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By M Dean, M Nehring, P Knights, M S. Kizil

Integrated continuous mining techniques such as fully mobile in-pit crusher and conveyor (FMIPCC) systems offer inherent labour, energy and environmental benefits to deep pit metalliferous mines. However, before such systems become commonplace, a number of barriers must be overcome.This paper outlines a number of commonly perceived barriers to FMIPCC application, together with a number of suggested solutions. The paper advances a design approach for specifying FMIPCC systems for deep pit metalliferous applications. A novel FMIPCC configuration is advanced using a hydraulic excavator in backhoe configuration. Because of the requirement to minimise belt extensions, a mine planning approach is presented based on a series of parallel and radial belt conveyor moves.The FMIPCC system does not fully replace truck-shovel systems. In the proposed mine plan, sinking is undertaken with truck-shovel systems using a series of box cuts, whereas pit ‘widening’ activities are accomplished via the FMIPCC system. Because of inherent differences in mine sequencing, the net present value derived from the FMIPCC mine will differ markedly from that derived from traditional, nested-pit, truck-shovel mining approaches. Therefore, any comparison of the FMIPCC and truck-shovel approaches must take into account radically different mine planning approaches.CITATION:Dean, M, Knights, P, Kizil, M S and Nehring, M, 2015. Selection and planning of fully mobile in-pit crusher and conveyor systems for deep open pit metalliferous applications, in Proceedings Third International Future Mining Conference, pp 219–226 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 4, 2015

By Morland R

In the course of an exploration program aimed at increasing Pasminco Mining's ore reserves, an electromagnetic survey down one of the underground drillholes at the North Mine, Broken Hill, recorded a broad and persistent response. This paper demonstrates that the anomaly was not due to any geological feature, but rather was caused by 'self-response' of the sensing probe. The observed results are due to the surveyed hole lying within a resistive environment and having distinct, but not unusual, changes in dip.This phenomenon has not been widely reported and we believe that there are likely to be similar cases in company records where very genuine looking responses are due to self-response rather than sulphides. These false anomalies can be recognised by correlating the observed data with the calculated down-hole component of the transmitting loop's primary field.

Jan 1, 1994

By D Carroll

Mining of the zinc, lead and silver deposit at the Broken Hill Southern Operations site has been occurring for over 100 years. As a result of this, a significant amount of high-grade ore is now taken from narrow remnant pillars left between old stopes and zones of previously mined ground. Stopes have been filled with either hydraulic fill (also known as ‘sandfill’), cemented hydraulic fill (cemented sandfill), waste rock backfill or a mixture of these fill types.In the last ten years, there has been considerable success mining through narrow pillars where sandfill is exposed in the development face and/or walls using a ‘shell’ support regime, wherein a layer of bolted mesh is sandwiched between two layers of sprayed fibrecrete (25 mm fibrecrete, then mesh and bolt, followed by a final 50 mm layer of fibrecrete). Shell support is also used in very poor, broken, relaxed ground conditions and in areas filled with cemented fill (sandfill with a minimum four per cent cement content).The next stage of innovation has been to develop a technique for mining through old stope voids filled with uncemented sandfill, known locally as ‘contours’ (old cut-and-fill working), an activity where unconsolidated sandfill can run at the face and from the backs. The challenge is to prevent exposed sandfill in the face and the backs from failing before it can be supported.To achieve this, the Southern Operations mine has implemented a technique in which 6 m long spiling bars are used to strengthen and stabilise the sandfill in front of the face. The hollow steel bars are driven in around the heading perimeter in a closely spaced pattern then pumped full of grout. The bars and the grout stabilise the sandfill in front of the face, preventing it from failing into the drive during excavation and prior to further support being installed.A final support system consisting of shotcrete, mesh, bolts and steel girders is installed as excavation progresses. Both the initial and final support systems are essentially passive support systems designed for a low-stress environment (as the stress originates mostly from the mass of unconsolidated sandfill).This process is slow and labour intensive. Fifteen separate cycles of people/machinery are needed to progress one equivalent heading cut (compared to six for a standard fibrecrete- and bolt pattern-supported rock face heading). This slow pace introduces scheduling challenges, but the process opens up parts of the orebody that were previously uneconomical to mine.CITATION:Carroll, D, 2014. Mining through sandfill using spiling bars, in Proceedings AusRock 2014: Third Australasian Ground Control in Mining Conference , pp 95–100 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 5, 2014

By S Khadhraoui, T Yusuf, C Kirmse, E Hecker, R Degel, A Akouch, N Borowski, M Reuter

For an optimal design and control of metallurgical processes, a deep understanding of the thermodynamics of the governing reactions is required. Modelling the thermochemical behaviour of those reactions is complex, as it involves multi-component and multi-phase systems. For this purpose, thermodynamic computing systems such as FactSage™ (Bale et al, 2016), which combine Gibbs energy minimisation routines with large databases of optimised thermodynamic data of solutions and compounds, have been used within the SMS group GmbH. Recently, the successful integration of those thermodynamic computing systems into the digital platforms of SMS has been achieved through ChemApp, which made running complex thermochemical calculations in Python-integrated development environments possible. ChemApp is a programmer’s package for thermochemistry and incorporates the Gibbs energy minimiser of FactSage™ as reported by Petersen and Hack (2007) as well as by Zietsman and Petersen (2018). The digital platforms link the fundamental and the industrial aspects together and can be applied as a process advisor, or for the evaluation of the environmental footprint and the economic implications of different process routes, as discussed by Reuter (2023). Two examples illustrating the progress of the developments in this regard will be introduced: 1. The Tilting Refining Furnace (TRF) for copper scrap recycling and refining to anode copper (the BlueControlApp). 2. Dephosphorisation control for the oxygen steelmaking process (Basic Oxygen Furnace (BOF)).

Jun 19, 2024

By R Urie

Dilution and loss of ore during the mining process invariably occur in all underground mining operations. This dilution and ore loss can have a significant effect on the performance and value generated from a mining operation. Further, excessive dilution or greater than anticipated ore loss during mining is often one of the key reasons for the underperformance of a mining project when compared to a feasibility study or annual budget. Mining professionals often go to great lengths preparing detailed mine plans, schedules and economic models only to then apply high-level estimates or rule of thumb values for dilution and mining recovery that can ultimately lead to inaccurate forecasts for the performance of a mine with the resultant loss of value due to the mining of uneconomic material or the loss of potentially valuable ore. This paper discusses processes and practices that can be practically used to manage dilution and mining recovery in an underground mining operation with a focus on understanding and then maximising value. The processes cover items such as the definition and measurement of dilution and mining recovery, techniques for the estimation of dilution and mining recovery, consideration of the economic implications, management of dilution and mining recovery through the stages of the planning cycle, and practices to reduce dilution and improve mining recovery. Common misconceptions and omissions are also discussed.

Mar 29, 2023

By Creasey JW, Rixon KL

Underground mining in the Bowen Seam has shown that the majority of outbursts have co- incided with faults, igneous dykes and sills, stone roof rolls or some combination of these. The coal measures are deformed principally by N- S trending, easterly dipping thrusts presumed to he associated with the major, reverse Collins- ville Fault. The old Collinsville State Mine records suggest that thrusts and strike-slip faults have been common sites of outbursts. In contrast, normal faults have not been outburst- prone. Detailed geological mapping in Bowen No. 2 Colliery 53 east and west panels has been carried out in the hanging wall of a thrust zone of 6.1 m throw. The associated sheared coal has been defined and several fracture sets delin- eated. Sheared coal can be observed up to 170 m from this thrust zone, but this is dependent on the vitrinite content of the upper seam section worked. Fvidence indicates that outbursts have crnrroJ only in extremely sheared coal. Curious spherical- to cylindrical-shaped c,,.31 ohjects ("apples" and "rods") are related to the deformation in the vicinity of the thrust zone. The frequency of rods rises from 0 at 31)0 m, to I per metre at 150 m, and to 2.5-8.5 per metro at 10 m from the -

Jan 1, 1980

By K Vallo, T Haimi, J Pihlasalo, J Hamuyuni, M Lindgren, F Tesfaye

Decarbonisation of the steel industry has recently attracted a lot of research and technological development. Most of the technological developments are centred around the replacement of blast furnace (BF), which has been the main primary smelting furnace in the ironmaking step of steel production. Replacement of the BF is not an easy task because of BF’s many established capabilities over the years, especially its ability to use low-grade iron feed. In this regard, Metso has developed its own technology, Metso’s Outotec direct reduced iron (DRI) smelting furnace, to tackle this problem. The recently developed six-in line electric furnace for DRI smelting can be used for primary smelting of DRI from blast furnace grade iron ore. Unlike the electric arc furnace (EAF), the DRI smelting furnace can handle larger slag volumes that emanate from the high gangue in BF grade DRI. Therefore, fluxing plays an important role in operating the DRI smelting furnace. This paper presents fluxing options and proposes slag quality and operating windows for the DRI smelting furnace. Also, the effect of slag on refractory durability will be discussed.

Jun 19, 2024

By D Woolmer

Since January 2019, BHP Olympic Dam have been trialling the use of a drone based LiDAR mapping system for the purpose for surveying stope voids. This new technology utilises Simultaneous Location and Mapping (SLAM) algorithm providing positioning, stability and collision avoidance in GPS denied environments. Implementation of this system utilised underground personnel trained in the equipment’s use. The study’s intention was to evaluate the effectiveness of this equipment versus traditional surveying methods in regards to quality, safety and productivity. The trial results showed a marked improvement in the quality, productivity and personnel safety when conducting surveys. The use of the drone and LiDAR system reduced personnel and equipment requirements for surveys, thus allowing these resources to be deployed elsewhere. The technology’s simple and rapid deployment allowed multiple surveys to be conducted during a 12 hour shift, including ad-hoc work with minimal disruption to underground operations. After the drone’s initial trial, further work was conducted to utilise the Hovermap LiDAR scanner on other platforms to increase utilisation. A mounting system was created allowing the LiDAR to be mounted on a remotely operated loader or vehicle. This enabled drawpoint scans to be taken directly after production completion, resulting in faster stope close outs and drive scans for convergence monitoring. Implementation of the LiDAR system has resulted in improvements in the stope production cycle by reducing delays previously associated with data capture. The increase in the volume and quality of data has also allowed in-depth back-analysis of stopes in new mining areas to be conducted, which have driven improvements in the design process.

Mar 15, 2021

By G R. Ballantyne, V Souto, K Bartram

Particle sorting allows partially liberated minerals to be separated prior to energy intensive fine grinding. Sensors select particles for separation and air, water or mechanical ejectors are used to physically deflect those selected. To achieve effective separation there has to be sufficient liberation, accurate detection and presentation of a separated monolayer of particles. These three physical constraints determine the particle size limits, the sorting technology utilised, the separation efficiency, and the throughput that can be achieved. The combination of all these factors controls the effective limits on the degree to which sorting can reduce the specific comminution requirements and increasing energy efficiency. This paper will explore two case studies: the application of sorting in base metal mining and precious metal mining.CITATION:Ballantyne, G R, Hilden, M, Bartram, K and Souto, V, 2018. Characterising energy efficiency of particle sorting, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 531–540 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

Currently all engineering schools face a common problem, an ever expanding technological base which must be presented to students within a fixed time period. Traditionally the programmes of study taken by engineering students destined for employment within the mineral industry include formal instruction in aspects of management to an extent greater than that presented in other engineering disciplines. Providing an adequate coverage of an expanding technological base within a fixed time span can lead to a reduction in the time available for 'non-technical' subjects, such as 'management'. This situation calls for periodic review of course contents and allocations of time. Following consultation with an Advisory Committee representing the mineral industry, mining research establishments, and kindred teaching institutions, the University of Melbourne has revised its mining programme. This programme is offered as an example of how aspects of management such as communications, economics, labor

Jan 1, 1980

By G S. Beros

In 2019 the Chinese Ministry of Ecology and Environment issued guidelines promoting the implementation of ultra-low emissions in the iron and steelmaking industry. These guidelines aim to drive improvements in air quality through the reduction of particulate matter (PM), sulfur dioxide (SO2) and nitrogen oxide (NOx). Secondly, it also represents an initial means to commence decarbonisation of the industry. The ultra-low emissions guidelines propose that well over 80 per cent of China’s production capacity will achieve these targets by 2025. In response, many sintering operations have implemented numerous improvements to the process that result in significant efficiency gains. Of note is the adoption of deep bed sintering where, with some modifications to equipment, the sintering bed depth is increased resulting in sizable reductions of SO2 and NOx emissions. This paper will also provide an overview of the requirements to introduce deep-bed sintering into an operation and highlight test work completed which quantifies the resultant reduction in emissions.

Nov 8, 2021

By Abishev D. N, Balakirev V. F, Davydov G. I

The problem of recovery of cobalt products from poorly oxidised nickel ores (Kempirsaisk deposit) and pyrite concentrates with a low content of cobalt (Sokolovsk-Sarbaisky deposit) has not been solved to the present time in Kazakstan. The balance reserves of nickel ore of the Kempirsaisky deposit make up more than 35 million tons with a nickel content of 1.13 per cent and cobalt content of 0.05 per cent; besides there are 110 millions tons of out-balance ores (Anon, 1995). In a tailing dump of Sokolovsk-Sarbaisk Mining and Productional Association more than 320 million tons of tailings of wet magnetic separation have accumulated, which contain 7.2 per cent of sulphur, 0.022 per cent of cobalt, 0.012 per cent of nickel, 0.094 per cent of copper, 0.079 per cent of zinc, 16.45 per cent of iron, and from which a high quality pyrite concentrate car) he separated through flotation, containing 48 - 50 per cent of sulphur, 44.15 per cent of iron, 0.141 per cent of cobalt, 0.07 per cent of nickel, and 0.10 per cent of copper. The well-known technological flow charts for cobalt and nickel recovery from the tailings of sulphide-magnetite ores dressing (to give pyrite concentrate) and from oxidised nickel ores, are not profitable at the existing prices for metals, but are not worthless and require significant capital investments for the realisation of their value. The flow chart `sulphate roasting - leaching - solution processing' is used widely for combined processing of cobalt-containing pyrite ores and concentrates.

Jan 1, 1996

By K Zunica, A R. Penney

The principles of three-dimensional geological modelling are well understood and routinely used. Sample data is collated and geostatistical tools used to ensure that sample data is suitable for its end use, which is typically a block model that is appropriate for mine planning. What has become increasingly apparent is that physical rock properties and geotechnical parameters need to be incorporated into the three-dimensional geological model to create an integrated mine model.The approach to the collection of geotechnical information is not as highly prescribed and controlled as collection of geological data. Commonly, the geotechnical data set is incomplete and inconsistent, with little consideration of what the end use will be by those collecting the data, or how the geotechnical data might relate to the geological data. In some cases, specific geotechnical investigation programs are completed, yet correlation between those programs and previously collected data is rarely undertaken to the same level of diligence as found in the geology field.There are some obstacles that need to be considered when attempting to incorporate geological parameters, such as grade, lithology, and geological domains with geotechnical information such as rock quality designation (RQD), rock mass rating (RMR), rock strength, and geotechnical domains into the same three-dimensional block model. Interpolation or geostatistical estimation methods used for grade estimates might not be appropriate for many components in rock characterisation, particularly search geometries. A number of examples are provided to illustrate issues underlying some of the data collection procedures, and their effects on three-dimensional geotechnical modelling.The example presented attempts to highlight generally observed shortcomings in the collection of geotechnical information, parameters which need to be considered when combining geological and geotechnical data into the same model, and the benefits of having a combined block model from the beginning of a project.CITATION:Zunica, K and Penney, A R, 2014. Integration of geological and geotechnical data for three-dimensional modelling, in Proceedings Ninth International Mining Geology Conference 2014 , pp 291–298 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 18, 2014

By Boontanjai C, Boyapati ER

Reagents used for batch flotation tests were Aeroxanthate-343 & 350, Dow Z-6, & reagent-4037 (from Benambra) as copper collectors; Na2SiO3 & Na2S2O3as gangue depressants; lime & HCl as pH regulators; and pine oil & MIBC (methyl isobutyl carbinol) as flotation frothers. A Denver Sub A flotation cell of capacity 250 gms was used for the batch flotation experiments. Atomic absorption spectrophotometer was used for copper assays and microscopy for selectivity and liberation studies. Melbourne tap water was used throughout the experiments. Unless otherwise stated, the following parameters apply to the flotation experiments: flotation impeller speed - 1300 rpm, pulp density during flotation- 22%, reagents addition - in 4 stages, total conditioning time for collectors - 8 minutes, total flotation time- 9 minutes. A variable quantity of copper mineral collector according to the test in question was added, then conditioned the pulp for 2 minutes. The froth was removed by hand, scraping the full length of the cell at constant depth every 10 seconds. No frother is required for this copper tailing flotation. Four concentrates were collected after addition of collector and conditioning at 2,4,6 and 9 minutes. The pulp volume was maintained at a constant level to yield a constant froth depth.

Jan 1, 1990

By F D Durao, Muge F. H, Rogado J. Q

In the scope of the project named CAPUME II (EEC BRITE/EURAM contract - project MA2M-CT90,-0042(SMA)) for the development of an integrated mine planning system for underground mines, two of the main tasks were the development of a short-term mining planning procedure (module) and a numerical simulator of the mineral processing plant of Pirites Alentejanas - PA. The short-term mining planning module defines the mining sequences by solving a constrained minimisation problem. The ore grade variability is the objective function subject to the geometrical constraints of the mining method and to the maximum of `internal blending'. The optimisation problem is solved by applying a dynamic programming algorithm. The plant simulator is an essential tool of the planning system allowing the preview of metal grades/recoveries of copper, lead and zinc of concentrates streams, given the corresponding metal assays of the run-of-mine ore, defined by the short-term mine planning module. This way, the management can plan the short-term mining operations (the weekly sequence of exploration blocks and the internal planning) in order to fulfill given required conditions, based on a shipment schedule and on a purchaser's formula. In this paper, after a short description of the short-term mining planning module and of the simulation package named SIMUL, a synthesis of the main model development steps and the results of some simulation runs are presented and discussed.

Jan 1, 1995

By H R. Pein

"The Corridor Sands deposit is situated approximately 190 km north east of Maputo, Mozambique adjacent to the paleo-mouth of the Limpopo River. This deposit is one of the worldÆs largest known economically viable resource of titanium, accounting for approximately one third of the global resource. As part of the pre-feasibility and feasibility study for development of the Corridor Sands project, various geological and geotechnical investigations were undertaken, selected results of which are presented in this paper. These investigations have enabled a detailed understanding of the material characteristics of the orebody as well as the tailings materials, such as the fines, to be developed. These material characteristics have had a significant impact on the selection of the mining and disposal methods currently being implemented."

Jan 1, 2001

By C K. McKenzie

As more and more mining operations around the world either switch to, or trial, electronic initiation systems, the breadth of knowledge and experience regarding their effective application has widened considerably.In South America, for example, there is a strong perception that in order to achieve the finest possible fragmentation, very short electronic delays must be used between successive holes within a row. Limited field studies involving measurement of fragmentation have been conducted to support that paradigm and there are few long term studies which have been strongly supported by measurements of productivity either in the pit, in the plant, or in the leaching pads.On the other hand, some well documented studies have been conducted in North America, showing not only the impact of delay timing on fragmentation but also the effect on semi-autogenous grinding (SAG) mill productivity over extended periods of in excess of 12 months. To date, those studies suggest that optimum timing is considerably longer than the times commonly used in South America.This paper explores the current knowledge of the effects of delay timing on issues ranging from size distribution to vibration impacts in pit walls, to vibration and overpressure impacts in surrounding communities. It also explores how fragmentation modelling can be adapted to reflect fragmentation trends that have been reported in various technical conferences around the world.

Nov 8, 2011

By N Setoudeh, A Nosrati, N J. Welham

The current surge of interest in lithium (Li) is due to the anticipated demand for electric vehicles and small scale power storage. Brine deposits contain most of the global Li resource, however hard rock deposits can be more readily and rapidly developed and comprise the majority of proposed projects. These projects plan to use the conventional processing routes of dense medium separation and / or flotation to produce a spodumene concentrate for sale. The standard route for subsequent processing of spodumene concentrate is thermal decrepitation, acid leaching, solution purification and precipitation of lithium carbonate. This is typically followed by further purification. A number of projects have ores which contain other lithium minerals, principally micas, lepidolite and zinnwaldite, necessitating an alternative treatment route. Several different routes for spodumene processing are under development to reduce costs to compete with brine projects. This paper will give an overview of the strengths and weaknesses of the current and alternative processes.CITATION:Welham, N J, Nosrati, A and Setoudeh, N, 2017. Lithium ore processing – an overview of the current and new processes, in Proceedings MetPlant 2017, pp 185–194 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 11, 2017

By M Scoble

This paper is based upon the experiences of collaborating academics in two mining schools and their personal view of attempts to integrate the principles of sustainable development into mining education and research. In this quest, the concept of sustainable mining practices is proposed, not only relating to environmental, social and economic performance but also stressing mine safety and efficiency. These practices need to support strategies that enable flexibility and resilience within mine operations to counter recessionary cycles. Also, these counter-cyclical strategies are now imperative for sustaining mining education and research itself. There is a critical interdependence between these two different perspectives on æsustainabilityÆ. The paper concludes by demonstrating models of strategies that promote inter-disciplinarity, collaboration and networking for sustaining mining schools.

Jan 1, 2009

Nickel laterite HPAL circuits are known for their complexity and have presented a large number of challenges to process engineers worldwide. An attitude commonly encountered by the author is that the beneficiation of the ore is relatively simple and that the difficult problems are in the realms of hydrometallurgy. On a number of occasions beneficiation has become the 'poor cousin' in the process design phase. Another common theme is that significant difficulties are encountered when beneficiation circuits are started up, invariably slowing the ramp-up of the remainder of the circuit. In some cases the problems impact on throughput for a long period and can require major rectification capital. The HPAL Ni laterite projects encountered each have their own set of beneficiation problems that need to be understood before an appropriate circuit can be designed. This paper will discuss a range of design issues including geometallurgy, ore characterisation through laboratory testing, the application of appropriate sizing and analytical procedures, the selection of appropriate unit operations, materials handling of plant feed and products and setting meaningful plant design requirements.

Jan 1, 2008