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By D Head

IonicRE acknowledges within our mining industry, there is a common belief that workplace health and safety, often referred to as safety, is just a matter of ‘common sense’ – something obvious and easy. However, at IonicRE, we hold a different perspective. We understand that safety is far from easy. We recognise the need to emphasise the importance of understanding and conveying the inherent difficulties of working safely. We are committed to implementing processes that support individuals in achieving our safety objective of eliminating fatalities and permanently disabling injuries. To build resilience and sustainability into safety performance, we draw parallels with the principles underpinning sustainable and exceptional production performance. Achieving sustainable safety performance demands effective leadership, meticulous planning, adept management, genuine care and unwavering commitment. We’ve leveraged various tools and techniques, such as DISC theory, Maslow’s hierarchy, process control, Kaizen, Six Sigma and Kirkpatrick’s 4 levels, among others, to facilitate this improvement. There methods play a pivotal role in developing a Safety Blueprint for enhanced safety performance. This paper provides an overview of IonicRE’s Safety Blueprint, a strategic framework for developing our safety capability. Our capability is underpinned by three key pillars. Firstly, a comprehensive risk management approach is imperative, encompassing the understanding of hazards, the identification of threats to our people and the associated risks. Secondly, it entails providing and enforcing accountability to sustain our safety capability. Lastly, it involves constructing an effective defence system against threats and harm. Implementing these pillars requires a meticulously devised change process. Anticipating resistance and potential setbacks, we underscore the importance of having the right people and a wellcommunicated vision for safety at IonicRE. A Safety Blueprint serves as a detailed plan outlining the path toward a future goal. At IonicRE, we contend that safety in the mining industry has generally lacked a coherent and effective Safety Blueprint – a comprehensive plan to navigate the journey toward a destination. Drawing parallels with NASA’s detailed plan for landing a man on the moon safely, we question why, as an industry, we cannot similarly eliminate fatalities. While progress has been made in the last century, we must not wait another 50 years to eradicate fatalities from our industry. Examining Safe Work Australia data from 2008 reveals that 47 per cent of mining fatalities result from vehicle activity and 40 per cent stem from individuals being struck by an object. As of December 7, 2023, seven lives have been lost in the mining industry in Australia this year, indicating a stubborn trend mirroring 2022, with limited improvement over the past 25 years. These incidents are not isolated or unexpected. We understand the hazards and controls, yet fatalities persist. IonicRE considers that the mining industry stands at a critical juncture – do we accept a plateau in mining safety performance, or do we rethink our approach? At IonicRE, we are thoroughly reassessing the hazards that threaten our people, systematically redefining effective risk control measures and establishing a robust framework to hold individuals accountable for the effective implementation of the control measure.

Apr 16, 2024

By Scaife PH, Cripps Clark J, Cameron DB

Tuyere coke samples have been taken through the tuyere openings of B.H.P. International Blast Furnaces since 1978 with Whyalla No. 2 Blast Furnace taking samples on a regular basis since 1982. The degradation of coke during it's passage through the Blast Furnace can be measured and the relationships between these data, feed coke data and blast furnace operating data demonstrated. Tuyere coke sampling has been useful in revealing misleading external coke testing results and is still the method to monitor directly the performance of coke within the Blast Furnace.

Jan 1, 1987

THE Company's smelting equipment consists of three blast furnaces, supplied with blast from two sets of vertical piston blowers, each capable of delivering 8000 cub. ft. of air per minute at a pressure of 60 oz. per sq. in. Each blower is belt-driven by a 1:30 h.p. motor. The maximum speed of the blowing engine is 35 r.p.m.No. 1, the largest of the three blast furnaces, has a crucible area of 49.5 sq. ft., and measures 11 ft. 6 in. x 5 ft. at the tuyeres.From tapping floor to feed floor measures 35 ft. 9 in., and holds, when full, 100 tons of charge. Blast enters through thirteen 3-m. tuyeres at 60-oz. pressure. Working normally, this furnace is capable of treating :300 tons of charge, exclusive of returned slag and coke, per 24: hours, with an output of 100 tons of lead. Tapped slag flows into a C.l. forehearth mounted on wheels, where any lead and matte is caught, and the slag overflows into a 3-ton cast-iron pot, in which it is drawn away by an electric locomotive and poured over the dump.

Jan 1, 1918

By G Billing a, D Gribble, E Hall, D Varga

The theoretical benefits of electronic detonators have been reasonably well documented. To support this, a practical comparison was made between the performance of the standard shock tube system, NONEL, and a high precision electronic system, HotShotÖ, at the Sunrise Dam Gold Mine. The expected benefits from electronic detonators to Sunrise Dam were identified prior to the trial. Based on these, a number of objectives were set to demonstrate the value of the HotShot system. These are an improvement in fragmentation leading to an increase in productivity, less oversize rehandling, increased throughput and more uniformity in muck pile movement. To maintain the integrity of the trial, the nominal timing of the shots was kept exactly the same, thereby restricting any performance improvements to the precision of the electronics. Accordingly, adjacent shots were chosen with consistent geology. Video footage was taken of the blasts and vibration monitoring was carried out by fixed geophones throughout the mine. Spot heights of the muck pile swell were taken immediately after the blast and heave profile graphs were generated for comparison. Video footage was taken for a period of three hours for both shots to analyse cycle times of the excavator and trucks. PITRAM data was also collected for analysis. As far as practicable, the ore was taken to the same finger on the run-of-mine (ROM) pad to assist in single sourcing for the crusher and to allow oversize to be separated out. From specific metrics taken during the trials, it was shown that the expected improvements due to the high precision timing of electronics were realised in all areas.

Jan 1, 2007

By M Hedley

Tracking plant and personnel in mining operations provides multiple potential benefits for a mine including improved safety, better monitoring of production, traffic control and, in the future, monitoring and control of autonomous vehicles. The main techniques currently proposed and used for wireless tracking are radio frequency identification (RFID), signal strength based techniques and time of arrival (TOA) based techniques. RFID provide poor accuracy in the complex radio propagation environment present in mines and does not provide continuous tracking and signal strength techniques. TOA based techniques are potentially the most accurate, however, most current equipment has not realised the potential of the technique. CSIRO has been developing the Wireless Ad hoc System for Positioning (WASP) system for wireless tracking in a range of challenging environments including underground mines and surface operations, where GPS reception is compromised by depth. The system utilises a number of ‘anchor nodes’ that are placed at fixed and known locations within the mine and tags attached to the plant or personnel to be tracked. The system provides an ad hoc data communication network, thus, wired data connections are not required to the anchor nodes. WASP uses transmissions in the 5.8 GHz ISM (instrumentation, scientific and medical) frequency spectrum to perform highly accurate ranging between nodes, hence tracking of tags. The localisation performance of the system depends upon the radio propagation environment, ranging down to 0.1 m in low multipath conditions. In this paper we describe the WASP system and provide results of testing in underground and surface operations showing the system achieving high ranging, hence localisation, accuracy.

Nov 22, 2011

By Qixiang Y

The strength of coal mass saturated with gas is an essential parameter in studying the mechanism of gas and coal outburst,and its prediction method. Up to now, there has not been a method for determining the strength of coal mass saturated with gas.This paper describes a new method whereby the strength of in-situ coal mass can be determined and stored continuously and automatically. The simulation results obtained in the laboratory indicate that the new method allows a fast, reliable, inexpensive and convenient determination of the strength of coal mass.

Jan 1, 1992

Unprecedented political, economic, and social change throughout the world will have an increasingly profound effect on the dynamics of the world's mining industry. Analysis of the early financial trends in this development (statistics on exploration expenditure, and investment flows) gives some insight into the magnitude of structural change and its implications for established mining economics and companies.Increasing confidence in the stability of many third world and developing countries is attracting exploration and investment capital that had previously been largely directed to established mining economies in North America, Australia, Europe and Southern Africa. Some of the projects requiring capital and technology in the CIS, Africa and Latin America are technically very attractive. The end of the 'cold war' and the influence of the IMF is gradually changing their risk profile for mining investment.

Jan 1, 1993

Spiral separators have been used to treat heavy mineralsands in Australia for some 35 years. During the last five years the logical extension of this technology has been torecover cassiterite from alluvial deposits. Plants incorporating spirals are already operating in Indonesian andAustralian tin mines. A more fundamental understanding of the design of spiral separators has recently led to their use in other mineral treatment plants.In particular, the treatment of alluvial gold and fine coal has been most successful. The new generation of spirals that has been developed to treat these minerals is more easily operated than other competing processes and is therefore ideal for new mine situations.

Jan 1, 1986

For several decades miners have been obliged to maintain a vast supply of sharp steels at the working face to meet the hungry needs of rock-drills. In medium and large size mines this has meant the setting up of an organisation to store steels, to make and sharpen bits with all the complication and skill of forging, hot milling and heat treatment, and to transport sharp and dulled steels to and from the working face with all its labour, wastage, and inconvenience to other mining operations.In a mine with 250 rock-drills in use, a flow of more than 60,000 sharpened steels each month has to be maintained to keep the machines fully employed, so some idea of the magnitude of this problem may be grasped.For a long time it has been apparent that it is mainly the bit itself that wears, and many attempts have been made to reduce the enormity of the problem by providing detachable steel bits which could either be used once and rejected, or sharpened three or four times before rejection.At the same time metallurgists have striven to 'improve the quality of the steel and the heat treatment afforded it so that a bit, readily workable In a normal mine drill-shop, could be produced having a high resistance to wear and fatigue; but, although various alloy steels have been marketed, it is still usual to find many mines relying on a "straight" carbon (0.6 - 0.9% C.) steel for their drill steels.Since 1915 increasing use has been made of tungstencarbide as a cutting implement in the engineering industry. Where, on account of its great hardness and long life, it...

Jan 1, 1948

By Tonegato S, Wood M

The lack of objective data on roof bolting machines, bits, rods and overall system has created the need for an objective assessment of roof bolting. This work outlines a test rig for such objective assessment of component parts of the roof bolting system.

Jan 1, 1986

By H P÷llmann

Calcium aluminates, calcium aluminate ferrate and calcium aluminate sulfate were synthesised by solid-state reaction, sol-gel method, a self-combustion method and by a polymeric precursor process. For chemical sintering methods the base chemicals CaO, CaSO4, Al2O3 and Fe2O3 were used. As precursors for sol-gel synthesis metal nitrate hydrates and Al2O3-Sol were used. In order to synthesise pure phases by a self-combustion reaction glycine was used as fuel and nitrates as metal components. In the polymeric precursor process metal nitrates and diluted H2SO4 were used as metal components and the resin was made using citric acid (C6H8O7) and ethylene glycol (C2H6O2). Precursor phases synthesised by these different methods were sintered step-by-step in order to investigate the crystallisation. Further on single phases were hydrated and their hydration behaviour was studied by heat flow calorimetry, X-ray diffraction and cryo-transfer scanning electron microscopy. Due to the different synthesis procedures different hydration reactions and microstructures of the phases will be shown.

Jan 1, 2008

Future hard rock mining will gradually move towards complete mechanisation which lends itself to remote control and ultimately to robotic mining. This will require different technical inputs into mining engineering and one of these is in the area of rock'mechanics. Traditional hard rock mining has had little rock mechanics input. Problems arising from high stresses and poor ground conditions have in most cases be remedied after they occurred, in the worst case by abandoning a particular stope or area and starting elsewhere. In a fully mechanised remote or robotic mining situation the financial penalty for such an approach could be severe, as a major part of the production costs will be in the development and the equipment. It is therefore imperative that a complete rock mechanics feasibility study is undertaken before an area is set up for robot mining and that a continuous stability monitoring system is installed that will predict rock behaviour well in advance of mining, such that the necessary ground control measures can be implemented without impeding the continuity of mining. This system will utilise already existing instrumentation such as extensometers and stress cells, and possibly additional improved instrumentation which has to be developed for this particular Application.

Jan 1, 1986

By D V. Bright

Oroya Mining LimitedÆs Mt Gibson Gold Project, 280 km north east of Perth, is one of Western AustraliaÆs more recent discoveries of a major gold resource. Modern gold mining commenced in 1986, on a shallow laterite reserve of 6.62 million tonnes averaging 1.50 g/t gold. By the end of 1998, mining had progressed from an initial three shallow laterite pits to a series of 14 open pits with maximum depth of 100 m, on three separate trends with a combined strike length of over 10 km. The Project has yielded 868 400 ounces of gold from 16.5 million tonnes of ore at an average recovered grade of 1.64 g/t gold, from near surface laterite, supergene and primary sulfide ores. This includes a 160 m deep underground decline operation which mined 120 000 tonnes at an average grade of 9.1 g/t gold and a four million tonne Dump Leach on a synthetic base which yielded 68 900 ounces. The Project was placed on Care and Maintenance in 1999 pending drilling to refresh reserves. Hosted by strongly tectonised and altered Archaean volcanic rocks within and adjacent to a major regional shear, primary gold mineralisation occurs as structurally emplaced sulfide and quartz lodes. On the main Gibson Trend, multiple zones of mineralisation occur within a zone up to 600 m in overall width. The overall footprint of known mineralisation exceeds 20 km2 and the potentially mineralised domain exceeds 100 km2. The current estimate of a combined resource of 9.4 million tonnes averaging 2.47 g/t gold (749 500 ounces) is derived from a database of 10 500 drill holes, of which only four per cent test below 100 m vertical depth. Ore envelopes which remain open at depth and major gaps in the drilling pattern beyond the currently defined resources promise straightforward potential to define additional resources. Oroya Mining Limited and its joint venture partner Barrick Australia are targeting a major gold mining operation from this potentially world-class mineralised system. Oroya has the exclusive right to produce up to 500 000 ounces and is working toward the completion of a feasibility study into a resumption of mining using the existing 1986-built 1 Mtpa processing plant. The joint venture is in the early stages of testing the depth and lateral potential of the Mt Gibson mineralised system. Mining options currently under review include progressive open pit extension and amalgamation leading to one or more large open pits, and underground operations. It is too early in the development of the Project to offer definitive economic models of potential large-scale mining operations.

Jan 1, 2003

By Veal FL

Technological changes in Portland cement manufacturing during past years have reflected changes in the economics and availability of various types of fuel such as coal, fuel oil and natural gas. The industry consumes a sig- nificant quantity of both thermal and electric- al energy. The nature of the process and its chemical constraints does however permit the use of comparatively low grade fuels such as high ash coal and high sulphur oil. In striving for increased daily kiln outputs and conservation of energy, there is a worldwide trend towards the use of dry process plants. Wet process kilns of about 2 500 tonnes per day assume massive component sizes which present difficulties in manufacture, and transport to plant sites. Large capacity dry process units in excess of 8 000 tonnes per day are now in operation using precalcination techniques in which part of the fuel is introduced in the static preheater section ahead of the kiln while the balance is added to the kiln in a conventional manner. This technique has virtually doubled the potential output of any given single kiln.

Jan 1, 1976

Difficult ground conditions in the area planned for placement of vent rises to the surface at the Porgera Goldmine led engineers directing the project to chose blind shaft boring methods of shaft construction from the available alternatives. Zeni Drilling Pty Ltd was first contracted in 1988 to install a group of three closely-spaced, steel lined shafts. The success of these led to an order for a fourth hole in the same group followed by two more, less than a kilometre. away, under a separate contract in 1992. All of the shafts were completed on.schedule to within one day. The only significant difficulty arose during commencement of the last shaft when the strata collapsed trapping the drilling tools and jeopardising the stability of the surface collar pad. The situation was corrected by innovative lining techniques and the project went on to finish on schedule. This paper discusses the application of various technologies associated with the project including aspects of geotechnical input, drilling fluid chemistry, mining engineering and logistics.

Jan 1, 1993

By Fernando N, Guang LX

Brown coal in Victoria in spite of its substantial reserves is not utilized greatly because of its high moisture content(-65% w/w). Transportation and handling costs of raw brown coal, on an available energy basis are so expensive that 93% of production is burnt for electricity generation on or adjacent to the coal deposit in Victoria. With direct firing of moist brown coal in power stations, approximately 20% of the gross calorific value of the fuse is used to evaporate the water contained in the coal. This energy is lost as vapour with the flue gas which is vented to the atmosphere. Also there is a 25% increase in flue gas volume and the size and cost of most of the units through which it passes must be appropriately larger. Since there are large quantities of water present the flame temperature is significantly reduced. For zero excess air and no air pre-heating the theoretical flame temperatures are: 609'o wow moisture 1450¦C 40% ª ª ª 1790¦C ZOO ª ª ª 1990¦C As a result of this there is a reduction in radiant heat transfer leading to a requirement for a two fold increase in radiant tube area. A boiler of much greater size and cost is thus required to house the additional tubes. Figure 1 illustrates the relative sizes of a boiler fired with 60% moisture brown coal with a boiler or similar output fed with a British bituminous coal, 14% moisture.

Jan 1, 1989

In essence, these statements concur, However, management predominantly controls the organisation's communication environment (5), Consequently, the participation by employees in safety is greatly influenced by the quality of upward communication, (See section on authority for discussion on two way communica-ò tionò) Emotional survival contributes to the communications and it is said to occur as follows: -- We. aU tend to move towaAA 6.itw tLon,s which aid the achievement oj5 owc goa o and way {y/wm ones which testh ict achievement." Consequently, although the work force are prepared to contribute, they will not make the effort for long if management does not respond in deed. The Robers report includes the following statement; "Satiety and heat h at wank is a matte o6 e66ic,ient management. But it .L not a management pn.enogative. Wank people muht be encouAagad to pattiaipate úu.Uy in the making and movutoni:ng ob a/vua.ngements ban .6aJety and heath, at their. pace ofj wonk.t'(3) Attitudes dominate within this region. Emotional surviv- al is paramount. Management is the catalyst. They dominate the communication channels. Participation does not exist without two way communications and positive responses by those involved, Fault Doctrine. Eliminate faulty human behaviour. This concept lives with us as the predominant prior- ity of many safety programs. The concept is a drain on limited resources., Remember, malaria. At one stage this disease was believed to be caused by the mat or bad air emanating from persons whose profaneness or impious behaviour incurred such reprisal. Today, such a concept of malaria seems so ridiculous, (9)

Jan 1, 1979

The correct design and effective operating strategies of metallurgical plants require a constant analysis of data gathered for process control, or for due accountability. Conventional, oldfashion statistical tools often fall short of helping management, either because they are too complicated and ambiguous, or because they fail to address structural problems leading to causes of setbacks. This paper focuses on three statistical tools known for their practicality and the in-depth perspective they offer in attempts to retrieve important information from existing data. These tools also provide a better appreciation of the importance of carefully selected data quality objectives. Chronological data are meticulously gathered and stored at considerable expense: They have value, and it is the duty of management to take full advantage of them. These three selected tools are the variogram and its auxiliary functions, the moving average and its auxiliary functions, and the relative difference plot. This paper offers solutions, and a reference for managers to optimise metallurgical plants.

Jan 1, 2002

By Wetzeil N

High ambient temperatures combined with high surface humidity in the north of Australia and, in particular, the northern areas of the Northern Territory can make underground workplaces relatively inhospitable at certain times of the year. . Woodcutters' silver/lead/zinc mine, situated some 80 km south of Darwin, would be the most northerly underground operation of any significance in Australia. As such, during the build up to the wet season, it has a particular problem of ventilating a deep underground mine with already high dry and wet bulb temperatures at the surface. The Mine Management Act and Regulations mention only that workplaces shall be 'in a fit state for a person to work in or occupy'. Woodcutters therefore set in progress a Heat Stress Program to endeavour to set standards which would be more measurable and justifiable. The aim of the program was to compile a record of ambient atmospheric conditions in the working areas such that areas and/or work activities generating high ambient temperatures and humidities could be identified, quantified and qualified. Once the analysis stage of this program was completed, Woodcutters compiled a set of recommendations for the continued monitoring for, and control of, heat stress conditions to ensure that no underground employee was placed at risk from 'heat stress'. These recommendations are discussed in this paper.

Jan 1, 1994

By Thomas R

The successful `marriage' between a company seeking to raise funds to develop a project and their financiers calls for a strong mutual understanding of each other's needs. For a company attempting to raise funding, the alternative methods are ever expanding. The optimum method will vary depending on the financial position, risk/reward outlook of the company and the strength of the project for which development capital is being sought. It is likely that small mining companies will need to raise equity funds for advancing projects to the development stage. At that time, they will probably still require a reasonable level of shareholder equity to meet the requirements of banks and other parties to cover potential cost over-runs on the project and feasibility costs. Larger companies, however, are likely to find it much easier and cheaper to raise debt from banks. When evaluating companies and projects for funding, banks will pay particular attention to the quality and experience of management in developing similar projects and it may be necessary for some companies to retain the services of outside consultants. Before a project needs funding, companies should meet with potential financiers to develop relationships to select and ensure a smooth transaction to funding in the future.

Jan 1, 1997