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By D Hope, D Mitchell, B Metcalfe

In recent years there has been a major change among mining companies in their mining methods. This has been driven by the need to increase shareholder value and optimising the value from an operation. With this understanding there has been a need for all producers to become more efficient in their mining processes. An analysis of the coal losses at Mount Thorley Operations indicated that the major losses were in the dragline section of the mine due to coal damage from throw blasting. This damage was evident after the removal of the overburden by the dragline.Coal and Allied Mount Thorley Mine in partnership with Orica Explosives developed a process to reduce the coal loss associated with the throw blasting of Mt Thorley. Orica provided its specialised knowledge and experience in the drilling and blasting area and combined this with the local mining knowledge and expertise of Mount Thorley Operations personnel to conduct the project. This partnership reduced coal loss in excess of 50 per cent whilst maintaining targeted dragline productivity.

Jan 1, 2001

By H Kim, M J. Sun

Global steel companies are actively combating climate change by reducing carbon emissions. Traditional steel production, using the blast furnace (BF) – basic oxygen furnace (BOF) process, heavily depends on coal and emits substantial CO2. To mitigate this, companies are transitioning to the more eco-friendly DRP (direct reduction plant) – EAF (electric arc furnace) process, which lowers CO2 emissions. This study quantitatively evaluates the impact of increased hydrogen consumption on the carbon footprint of product (CFP) through an analysis of direct reduction process heat and mass balances. The study prioritises a comprehensive material balance based on mass conservation principles. The heat balance is calculated using differences in enthalpy through state energy properties, avoiding heat consumption. Validation using operational data from Hyundai Steel Dangjin works’ blast furnaces shows close alignment between calculated results and actual data, with less than 1 per cent error. This methodology facilitates a detailed analysis of the direct reduction process, offering insights into its feasibility and efficiency. Analysis of the operational impact by increasing the hydrogen ratio demonstrates reduced CO2 emissions and increased heat requirements due to the endothermic nature of hydrogen reduction, in contrast to the exothermic CO reduction. Possible solutions include raising reducing gas temperature or enhancing flow rate. The study effectively utilises designed heat and mass balances to assess material quantities and thermal balance under different operational conditions. It lays the foundation for the initial direct reduction process design, aiding in deriving and optimising operational parameters. Additionally, it provides valuable insights into the challenges of increased hydrogen, contributing to the production of greener steel by addressing these issues.

Aug 21, 2024

By S Basu, P M. Midhun

Electro-Slag Remelting (ESR) is a process capable of producing ingots with much lower centre-line segregation and better internal soundness than conventional ingot casting processes, as well as lower inclusion and sulfur concentrations. This process is commonly used for alloyed steels intended for critical applications like components of marine turbines, supercritical powerplants and rocket motor casings. It involves melting a metal electrode using electrical resistive heating in a slag pool and re-solidification of the resulting metal droplets beneath the slag layer, forming an ingot. Conventional ESR fluxes consist primarily of CaF2, Al2O3 and CaO, along with minor concentrations of SiO2, MgO etc. The emission of fluoride vapour from the molten slag causes several environmental and health problems, triggering a need to develop and reduce the fluoride content in the ESR flux. The present study aims to develop low-CaF2 alternatives to commercial ESR fluxes without compromising on productivity and the surface quality of the refined ingot. Thus, the modification in chemical composition needs to satisfy properties like electrical resistivity, viscosity and liquidus temperature, essential for efficient ESR operation. Since electrical resistivity and viscosity are highly dependent on the ionic structure of the molten slag, it is important to understand the effect of compositional modification on the structure of the flux. The present study employs Fourier-transform infrared spectroscopy (FT-IR) and Raman spectroscopy to investigate the structural variations in the modified fluxes, especially the effect of changing SiO2 concentration, in comparison with conventional CaF2-rich fluxes. Additionally, thermal analysis (Differential Thermal Analysis (DTA) and Thermogravimetric Analysis (TGA)) has been carried out to characterise the melting behaviour of the fluxes. The findings are compared with simulations carried out using the FactSage™ software, ver 8.3 (GTT Technologies, Aachen, Germany). Simultaneous analysis of liquidus temperature and the structure is expected to help in identifying the practical suitability of modified ESR flux compositions for industrial implementation.

Jun 19, 2024

By P B. Swart, P D. Erskine

Despite an increasing focus by media, communities and activists driving an elevated regulatory focus in Australia and indeed some other mining jurisdictions, the mining industry globally has had limited successful mine lease relinquishments and transfers to support a next land use.Critique from anti-mining lobbyists frequently uses the large estimates from historically abandoned mine sites to influence risk-averse regulatory reforms to improve environmental performance. The mine rehabilitation regulatory processes in Australia, and specifically in the State of Queensland, are thus largely in place to prevent mining operators from abandoning their obligations.Regulatory responses to the lack of mine rehabilitation and closure performance in the last five to ten years have primarily focussed on compliance and enforcement of rehabilitation conditions in environmental approvals. Additionally, financial assurance measures have been tightened to protect against abandonment of rehabilitation obligations by the Industry, including the Chain of Responsibility legislation (Queensland Government, 2016b) in April 2016, to hold to account those who have benefitted from mining and processing/refining projects, and then avoid their environmental obligations.CITATION:Swart, P B and Erskine, P D, 2018. Are our closure planning and regulatory processes adequate to identify, quantify and appropriately transfer residual risks after successful mine rehabilitation?, in Proceedings Life-of-Mine 2018, pp 155–158 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 25, 2018

A method is presented for calculating the number of cycles of stress to failure of a drill rod from operating variables; a mathematical analysis by Cooper of the stresses present in drill steels is applied to the forged collar, i1i-in. hexagonal hollow drill steel in common use in Australia; and an estimation is made of the dry fatigue limits at various points along a drill rod.It is shown that these calculations predict failure at a 'point where failure rarely occurs, and do not predict that failure should occur where it does in practice. The reasons for this anomaly lie in the neglect of bending stresses in the stress calculations, and in failuredue to corrosion fatigue at a preferred section rather than to simpler fatigue under non-corrosive conditions.INTRODUCTIONIt has long been recognized that failure of metal sections by fatigue is influenced both by the number of cycles of stress imparted to the section (N) and by the magnitude of this cyclic stress (8). In this paper, both Nand Shave been calculated for rods which have failed in service, and whose operating history is known. While the calculation of the number of cycles to failure is·simple, the calculation of stress is more complex. The results of stress caIculations predict that failure should occur only hi short rods, and then preferentially at the tip end rather than the shank end.However, in actual fatigue failures of steel rock drill rods, approximately 75 per cent. of such failures are close to the shank end, and failures near the tip end are rare.The usual explanation given for this high incidence of shank-end failures is that at the point of failure there exists, in forged collar steels of the type common in Australia "hardness valley" or. "m'etallurgical notch". This narrow valley in hardness is a weakness, and failure is expected to occur at the weakest point at the bottom of...

Jan 1, 1955

By R Valenta, I Fahey, M Klawitter, N Spanswick

Zinc-Lead-Silver (Zn-Pb-Ag) mineralisation at the George Fisher Mine occurs in multiple structurally-disrupted stratiform orebodies hosted within a mid-Proterozoic sequence of calcareous siltstones and variably pyritic shales (e.g. Valenta, 1994; Chapman, 2004). The geological model for the mine has been constructed based on a large number of stratigraphic domains which have been defined using recognised patterns of the constituent rocktypes, aided by recognition and mapping of K-rich tuff marker beds (TMBs). The continuity of these domains has been affected by the presence of several sets of faults which are extensional in the plane of stratigraphy, leading to the common occurrence of fault-related stratigraphic gaps in drillholes. Recent improvements to the detail of the geological model have led to significant improvements in the head grade of ore at George Fisher, with relatively small loss of metal. Recognition and accurate logging of these domains requires a high level of knowledge and expertise amongst mine geologists. In order to aid this process, the George Fisher mine installed a Minalyzer CS (core scanner) on site, with the aim of using high resolution X-ray fluorescence (XRF) geochemical data and core photography to increase the speed, accuracy and consistency of the site geological logging system. This contribution describes some preliminary results from a research project aimed at using the Minalyzer CS XRF data to perform high-resolution rocktype identification and domain boundary mapping in drillcore at George Fisher. CITATION: Spanswick, N, Klawitter, M, Valenta, R and Fahey, I, 2018. Rocktype classification and domaining of complex stratiform Zn-Pb-Ag mineralisation at the George Fisher Mine using high resolution XRF Core scanning, in Proceedings Complex Orebodies Conference 2018, pp 58–59 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 21, 2018

The mining industry was one of the first industry groups to be confronted by and to respond to public and government pressure to improve its environmental management. Companies operating in New Zealand and the parts of Australia with firmer environmental and planning controls responded quickly with environmental staff appointments to their development and operating arms. Even in less demanding jurisdictions in Western Australia and Papua New Guinea environmental staff were added to the payrolls. The issues then and now were seen as pollution related with land and water housekeeping leading to progressive or eventual site rehabilitation. Increasingly, however, environmental issues are being recognised as being more complex. They are about equity and social justice. Pollution of water, air or land is seen by the public as a question of personal and public rights, more or less wherever the pollution takes place, on public or private land. Environmental issues in mining have become caught up in the global perspective and a more holistic approach to environmental management. Environmental issues touch every comer of the community and action is being demanded. Nowhere is this better illustrated than on Bougainville Island where increasingly militant demands by land- owners for redress for environmental degradation from the Panguna Mine, on close examination, revealed many years of disenchant- ment with the government and the mining company over a wide range of social, cultural and environmental issues. Failure to address this satisfactorily eventually led to a bloody rebellion and finally an act of secession.

Jan 1, 1991

By P Dean, M Elmouttie, Y Duan, X Luo

Slope instability is one of the major concerns in open pit mining operations. A significant collapse of the pit wall can result in injuries, damage to machinery and interruptions to production. A broadband microseismic monitoring technique has been developed for diagnosing the healthy condition of a target slope area. This technique has been successfully applied to an open pit mine in Chile. Our research has found that this microseismic monitoring technique can be used in open pits for tracking and locating a falling rock that is rolling on a slope, if a dedicated seismic sensor network has been established. In collaboration with other monitoring techniques (radar, laser scan, aerial photography), more accurate determination of rock rolling trajectories can be obtained. In this paper, an example of using the CSIRO microseismic monitoring technique at an open pit mine is presented. Results from an experiment where we used the microseismic technique for determination of the trajectory of a rockfalling on a slope are also presented.

Nov 8, 2021

By Coxhead B. A, Brandt B. A

The geological exploration and evaluation of coal reserves involves the appraisal of very large amounts of data. Computers afford an ideal means of handling and manipulating the data, thereby avoiding the laborious and expensive method of manually compiling the logs in full descriptive language. The Minad system of computer storage and retrieval of geological and analytical data is particularly suited to the description of cores and cuttings from exploration drill-holes. The encoded data is arranged in a 120-column computer output sheet format; descriptive geological information in a 54-column geolog and analytical information in a 64-column assaylog. The acquired data is quantitative, uniform and relatively complete and can be selectively retrieved for processing by a wide range of specialized computer programs developed for the coal mining industry. Visual retrieval of data for manual processing is facilitated by the use of simple codes and logical word abbreviations.

Jan 1, 1977

By Paine GG

In coal mining each of the unit operations are interrelated with each preceding operation having an effect on subsequent operations. This presents difficulties for determining when the lowest overall costs for a particular mining system are achieved. Drilling and blasting is the first mining operation for production and is known to have an effect on the subsequent loading, hauling and crushing operations. Computer blasting models developed over the past 15 years can be used to describe the drilling and blasting operation. This paper describes the ICI Blasting Model "SABREX" in detail. Methods of using the model are discussed. This involves field measurements of geological structure, shallow refraction seismic surveys, laboratory measurements of rock properties and high speed photography of blasts. The predictions are compared with actual blast results for fragmentation sizing and muckpile profiles. Outputs from the model are described and these can be used for input to models of subsequent operations.

Jan 1, 1987

By Cottrell EC

Remote sensing has been used for many years but until recently its application has been limited by the resolution of the data available. High resolution airborne multi-spectral scanner data (MSS) has proven suitable for a number of applications including environmental management and monitoring. A shallow water mapping research. project completed on the Gold Coast has shown that- remote sensing can be used as a cost effective tool for environmental management and Monitoring.

Jan 1, 1987

The maintenance system for underground mobile equipment at Cobar Mines Pty. Ltd. has been modified from that originally planned as a result of experience gained in operating the equipment.Downtime due to breakdowns has been reduced by improvement of vehicle servicing and overhaul procedures.Frequency of breakdowns can be reduced by training operating and maintenance personnel to a high standard, ensuring adequate numbers of tradesmen and supervisors, good maintenance facilities and communications, a well designed mine layout, and a comprehensive stock of spare parts.A maintenance and downtime summary is compiled for each four-week operating period and this is useful in highlighting particular problems where corrective action must be taken.

Jan 1, 1969

The factors affecting performance of base and precious metal smelting and converting processes are considered in relation to reactor characteristics. The chemical differences between processes are related to these factors for different reactor systems. The complete smelting and converting flowsheet involves a number of operations. The process selected for a particular feed and product requirement should be one which optimises the efficiency of the process, the cost of building and operating the technology and the long-term maintenance and productivity of the units.Ausmelt's approach to achieving an efficient process using its technology is described in relation to the smelting of copper concentrates for production-of blister copper.

Jan 1, 1992

By X Li, H Alehossein

The oscillating disc cutter (ODC) is an innovative technology for the continuous excavation of hard rock. This paper will discuss:the reasons for its development;its method of operation;current experimental results and mathematical modelling undertaken at the CMTE; andapplications in the mining and rock excavation industry.

Jan 1, 1999

By Stephenson IM

Research to develop the use of L.D.slag as an aggregate in road construc-tion is described. The chemistry and mineralogy of L.D. slags are shown to be generally similar to S. Yorkshire arc furnace slags, which have been success-fully used for road construction for many years, although both free lime and iron contents were found to be higher. Physical and mechanical properties are good but the slags' high density will result in lower "covering capacity"."Weathering" in stock piles is shown to significantly reduce free lime levels fairly rapidly although around 50 per cent of the mean "fresh free lime" content is still present even after two years treatment.

Jan 1, 1979

The Ausmelt Catalytic Waste Converter (CWC) has been developed for use in the treatment of industrial wastes and for the recycling of secondary materials. Ausmelt Technology uses a top submerged lance system within a versatile and efficient slag bath reactor. High temperature pyrometallurgical reactions are carefully controlled within an oxidised molten siliceous slag such that metals can be extracted from waste feedstock for recycling, with non-volatile elements reporting to the slag, usually as oxides. Modification of the slag chemistry results in a final slag product that is stable, vitrified and is able to pass standard leach tests such that it is safe to discard or be used in civil engineering applications. Toxic components in the wastes such as organohalides can be completely destroyed and are prevented from reforming. Waste to energy conversion is practiced by the addition of a heat exchanger/steam generator in the converter offgas system. The Ausmelt CWC has been used for recovering zinc from residues and slags, treating spent potliner (SPL) from the aluminium industry and a wide range of electronic and other potentially valuable waste materials. Methods of monitoring the exhaust gases at different stages in the CWC gas handling system are discussed. The assay of these gases prior to emission is used to assist in the control of the converter chemistry to ensure the complete oxidative breakdown of the feedstock.

Jan 1, 2002

By Merritt RR

The equilibrium phase relations in the Fe- Mn-Ti-0-S system were established at 1380 and 1485 K. The elemental distributions between the equilibrium phases were obtained by chemical- ly analysing selected samples from the phase study. The results are considered in relation to the coal reduction process for upgrading ilmenite. The beneficial effect of adding sulfur to a kiln that uses a manganese-rich feed is ex- plained by the formation of a metal-sulfide solid-solution phase that removes part of the manganese from the oxide system. The optimum conditions for operating the reduction kiln are determined, and the practical need to operate the kiln at other than optimum conditions is explained. It is shown how the experimental data can be used to predict the best compromise conditions for reduction and the resultant purity of the product.

Jan 1, 1980

By E Jak, M Shevchenko, D Shishin

One of the key aspects to develop sustainable metallurgical production is to ensure that the predictive power of thermodynamic tools is brought up to a new level of accuracy and reliability. Exploring new polymetallic processes, integrating primary and recycled materials, means utilising the uncharted areas within the Cu-Pb-Zn-Fe-Ca-Al-Mg-Si-O (major) – Cr-Na (slagging) – As-Sn-Sb- Bi-Ag-Au-Ni-Co (minor) slag-solids-metal-matte-speiss-sulfate system. This requires extensive integrated experimental and thermodynamic modelling study, which is underway at PyroSearch at the University of Queensland (UQ).

Aug 21, 2024

By R L. Grogan

Regulators of deep-sea mining projects are becoming increasingly hesitant about the concept of adaptive management as a tool to facilitate compliance and continuous improvement. Adaptive management is a relevant and useful instrument to ensure that the mine plan is successfully implemented throughout the life of mine, in parallel with optimum environmental performance and compliance.CITATION:Grogan, R L, 2018. Adaptive management in deep sea mining – looking like you know what you’re doing when it’s never been done before, in Proceedings Life-of-Mine 2018, pp 20–22 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 25, 2018

By Scott SD

The 1986 PACLARK Expedition established that propagation of a seafloor spreading zone into continental crust has created a complex series of volcanic basins on the floor of the Western Woodlark Basin. In addition to abyssal basalts, felsic volcanic rocks were recovered - especially at the leading edge in the extreme west. A recent deposit of hydrothermal Fe-Mn oxides was discovered on an axial seamount of basaltic andesite, and seawater plume anomalies suggest current hydrothermal venting elsewhere. As a modern analogue for the settings in which ancient volcanogenic massive sulfide orebodies probably formed, the Western Woodlark Basin warrants further investigation.

Jan 1, 1987