously been demonstrated (Hoberg et al, 1990) that when process water circulates in mineral processing operations, residual amounts of polymeric flocculants can have extremely adverse effects on the selectivity of flotation processes. The adsorption behaviour is consequently one of the most important considerations in the development of new polymers, the aim being to minimise the amount of non-absorbent matter. The objective of the investigations carried out on ampholitic synthetic polymers of high molecular weight to be reported on here was to permit the connection between settling index and adsorptivity to be characterised in greater detail. As the level of knowledge concerning flocculation and polymer adsorption in real systems is still limited in spite of numerous practical and theoretical studies in this field, the experiment was designed to be relatively broadly-based. As well as investigating various raw materials, an attempt was made to compile results on the influence exerted by different surface charges.

Jan 1, 1993

The application of reinforcement techniques to enhance the stability of underground coal mine roadways subject to high stresses is discussed. Research conducted in the Illawarra Coal Measures has been aimed to delineate the factors which influence the behaviour of rock above roadways and the performance of the reinforcement placed. Design considerations for the reinforcement of mine roadways in the Bulli coal are based on a quantification of the rock response together with a reinforcement strategy to enhance the structural integrity of the roof strata.

Jan 1, 1986

By Vynne J. F

Drill monitors for blasthole and exploration drills have been available to the mining industry since the 1970s. The early monitors were pen strip chart recorders which were developed for the oil drilling industry and adapted to mining. They recorded drilling parameters such as depth, pull-down pressure, torque, RPM, and bailing air pressure. While these recorders could generate a large volume of paper, the amount of useful data was minimal. The data was not summarised and required an engineer to interrupt the chart traces. Being a mechanical recorder, the devices were also susceptible to frequent failures.

Jan 1, 1993

By Hermulheim W

In the Federal Republic of Germany hard coal is mined underground only. The coal mines reach down to 1 500 m deep, recently having an average depth of 900 m. The commonly used winning system is long- wall mining with face lengths up to 250 in. The gate roads, which separate the seam into single panels, have an average length of one kilometre with a cross- section up to 20 m2. These single entries are usually supported by yielding steel arches. The installation of steel arches can hardly be mechanized. The choice of heavier support, caused by increasing depth and roadway cross-section, results in high cost for labour and material in gate roads. Furthermore, the heavy steel arch is acci- dent-prone, not only during installation but also during transportation and ship- ment. Rock bolts combined with a suitable lagging offer a way of mechanizing support work in headings. The aim is to decrease cost and to increase mine safety and pro- ductivity. Over the last ten years, 50 km of gate roads have been reinforced by a combination of rock bolts and weld mesh. Nevertheless, there are still differing opinions on the feasibility of rock bolting in gate roads. In Germany a long tradition and experience with steel arch support exists, whereas the function of an anchorage is a closed book to miners, preventing this new technique from spreading more quickly. Advantages and shortcomings of both steel arch support and rock bolting are compared. The experience with rock bolting up to now is reported. Possible improve- monts arm discussed.

Jan 1, 1986

By P Ottenio, B CarrT

In the last 40 years, the froth flotation process widely spread in the paper industry becoming the dominant technology for ink removal from recovered paper slurries and cellulose fibres recovery. Most of current models used to describe the flotation deinking process are based on hydrodynamic and statistical theories of ink particles collision/attachment to air bubbles. The complexity of these theoretical models, together with the variability of the recovered papers composition, does not allow to define a set of æeasy to handleÆ equations to be used for modelling industrial flotation cells. This main limiting aspect makes that, in several deinking process modelling tools, basic parameters used to characterise the flotation unit, ie yield, ink removal efficiency, water loss, are constant parameters. Although in some process simulation tools the flotation yield/efficiency is adapted to process control parameters (air ratio, pulp flow, pulp consistency), physicochemical variables (namely the pulp frothing aptitude, the pulp surface tension and the ink adhesion energy to air bubbles) are not taken into account to adjust the flotation yield/efficiency. Data collected during recent laboratory and pilot plant experiments focusing on the role of surface active substances on the flotation efficiency were therefore interpreted and used to identify general trends that could be described with simple semi-empirical models. A set of model equations using surface tension and froth removal height as main variables was then defined in order to describe the behaviour of a pilot flotation cell. Trends obtained during the dynamic simulation of the deinking pilot plant were in good agreement with experimental data obtained under similar experimental conditions, thus indicating that developed equations can forecast with good approximation the behaviour of a flotation deinking unit.

Jan 1, 2005

Computers represent substantial capital investment. A better return on that invest- ment comes from more effective use of the computer's facilities. By using Telecom's data communications facilities, more people in more locations can have ready access to those facilities.

Jan 1, 1983

By Griffith L, Lama RD

West Cliff Colliery mines Bulli Seam occurring at a depth of approximately 480 m. The Seam is intersected by a number of small shear zones and faults. While the faults have caused displacement of the seam, the shear zones are strike-slip structures with small apparent displacement of seam. Outbursts at West Cliff Colliery occur while driving through these shear zones. Few outburst wave occurred where faults have been intersected. In the last 3 years, over one hundred outbursts have occurred at West Cliff Colliery. The size of outbursts varies from a small bump to exceeding 140 tonnes of coal. A number of studies have been undertaken at West Cliff Colliery to control outbursts and predict Outbursts in advance of workings. These include: geological investigations, microseismic techniques, gas adsorption studies and gas drainage. The investigations to date suggest that outbursts of gas at West Cliff Colliery are more a gas phenomenon similar to what occurs in overseas mines. The results of various investigations are reported. West Cliff Colliery is located in the mid- west of the southern coal fields of N.S.W.

Jan 1, 1980

By Murray C. G

A database of over 1300 earthquakes has been used to investigate the relationship between seismicity and tectonics in two areas of eastern Queensland and NE New South Wales. These areas have been monitored by several networks that were installed primarily to monitor seismicity associated with the impounding of large reservoirs. Events that occurred prior to the installation of these networks have been excluded from the analysis because they have large uncertainties in location.Seismicity in SE Queensland and NE New South Wales is concentrated in the coastal regions. Activity also extends off the coast of Queensland and beyond the continental shelf. The coastal activity is mainly within the New England Fold Belt. An area of the fold belt overlain by the Clarence-Moreton Basin is also active. There is an area of activity near St. George that correlates to the Wunger Ridge. Fraser Island and the adjacent onshore area, near Maryborough, are notably aseismic.Within the New England Fold Belt there is a NNW trending zone of concentrated activity that includes the South D'Aguilar Block and the Esk Trough as far as Gayndah. The Nambour Basin, the Gympie Province, and the southern portion of the Yarrol Block are significantly less active.Composite focal mechanisms of several groups of accurately located earthquakes in SE Queensland indicate predominantly reverse faulting. This faulting is the result of the crust being compressed horizontally in a NE-SW direction.Activity in the Burdekin Falls Dam area of central eastern Queensland is confined to the Drummond and Bowen Basins. There is also significant activity offshore from Townsville and Bowen.

Jan 1, 1990

By Barber S

The Golden Cross Mine is located within the Waitekauri Valley near the southern end of the Coromandel Ranges, eight kilometres north-west of Waihi, North Island, New Zealand. The mine is owned and operated in a joint venture by Coeur Gold NZ Ltd (80 per cent) and Viking Mining Ltd (20 per cent). The underground mine produces gold and silver from low sulphidation epithermal quartz veins which developed in the shallow parts of a meteoric water dominated system during the Upper Miocene (7.36 - 6.67 Ma). The Empire Vein System is hosted within a dilational structural environment which developed at the lithological contact between acid intrusives, rhyolitic-dacitic tuffs and reworked pyroclastics, and undifferentiated andesites. The formation of the Empire Vein System was controlled by the rheological properties of the host rocks and variable displacement along a series of normal, right lateral, easterly-dipping faults. These faults represent sub-parallel zones of master shearing within a Riedel shear model. Underground mining extracts ore from the steeply dipping hangingwall and the complex footwall veins of the Empire Vein System. Initially sills are driven along the hangingwall vein on ten to fifteen metre sublevel intervals. In the footwall zones where significant mineralisation adjacent to the hangingwall sill drives has been identified, a series of cross-cuts and footwall drives (sub-parallel to the hangingwall sill) are also developed. Where continuity of mineralisation and ground conditions permit a combination of post pillar flatbacking and AVOCA longhole benching methods are used. Detailed underground mapping of lithology, quartz veining and major structures provides the information for designing ground support and footwall pillars, planning mine development and ore extraction sequencing. Sectional interpretation displays the vertical extent of faults, fractures and the vein system. The mining methods used underground at the mine have evolved through a thorough understanding of the structural complexity and the systematic geological mapping of the Empire Vein System.

Jan 1, 1997

By P N. Duan, Z G. Liu, M S. Chu, X X. Xue, B Liu, G J. Cheng, T Jiang, J X. Liu

High-chromium vanadium-titanium magnetite has not been exploited and made full use of on a large scale so far due to the immature utilisation technology and the reality that the utilisation efficiency of valuable metals still urgently needs to be improved. In the present paper, the isothermal reduction kinetics and mechanism of high-chromium vanadium-titanium pellets were studied at 800–1100°C. The mineral composition transformation of pellets before and after reduction was analysed by means of X-ray diffraction (XRD), and the microstructures were examined by scanning electron microscope (SEM) equipped with energy dispersive X-ray (EDX) to reveal the elemental distributions. The effect of reduction temperature on the volumetric swelling degree and cold crushing strength was also studied. It was found that reduction temperature has a large effect on the reduction rate of pellets, and the increase in reduction rate is more obvious in the range 1000–1100°C than 800–1000°C. The volumetric swelling degree of pellets increased with increasing reduction temperature, while the cold crushing strength decreased. The transformation of mineral species can be expressed as Fe2O3 ? Fe3O4 ? FeO ? Fe, Fe2O3·3TiO2 ? Fe3O4· (2FeO·TiO2 ) ? 2FeO· TiO2 ? FeO·TiO2, (Fe0.6Cr0.4)2O3 ? FeO· Cr2O3 ? Cr2O3 , and Fe2O3· VO/V2O3 ? VO. The apparent activation energy of the reduction reaction was calculated to be 44.3 kJ/mol, and the reduction rate is controlled by the combined effect of interfacial chemical reaction and gas diffusion through the porous product layer. The rate controlling steps were further studied by calculating the resistance percentages. The interfacial chemical reaction was found to be predominant in the initial reduction stage, with the percentage effect of gas diffusion through the porous product layer gradually increasing during reduction.CITATION:Cheng, G J, Xue, X X, Liu, J X, Liu, Z G, Chu, M S, Jiang, T, Liu, B and Duan, P N, 2015. Reduction kinetics and mechanism of pellets prepared from high-chromium vanadium-titanium magnetite concentrate, in Proceedings Iron Ore 2015, pp 349–358 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

By Gray N. B

The need to improve existing metallurgical processes and to develop new processes to meet the economic challenges that lie ahead requires the application of the tools of process analysis viz. mathematical models, physical models, pilot plants, laboratory measurements and plant tests. Examples of the application of these techniques to processes are described in this paper. Several of these techniques, combined with basic knowledge, are necessary to make improvements and for existing processes this always involves plant measurements. Also because metallurgical processes include extraction, refining, alloying, casting, mechanical working and heat treatment, an interdisciplinary approach to research and development is essential. This paper argues that metallurgical engineering is a discipline that is uniquely able to encompass the broad spectrum of chemical- and physical-metallurgy processes and is therefore essential to the health of the metallurgical industry.Regrettably many metallurgical engineering departments are not offering courses on process analysis, control, optimization, etc so necessary to meet modern industrial challenges.

Jan 1, 1985