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By D La Rosa, W Valery, A Jankovic, S Ese

Metso Minerals Process Technology Asia-Pacific (MMPT-AP) has been working with many mining companies worldwide performing æMine to MillÆ or Process Integration and Optimisation (PIO) studies. MMPT-AP has developed a proven methodology to improve the efficiency of the mine-mill interface and gain maximum benefit. The PIO methodology involves rock characterisation, mathematical modelling and simulation to generate a list of operational and control changes for both the mine and concentrator. Following the methodology, the list of recommendations is developed relatively easily; the more challenging part depends on the company. Success of a PIO project relies on the ability of an organisation to implement change û both operationally and culturally: the human element. When a PIO project is started, there is initial interest and commitment from the company. But how can this be maintained? How does an operation know if the benefit continues? MMPT-AP is now developing long-term relationships with clients to ensure that the increased production and improved efficiency continues. Direct and indirect measurements are used to determine the key factors involved and to understand the cause/effect relationships. Simulation tools also can be used to compare current with recommended practices û so when material properties vary over time, the benefits can still be quantified. PIO is about empowerment: by measuring and understanding what parameters affect concentrator performance, the site personnel now have the knowledge to make a difference. Rather than simply reporting variable or poor concentrator performance, operations can predict when production will be affected and put controls in place to prevent it from happening. This requires support and commitment from the company or æbuy inÆ. Ensuring this buy in continues is the challenge facing every company involved in PIO work û but the benefits are well worth it. This paper will review MMPT-APÆs experiences in implementing PIO projects in the long term: from both the consulting and operational viewpoints. MMPT-APÆs involvement with a number of companies will be discussed as examples of what works and what does not.

Jan 1, 2007

By P F. Knights

Mining companies are striving to achieve new levels of operational maturity and drive process improvement across the organisation in the face of unprecedented demand and limited supply of experienced human resources. Advanced analytics techniques can help overcome these fundamental challenges by applying data techniques not previously applied in mining. Today, decisions are usually locally optimised but do not achieve optimum capability for the value chain. Although more information is collected then ever before, it is difficult to link many sources of data together in the same place in real-time, for example plant history, maintenance, mine planning, logistics and engineering data. Consequently complex analysis of data is time consuming and requires specialist skills and knowledge, and is often neglected in the decision-making process. In the future, analytics will close the loop between analysing data and taking action. Analytics will become embedded in the business and routinely applied to improve decision making across the organisation, from senior management to operations and maintenance workers, but will not require specialist skills or be time consuming to analyse data. As analytics becomes embedded in the business process, decisions are supported by data (not on gut feel), and critically, data from many sources are integrated in real-time to improve the quality of decisions. Ultimately, predictive tools will help suggest, or even in some cases automate, courses of action. The main opportunities for analytics exist where the enterprise requires supporting technology to enable it to continue to evolve to higher level of maturity. This will be in the areas of asset management, rapid reconciliation and adaptive planning, and the inbound and outbound supply chains. Advanced analytics are also a key enabler for increasing the effectiveness and realising the true value of Remote Operations Centres to safely and efficiently support operations in remote locations with smaller workforces.

Jan 1, 2008

This paper summarises the results of a study carried out for the Sustainable Minerals Institute, University of Queensland, aimed at identifying the major water-related issues facing the minerals industry internationally and the research required to support the development of practicable solutions. An overview is given of the sources and uses of the worldÆs water resources and of the regional and global sustainability of water supply and management. Agriculture is the worldÆs major user of water; it wastes more water than the minerals industry uses. Water reform and its potential impact on the minerals industry are discussed with particular reference to Australia and South Africa. The sources, uses and management of water on mine and processing sites are outlined. Particular attention is paid to the importance of groundwater as a source of often saline water that can be used in mineral processing and for other purposes. Aquifer storage and recovery has the potential to help conserve water resources. Generally, the major uses of water on mining and processing sites are for mineral processing and refining and for the associated tailings disposal. Water consumption for these purposes may be reduced by recycling process water, using saline water, paying close attention to water management, thickening tailings and using techniques such as dry stacking and paste. A change in the minerals processing paradigm in respect of water use could come through research into new, improved and less costly dry processing techniques. The treatment of mine and processing water will be required increasingly before water is reused, stored, discharged or sold, and before sites are decommissioned. Research and development are required to reduce costs and develop new treatment methods. Mine closure and decommissioning raise a number of long-term water issues requiring continuing generic and site-specific research and development.

Jan 1, 2003

A static equilibrium mathematical model of the lead,flotation circuit at The Zinc Corporation Limited is developed to permit the feasibility of applying computer control techniques to be studied. The model is based on the relationship between the cumulative recovery of a mineral species R from n flotation cells or assemblies in a unit given asR = M(1-(1 - p)?)where M is the maximum possible: recovery and p is the probability of flotation for the particular mineral.The verification of this relationship by data from pilot plant cell-to-cell and plant open flow flotation units shows that these systems behave as if the probability p is constant for each cell or assembly of anyone unit. It is also concluded from this study that mineral recovery is independent of the head assay. Two consequences of this probability relationship, are demonstrated.1. The total recovery from an open flow unit is enhanced by increasing the number of flotation assemblies but maintaining a constant flotation time and total air addition.2. The rougher and scavenger capacity required to recover a bulk lead-zinc concentrate is approximately half that used for selective flotation.The static equilibrium model is derived by solving a series, of mass balance equations which incorporate the recovery-probability relationship for each type of flotation unit. It is used to calculate the complete metallurgy of the circuit for any arrangement of cells knowing only the plant feed assays and the probabilities of flotation for the three mineral types, galena, marmatite, and gangue for rougher, scavenger, and cleaner flotation. The high degree of prediction obtained is demonstrated by comparison with plant results.Pulp flowrate is the principal variable affecting the accuracy of the present model. Work is in progress to establish this effect and permit the derivation of a dynamic model. Even so, the static model is valuable in its present form for the analysis and design of circuits, and optimisation studies using computer services have been conducted.

Jan 1, 1964

By G Power

The successful implementation of sublevel caving (SLC) at Ridgeway Gold Mine (Ridgeway) requires the technical aspects of caving and flow behaviour to be understood. Cave propagation must be controlled and continuous to allow safe extraction of ore below. The understanding and use of processes to manage granular flow behaviour are also required to ensure economic metal resource recovery. Caving and flow technologies are thus critical to the economic viability of the application of the SLC mining technique to Ridgeway Gold Mine. At the time the Ridgeway SLC design was approved there were significant technical uncertainties associated with cave mining methods, including the SLC mining method in competent rock masses. This was in spite of the fact that caving is a relatively low cost mining method. Unique features generating technical risks at Ridgeway include: the fact that the orebody is blind (550 m below surface); highly competent cap rock (RMR >50); and high aspect ratio (height to width ratio of 3:1). Due to the presence of these unique features Ridgeway is considered to be beyond the current state-of-the-art in SLC mining technologies. The success of the technique at Ridgeway to date has indicated that blind SLC mines in strong rock mass can be operated safely and productively, if the technical risks are understood and properly managed. The risk management process was defined by the use of a formalise process to identify and assess the risks to the mine. The major mining related risks were formalised into Major Hazard Management Plans (MHMP) which contained a description of the risk, early triggers indicating the creation of a hazard and a series of agreed responses to be automatically initiated in the event of each trigger occurring. This paper outlines the following with respect to the critical technology areas of caving and flow: international industry, state-of-the-art technology; gaps in the application of this technology; the application of risk management, new processes developed at Ridgeway to bridge these gaps, including issues encountered; and trials and experimentation conducted to develop the new processes.

Jan 1, 2003

Coal has been mined in New South Wales for nearly 200 years and prior to 1970 the vast majority of this coal was mined from underground mines using bord and pillar or similar systems.Since 1970 there have been two notable changes in coal production trends in New South Wales as can be seen from Figure 1.1. The steady growth in coal mined by open cut methods. Open cut output grew from about seven per cent of the State's output in 1970/71 to 43 per cent in 1990/91.2. The steady growth in coal mined by the longwall method. longwall output grew from negligible amounts in 1970/71 to 48 per cent of underground production in 1990/91. mines operating longwall units produced 61 per cent of underground production in 1990/91.

Jan 1, 1992

Because of the mineralogical complexity of nickeliferous laterites, most commercial and laboratory extractive processes require the ore to be blended to a feed of "constant" chemical composition. Even using the "constant" feed there are significant variations in processing behaviour within and between different feed lots. Chemical and mineralogical analyses of lumps of ore taken from the Yabulu stockpile of Queensland Nickel have highlighted the complex- ity of the ore making up the blended feed material. Each sample has been subjected to acid leaching and reduction/ammonia leaching tests and the results correlated with the mineralogical location of the nickel. The consequences of the variability in ease of leaching of the nickel are indicated.

Jan 1, 1978

By J Player, K Braddon

High productivity mining is the key to the financial success and stability of modern mines. This can be achieved through the use of new technologies, the development of innovative work practices andoptimisation of the mining method to suit the mining environment.Big Bell Mine is a 1.7 Mtpa longitudinal sublevel caving operation at a head grade of 3.14 g/t. Annual production is 170 000 ounces of gold. The selection and implementation of bulk emulsion explosives was seen as the logical progression from blow loaded ANFO for the high tonnage rate required from the longitudinal sublevel cave.Prior to the implementation of bulk emulsions an investigation wasrequired to examine the technical and financial benefits available with the introduction of bulk emulsion. This paper examines the review process and the successful implementation of bulk emulsion explosives at Big Bell.

Jan 1, 1999

By Happ J. V

Factors affecting the rate of arsenic removal from lead bullion during softening processes were studied. Very high rates of removal could be obtained under conditions of intense agitation and ready availability of oxidant. Reaction mechanisms were proposed to explain the sequences observed. Selective removal of arsenic with minimal loss of antimony from bullion was favoured by a low temperature Harris process and oxidizing via a caustic soda medium.

Jan 1, 1987

By T Gibbons, M Korte, C Brent, K Runge

The Barrick Osborne concentrator has gone through a number of upgrades since commissioning and steadily increased production from the original 119 t/h design capacity to 265 t/h milling throughput in 2008. This was achieved incrementally over several years, by maximising operating efficiencies, in order to minimise capital expenditure, and take advantages of economies of scale; but more importantly it was reached with no measurable loss of recovery. Osborne currently processes a blend of under- ground with open pit material from the nearby Trekelano deposit. Following primary/secondary crushing, the material is processed through a rod/ball mill grinding circuit ahead of rougher/scavenger flotation that produces a copper concentrate.Osborne was seeking a further increase in plant throughput of the order of 15 per cent, but at more sustainable levels of secondary crusher plant utilisation. In early 2008, Osborne contracted Metso Minerals Process Technology Asia-Pacific and South America (MMPT) to review the entire process from run-of-mine feed to final copper concentrate. This review would be done concurrently, with surveys of both the crushing/ grinding and flotation circuits being performed at the same time. The outcome would be a steady-state model of the complete flow sheet allowing the crushing/grinding model to interact with the flotation circuit model such that overall process optimisation was possible. Two key outcomes for the operation are exploration of the operating limits of the currently installed plant, and projection of the logical next stage of potential capital plant expansions. This paper covers Part B or the flotation component of the project. A separate paper discussing Part A or crushing and grinding is also being presented at this conference. Surveys of the Osborne flotation circuit were performed along with a comprehensive review of the cell characteristics including measurements of the gas and froth phases of individual flotation cells. These data resulted in a size-by-size floatability component model of the complete circuit. This circuit model was then used to perform steady-state simulat- ions to evaluate options to improve both overall circuit and individual cell performance. The grinding circuit model discussed in a separate paper or Part A of this project was then used interactively with the flotation circuit model to recommend the best operating regime to maximise overall efficiency. For example, the balance between increased crushing and grinding costs versus higher copper recovery and final concentrate grade. Due to changes in market conditions in the fourth quarter of 2008, the focus was shifted to prioritising operational changes rather than capital expansion modifications, in order to improve circuit performance.

Jan 1, 2009

By D L. Richardson, B Tiedt, C D. Morgan

Following residentsÆ concerns that the ongoing operations of Collinsville Coal (CCP) mine may be resulting in the release of contaminants, including products of acid mine drainage (AMD), into downstream environments, the Queensland Environmental Protection Agency (QEPA) issued CCP with a Notice to Conduct or Commission an Environmental Evaluation at Three Mile Creek. A key objective of the Environmental Evaluation was to assess the extent and magnitude of impacts to aquatic communities and their habitats. A multidisciplinary investigation examined a suite of physical, chemical and biological indicators to meet this objective. The study also aimed to identify contaminants of concern and the location of potential pollutant sources. Potential indicators of AMD, including elevated dissolved solids concentrations and low pH, were evident within the mine lease. However, significant differences in concentration of these indicators upstream and downstream of the confluence with Three Mile Creek were not observed. Although only proxy indicators of AMD contamination, these results suggest that the extent of impacts downstream is minimal. For the purpose of this study, physio-chemical indicators were selected on the basis of those best likely to provide an understanding of the likelihood of contamination, within the constraints of readily available long-term monitoring data. Ecosystem health indicators were adopted to supplement the existing data set and provide a more æroundedÆ perspective of water quality attributes within the system, generally unattainable by standard physio-chemical assessments. In contrast to AMD products, sediments were considered more likely to have a widespread impact on aquatic ecosystems. Waterways throughout the study region, including those unaffected by mining, have been affected by broad-scale sedimentation and were typically highly turbid. Due to the many diffuse sources of sediment potentially liberated within the catchment, the contribution of the mine compared to other land uses on total sediment loads entering streams is difficult to determine. This is clearly a major management issue for mines throughout the Bowen Basin. Streams of the central Queensland region display enormous variability in water flows and physio-chemical characteristics over a range of spatial and temporal scales. This variability presents major difficulties in distinguishing anthropogenic impacts from natural variability (noise). Despite this variability, impact monitoring by mines in the central Queensland district has tended to focus almost entirely upon physio-chemical indicators. The results of the present study indicate that a multiple indicator approach to environmental assessment is more useful for separating mine related impacts from natural ænoiseÆ and impacts from other land uses. In the absence of such information, by adopting the precautionary principle of Ecologically Sustainable Development (ESD), there is potential for an environmental impact to be incorrectly attributed to mining when other activities in the catchment may be contributing to changes in stream æhealthÆ.

Jan 1, 2003

Detailed studies of mineral paragenesis, isotope and trace-element geochemistry, and physical mineralogy at Mount Morgan are compatible with deductions by Geopeko Ltd geologists concerning field relationships in the mine area. Considered together, field and laboratory data suggest that the Mount Morgan deposit originated from a shallow, intrusive, acid volcanic dome similar to those which produced the Kuroko-type deposits in Japan. At Mount Morgan, however, interaction with sea water was much less, the sulphides were concentrated rather than forming a group of deposits, and only the throat of a breccia vent is pre- served, so that only the lowermost parts of Kuroko-type deposits can be compared with the Mount Morgan mine. A final difference lies in the presence at Mount Morgan of a quartz diorite adjacent to the ore. Mineralogical data are compatible with post-ore intrusion, possibly up an earlier volcanic fissure.

Jan 1, 1974

Structure is the most important control on the location of hematite deposits in the Hamersley Province in the Pilbara region of Western Australia. Unravelling the structural history of mineralised areas, however, is complex because the Province underwent three orogenic events, and three regional extension events followed the main episodes of compression. Steeply E to ENE dipping normal faults immediately predated deposition of the Beasley Quartzite of the lower Wyloo Group after the Ophthalmian Orogeny. Steeply NE and SW-S dipping normal faults predated deposition of the McGrath formation of the middle Wyloo Group, following the Panhandle Orogeny. The resulting interpreted rift was subsequently reactivated and tilted during the Capricorn Orogeny. Late NE trending normal faults are confined to the eastern half of the Province. High-grade hematite deposits occur in rocks that range from intensely folded (Mt Whaleback, Giles Mini) to rocks with less, or only little deformation (Paraburdoo, Channar), suggesting that folding had at best limited influence on ore genesis. In contrast, extensional normal faults are always associated with high-grade hematite deposits, and in particular faults that link the underlying dolomites of the Wittenoom Formation with the overlying iron formation, thus providing a pathway for mineralising alkaline fluids.

Jan 1, 2005

The decision to contract or owner mine should be independent of, and should be made before, definitive estimated cost comparisons could be available. There is substantial potential risk of estimated cost comparisons being flawed due to difficulties in compiling comparable estimates for differing business objectives, errors and omissions or because of significant bias. In the current economic environment, escalating cost pressures potentially lead to increased incidence of disputes in mining contracts. The apparent cost of contractorÆs profit and overheads has tended to become more significant to owners. Economy-driven trends towards higher levels of performance and commercial risk for contractors, and the potential for more adversarial, difficult management; with attendant disputation between contractors and owners, have encouraged development of so-called ærelationship contractsÆ û partnering or project alliance contracts. The paper discusses the issues, circumstances when owner mining or contract mining is favoured and perceived advantages and disadvantages of contract mining. The implications of owner-perceived core business and core skills and outsourcing are also discussed. Techniques of introducing objectivity into the decision to owner or contract mine using matrix analysis or benefit comparisons are described. A disciplined procurement process should deliver a decision to owner or contract mine independent of, and prior to, any definitive comparison of estimated costs. A generic procurement process model is provided as a basis for discussion. Risk is discussed generally and as a significant factor in comparison of estimated operating costs. Consideration of risk and any prudent cost treatment are promoted as necessary pre-requisites to any comparison of estimated costs. The paper develops the concept that the decision to owner or contract mine should be based on real benefits that become obvious in the early stages of the development, particularly the procurement process; and before definitive estimated cost comparison can be available. In the context of this concept estimated cost comparisons tend to be confirmatory. Problems with comparing estimated ownerÆs operating costs with tendered contract prices are also discussed, particularly recovery of capital cost of equipment; and the owner minerÆs trade-off of operating risks for the residual contractorÆs margin attributed to overheads and profit. The paper concludes that sole reliance on a comparison of estimated ownerÆs operating costs with tendered contract prices in deciding to owner or contract mine is questionable and likely driven by a need to satisfy specific in-house customers.

Jan 1, 2003

Geophysics is playing an increasingly important role in the exploration industry. In the soft rock scene the application of seismic techniques is basically mandatory prior to any drilling program. Simply, this is because, in a majority of situations, the seismic method is ideally suited to mapping accurately relatively flat lying strata and displaying structures that may host oil or gas. It is worth stressing that seismic methods do not delineate oil or gas but they map well in two or three dimensions. In the base metal arena, geophysical methods used are generally focussed on direct detection methods with the mapping application not often used except in potential fields (magnetics and gravity). The success rate in the last decade has not been good but this does not only apply to the application of geophysics; it really applies across the board of exploration techniques. Both geological and geochemical exploration have not had a success rate commensurate with the funds injected. Basically in the last ten years we have failed as explorers! As explorers we have been negligent in mapping. As geoscientists we have let the basic mapping and observation skills diminish û the old adage æboots on the groundÆ is still applicable but are we doing enough of it? The answer is clearly no. As explorers the huge burden of bureaucracy, eg Government Acts û local, state and federal, safety compliance, environmental compliance, etc has reduced the ægeologicalÆ time dramatically. This has culminated in an over-reliance on quick fix solutions, eg spot the bump geophysics or geochemistry. This obviously simplistic scenario is arguable but there is no doubt in the geoscientific areas we have failed in the last decade to provide adequate geoscientific maps to assist in exploration. This failure could partially be responsible for the current demise of the industry resulting in a reduction in exploration dollars and, hence, people. This trend is seen acutely in the geophysical area where the head count in comparison with the geological fraternity is low. Other trends during this downturn are inevitable as explorers maximise the use of the dollar in exploration and diminish spending on advances in geophysics. Improvements are being seen however in geophysical equipment, although it is considered that the main improvement will be in the interpretation of data. Specifically, the trend will be towards integrating geophysical data into geological, geochemical and spatial data sets producing quality interpretation and providing low risk drill targets. Examples of the current trends in hardware and future directions are discussed below. In interpretive schemes there are very few examples of integrated interpretation but the possible trends will be discussed with limited examples.

Jan 1, 2000

The paper reviews winder rope inspection procedures at the Non Destructive Testing (NDT) Unit of Western Australian School of Mines (WASM) and outlines measures taken to adopt the world's best practice. The measures include acquisition of a new type of rope tester, adoption of comprehensive rope rejection criteria, adoption of a standard rope inspection procedure and formal training of the wire rope inspectors.

Jan 1, 1995

By Bebb G

This paper describes the use of SURPAC, a survey/mine planning software package as used at Central Norseman Gold. It details the basic operating principles of the package, the applications in which it is employed, and its time and cost benefits and efficiencies as they apply to the above operations, both surface and underground.

Jan 1, 1985

Mary Kathleen Uranium Ltd. recommenced operations in early 1976 following a twelve year period of care and maintenance. Several sections of the plant were modified or completely changed for the second operation. The most important change was the replacement of ion exchange with solvent extraction as the means of purifying and upgrading uranium rich Isolutions Most of the problems experienced in the solvent extraction system originate from the leach liquor which has a strong tendency to form stable emulsions. This has been countered by some careful control of leaching conditions and by closer observation of operations in the solvent extraction area. Most problems have now been resolved and plant recoveries are quite Satisfactory.

Jan 1, 1978

By Stewart Gillies AD

Resource rent taxes are taxes which only become effective at such a time as a pre-determined rate of return has been achieved by an operation. Resource Rent Taxes have from time to time been considered for implementation in both Australia and New Zealand. The offshore petroleum industry in Australia is already subject to RRT as is the Roxby Downs (Olympic Dam) Mine in South Australia. Both the mining and petroleum taxation regimes in Papua New Guinea include a resource rent tax component called Additional Profits Tax.

Jan 1, 1995

By R C. Owen, M A. Ward

The paper describes the application of New Zealand's environmental impact assessment procedures to a proposed gold and silver mine in the North Island of New Zealand. The project is described and a summary is provided of the statutory permits or consents that are required prior to operation of the project. Emphasis is given to the requirement for environmental impact assessment and the preparation of a formal environmental impact report. The company's approach to impact assessment is described, with examples of how this assessment and the identification of management alternatives influenced the engineering design of the project. This paper was prepared as a contribution to a working session of the International Association of Impact Assessment VII Annual Conference, July 1988.

Jan 1, 1988