Search Documents

By M Paakkunainen

Sampling is often the most critical part in process analysis. When the mean of a continuous lot, such as a process stream within a given time interval, is estimated by calculating the mean of several samples, the uncertainty of the estimated mean depends usually on the sampling strategy. Three different strategies can be used: systematic, stratified or random sample selection. The standard deviation of the lot mean is different for these methods so that systematic sampling usually gives the smallest and random sampling the largest standard deviation. Pierre Gy developed a method where the sampling errors of one-dimensional lots for these three strategies can be estimated from a variogram, which is calculated from a variographic experiment, ie from a set of one-dimensional time series measurements with fixed sampling interval. While variogram is an excellent tool for characterising and displaying the variability of autocorrelated processes as function of time, the sampling error estimation from it is quite laborious, however. In this work an alternative method for estimating the sampling errors was developed. The process is divided into strata of equal sizes, varying the length of strata similarly to variographic analysis. For stratified sampling the standard deviation estimates are obtained by analysis of variance and for systematic sampling by fitting a linear regression line to each stratum and calculating the residual variances. By pooling the individual variance estimates the variance estimates that are corrected for autocorrelation are obtained. The new method was tested with simulated and real data sets having periodic, random and/or drift fluctuations. For stationary processes the results agreed well with the results of the GyÆs variographic method. The method can probably be generalised to estimate the sampling variance of higher-dimensional lots.

Jan 1, 2005

By L Klemettinen, A Jokilaakso, D Attah-Kyei, P Taskinen, M Tiljander, D Sukhomlinov, D Lindberg

In this study, the use of carbon neutral biochars as reducing agents in the pyrometallurgical treatment of nickel slag was investigated at 1400°C in order to recover valuable elements such as copper and nickel from the slag. A large amount of slag is generated during the nickel matte smelting. Nickel slag contains valuable elements such as copper, nickel and cobalt, which can be recovered. Disposal of this slag results in loss of resources and may cause pollution of the environment. It is important to retrieve these metals for environmental and economic reasons. In this study, the slag was reacted with non-fossil reducing agents (biochar) which were produced from hydrolysis lignin and black pellet biomass pyrolyzed at 600 and 1200°C and with metallurgical coke for comparison. The reduction experiments were done at 1400°C for 15, 30 and 60 mins under inert gas atmosphere. The samples were quickly quenched and analysed with Electron Probe X-ray Microanalysis (EPMA). The results showed that the use of biochar resulted in faster reaction kinetics in the reduction process compared to coke. The fast reaction kinetics is attributed to the relatively high content of volatiles in this biochar, leading to gas formation and thus mixing of the sample material. Moreover, thermodynamic modelling was also performed using FactSage™ to simulate equilibria with different amounts of biochar. The metal to slag distribution coefficient calculated from the results of thermodynamic modelling were consistent with experimental results. In addition, thermodynamic calculations confirmed that nickel is reduced rapidly and it deports to the metal alloy phase. As the reduction progresses or extra reductant is available for reactions, more iron is deported to the metal phase. The calculations also revealed that Zn vaporises into the gas phase.

Jun 19, 2024

The economic significance of a fundamental understanding of the mineral pyrrhotite is dis- cussed. Particular emphasis is placed on the relationship of other sulphide minerals to the pyrrhotite when it is the major sulphide mineral present in an ore body. Studies of the Kambalda nickel deposit are used to give a better under- standing of (a) the genesis and other character- istics of a particular ore body (b) the textural relationships between pyrrhotite and other sul- phide minerals (c) magnetic properties of natural pyrrhotite, and (e) the oxidation and supergene processes that take place in a sulphide ore body.

Jan 1, 1972

By R C. Morris

Secondary microplaty haematite in its variety of styles and generations is the defining component of the high-grade banded iron-formation (BIF)-hosted iron ores of the world that are dominated by martite (M; - haematite pseudomorphs after magnetite). The term microplaty haematite (mplH) was introduced during the CSIRO-AMIRA 1976-1994 iron ore program, and was used to differentiate the then main export martite-microplaty haematite (M-mpl H) ore types of Tom Price-Whaleback and Paraburdoo (Paleoproterozoic), from the newly exploited, more prolific supergene martite-goethite (M-G) ores (Mesozoic-Paleocene) of the Hamersley Province that are now the major Hamersley iron ore exports.Morris (1980, 1985) suggested that the most important genetic factor that distinguishes the two main ore types was regional metamorphism of Paleoproterozoic M-G ores at temperatures normally related to diagenesis (ca 80 - 100°C). As temperatures increased, mplH grew in goethite both spontaneously as well as by nucleating on martite and other pre-existing haematite. Because the conversion of goethite to haematite involves a ~27 per cent reduction in volume, the crystals probably grew within microvoids of their own creation, with iron transfer through water resulting from the process itself, a local hydrothermal process requiring no introduced hypogene fluids.Barley et al (1999) and Taylor et al (2001) concluded instead that oxidation of introduced siderite in hydrothermally metasomatised BIF ‘protore’ resulted in mplH + ankerite by reaction with heated meteoric fl uids. This postulated ‘protore’, still preserved locally at Mt Tom Price, was described during the CSIRO-AMIRA program as local post-ore BIF metasomatic residuals. These new hypogene-meteoric concepts for M-mpl H genesis have formed the basis for a range of varying local and international models that currently dominate the literature of iron ore.No valid petrographic data supporting the hypogene-supergene modelling was found but petrographic images of goethite-related mplH growth in a range of different environments are shown.

Jul 11, 2011

By S Furman, M Caccetta, A Hacket, B McDonald, M A. Wells, D Lau

In 2004, the Western Australian Department of Industry and ResourcesÆ Burrup Rock Art Management Committee commissioned a number of independent scientific studies to evaluate the condition of rock art in the Burrup Peninsula near Karratha (Western Australia). These studies are evaluating the physico-chemical aspects of the effect of environmental modification on the visible appearance of the rock art. Because of the cultural significance of the sites, the research approach has been to employ non-destructive testing strategies and work in the field has progressed with respect for the importance of the area. This paper only reports the spectral mineralogy monitoring at each of the sites to evaluate whether changes in mineralogy are observed on rock surfaces. Reflectance spectroscopy is a non-destructive, in situ materials characterisation technique that provides information about the mineralogy. The minerals detected include haematite, kaolinite, chlorite, goethite, gibbsite and manganese oxides. Current results indicate that the surface mineralogy of the rock art has not changed in the last four years.

Jan 1, 2008

By Wu H. W, Just G. D

Australia's mineral resources boom in the two decades up to 1980 saw the establishment of about 25 new mining towns across the continent Quality housing and a high standard of community services were incorporated to attract a labour force for the major mine or mines i eing serviced. Town construction costs were high and were principally born by the private enterprise mine developer. There has been a change in the pattern in recent years and over 20 new mine developers have adopted a fly-in fly-out arrangement rather than construct new towns. Employees are drawn from a home base which is typically a large city, coastal community or established mining town and flown to the mine site for intensive work periods of about two weeks. The change has occurred for many reasons. Mining companies have been unwilling to support the high construction costs of towns, short life and smallermining operations do not justify a town, fast jet aircraft are available and there is a better perceived family lifestyle in established (coastal) communities. On the other hand reduced permanent development at new mine sites does not assist Australia's perceived need for decentralization. There have been questions as to the social problems which may develop from the artificial separation of the "breadwinner" from his family. The paper reviews a recent survey of the attitude of Australian mining companies employees, governments and unions to fly-in fly-out arrange- ments. The support for this approach is analysed and conclusions drawn that the concept is likely to be with the Australian mining industry for some time in the future.

Jan 1, 1991

By Nilmani M, Malone J, Taylor RN, Floyd JM, Gray NB, Fountain CR

CSIRO staff and University of Melbourne staff and students collaborated in an intense programme of investigation on the CSIRO 50 kg Sirosmelt pilot plant.In two days of operation copper matte converting and zinc slag fuming trials were performed, whilst investigation of the process dynamics and process chemistry was carried out. This exercise is an example of the techniques available for process evaluation, which can rapidly advance the understanding of pyrometallurgical operations by use of a team approach covering a wide range of experiments.

Jan 1, 1985

An empirical method of estimating dense rock (D.R.E.) equivalent volumes erupted as airfall tephra, described in a companion paper in this volume, is elaborated, and its accuracy discussed. Estimates obtained from a single eruption can be classified as to whether they show positive, negative, or constant relative dispersion. For positively dispersed tephras (estimated volumes increasing with distance), this procedure improves the accuracy of the method. The technique is applied to selected andesitic tephras erupted from Egmont Volcano, New Zealand, during the last 28 000 years, which are found to range in volume from about 1.5 x 107 m3 up to about 2.4 x 108 m3 D.R.E. With a factor of about 16 between the smallest and largest volumes, this contrasts sharply with the rhyolite volcanoes in New Zealand, where the difference factor is usually of the order of 100. The largest tephra eruptions at Egmont are small compared to the largest debris avalanches, which have exceeded 1010 m3 (10 km3) in volume.The magnitude versus frequency relationship, calculated using a maximum likelihood method, establishes the limits of eruption magnitude at Mt Egmont as 107 to 109 m3 D.R.E. For some volcanoes, the magnitude-frequency relationship changes with time, owing to clustering of eruptions, separated by long dormant intervals. Ngauruhoe Volcano, New Zealand, is an example. Within eruptive episodes, the mean interval between eruptions of >_ 105 m3 is about 0.9 ¦ 0.65 years. The mean interval between eruptive episodes in which >_ 106 m3 is erupted, including episodes in which this volume is erupted gradually, is about 25.8 ¦ 6.6 years, and the mean dormant interval between all episodes is about 5.2 ¦ 3.0 years. At present Ngauruhoe is in an unusually prolonged dormant period, 50% longer than any in the historical record, since 1839.

Jan 1, 1990

By Dinuzzo P, Wychie J, Desoe C

The Selwyn Gold-Copper Mine is located 150 km southeast of Mount Isa within Proterozoic units of the Mount Isa inlier (Figure 1). Mineralization in the mine area is associated with strongly sheared ironstones and iron rich schists at the base of the mid- Proterozoic Staveley Formation. The ironstone horizons outcrop as a series of dominant ridges over a 10 km strike. Economic gold-copper mineralization has been defined in 4 separate zones within a 3.5 km length of the outcropping ridges. A current combined geological resource for the deposits is 5.3 million tonnes of 5.0 g/t Au and 2.02 Cu. Weathering of the deposits has resulted in a pronounced vertical zonation of mineralogy, especially copper, within the ore zones. This has produced 3 separate ore types which require different treatment techniques. The categorization is based on copper content and zones are termed leached (surface), oxide and sulfide. Ore removed from the pits will be mainly leached and oxidized with minor sulfide near the pits final depths, while the underground ore will be from the sulfide zone with minor oxide in some areas.

Jan 1, 1989

By Blockley J. G, Laeter J. R

The history of the Ph-Cu-Zn mineralisation in the orthampton Block of Western Australia has been further investigated. It was hoped that (1) Rh-Sr studies on partially-remelled granulites, wall-rocks to the dolerite dykes, should date the dolerite intrusion, (2) Rh-Sr data on hydrothermally-altered dolerite should date the sulphide mineralisation, (3) Pb model ages on the galenas might provide an independent dating of the mineralisation, in addition to any geochemical information that might be derived. Only the second dating aim was fulfilled, but the Pb isotope data, when combined with the Rh-Sr data, have permitted deductions about U, Th and Pb abundance changes during the regional metamorphism, and about a possible source of the ore Pb. In detail the following has been found. (1) The partially-remelted granulitic wall rocks yield a scattered whole-rock Rh-Sr isochron which seems not to have been reset by the dyke intrusion (age 1037 ± 146 Ma, with initial Sr ratio 0.7171 ± 0·0054, MSWD = 111). This date agrees well with that reported previously for granulites from another locality; together theyestablish the time the metamorphic period closed. (2) The hydrothermally-altered dolerites yield a Rh-Sr whole-rock date 434 ± 16 Ma, with initial Sr ratio 0.7072 ± 0·0029 and MSWD = 31, taken as referring to the time of Ph-Zn mineralisation. This contrasts with a report of much older palaeomagnetic and K-Ar datings of the dolerite (not less than 550 Ma, possibly older) and suggests that neither the dolerites nor their heat have had any connection with the mobilisation of the Pbscavenging solutions. (3) The Pb isotope ratios of galenas from the ores yield a well-correlated regression which is not amenable to any of the model-age calculations. (4) The Pb-isotopic trends negate any genetic connection between dolerite and mineralisation, but the country-rock granulites could be the Pb source. (5) Combination of the Rh-Sr dates and the Pb data in a "simultaneous isochrons" construct permits the inference of major losses from the system during the regional metamorphism, in the order U>Pb>Th, with substantial homogenisation of the remaining Pb. This left a wide range in local UlPb and Th/U among the source rocks which eventually were scavenged by the mineralising solutions. (6) These geochemical deductions are shown to be compatible with previously-published information on the abundance ofU and Th in the Northampton Block granulites, which are thus seen to be credible as source rocks for the ore lead.

Jan 1, 1985

About 90 per cent of the pre-mining BIF-hosted iron ore resource of the Hamersley Province of Western Australia is of the Phanerozoic supergene martite-goethite type. The remaining ten per cent formed as supergene deposits at ~2000 ¦ 200 Ma, and were later modified by burial to form the Proterozoic martite-microplaty hematite ores. The supergene-metamorphic segment of this general unified model has been challenged by three recently published hypogene-based genetic models for the hematite ores, all requiring meteoric oxidation to produce the ore. The most recent and detailed, by Taylor et al (2001), is based on data from the small Southern Batter and North deposits of the Mount Tom Price mine. The authors proposed that during Stage 1 æoverpressured bicarbonate-saturated basin brines from the dolomite aquifer of the Wittenoom FormationÆ at 150 - 250¦C, dissolved free silica from BIF to produce a stratigraphically thinned, magnetite-carbonate-silicate-apatite rock. In Stage 2, meteoric oxidation of siderite to secondary microplaty hematite + ankerite, and magnetite to martite, at unspecified elevated temperatures and pressures, was followed by carbonate leaching (Stage 3). Finally, during Stage 4, weathering with removal of apatite, produced the typical low-phosphorus, porous martite-microplaty hematite ores of the Tom Price-Whaleback type. However, evidence of both microplaty hematite and martite reduced to magnetite, and of infill silica, apatite, and ferroan chlorite, with late-stage pyrite, in the pore space of martite-microplaty hematite ore, shows that the hydrothermal activity at Mount Tom Price is a post-ore event. Neither pyrite nor ferroan chlorite could resist the oxidation required to form hematite ore. Recrystallisation of microplaty hematite in these infilled zones to a typically coarser form than present in most of the normal ores, is a further supporting factor. A more credible, post-ore alternative to the hypogene genetic model is suggested here. Re-exposure to leaching by ground water of the metamorphosed ore deposits in the Phanerozoic resulted in the partial removal of remnant goethite. Localised modifications in the porous BIF/ore contact zones were driven by exothermic oxygen/pyrite/carbon reactions in the footwall Mt McRae Shale. Cool descending oxygenated meteoric water in the permeable ore horizons, acted as one limb of a thermal convective cell. In the other limb, heated reducing solutions rose through the permeable contact zones, to produce the observed localised modifications of BIF and ore. Expelled silica from the carbonatised BIF invaded adjacent porous ore to form erratic silicified ore zones, and to produce the local quartz vein systems found in the associated overlying BIF.

Jan 1, 2002

By I T. Cameron

The commercial production of copper metal involves a sequence of purification stages. One step of this process eliminates bulk quantities of iron and sulphur from matte Cu2S(FeS to produce blister containing 95.5 per cent copper. This task is traditionally performed in the Pierce-Smith converter, a cylindrical vessel in widespread use throughout the copper industry. Typically, multiple Pierce-Smith converters are arranged along an aisle, simplifying material transfer from vessel to vessel. Materials are moved through the aisle in pots and boats, using overhead cranes. In terms of the overall process, the converter aisle represents a critical processing unitùit contributes significantly to the value added nature of the metal. The aisle is subject to significant process disturbances. Thus, improvements in the operationÆs modes and conditions have a direct impact on process profitability. As with any commercial operation, improvements are always sought to increase process performance. The general approach involves process modelling, followed by an application of control and optimisation theory to this model. The results of such a study are then applied to the real process, leading to improved performance.

Jan 1, 1998

The Australian minerals sector has a shortage of skilled professionals to satisfy an industry that is experiencing renewed vitality. Graduate numbers are low throughout Australia and the world, while economic rationalisation is seeing many educational institutions downsize, or even close, their minerals-related programs. In addition to requiring more entry-level graduates, minerals producers are looking to update the skills of their current workforce to keep up with the industryÆs continuing technological revolution. To address the issue the Minerals Council of Australia (MCA) endorsed collaboration between several Australian minerals producers and a team of universities to generate the Mineral Tertiary Education Council, or MTEC. MTEC recently initiated a venture to increase the availability of professionals with relevant skills to the minerals industry. Primarily aimed at delivering postgraduate programs, the initiative will allow graduates from other disciplines to æconvertÆ to the minerals sector as well as provide professional development training to an existing work force. This venture represents a novel approach in that courses will be delivered by more than one institution and will employ innovative teaching materials with flexible and remote delivery formats. The programs will cater specially for professional development in the minerals sector, which generally requires high flexibility due to the nature of work conditions and locations.

Jan 1, 2004

By D J. Williams

Tailings management is typically constrained by many factors that are taken as given. These include the tailings production rate that must be accommodated, the desire to deliver the tailings cheaply and easily as a slurry using centrifugal pumps, and a tailings footprint limited by the desire to minimise capital costs leading to a rapid tailings rate of rise and a low settled density. Other constraints include wall raises being delayed due to limited capital, inadequate tailings water and rainfall run-off management, and the net present value (NPV) approach to capital expenditure that puts off expenditure at the expense of performance. All of these constraints result in the tailings occupying much more volume than is necessary, being difficult to rehabilitate, and not being capable of supporting a beneficial post-mining land use or function. Ultimately, such constrained tailings storage facilities will assume very large dimensions, but each will typically be developed as a series of smaller storages that are filled rapidly and added to progressively. The optimal stage to efficiently recover process water is in the process plant, but this is limited by the desire to use centrifugal pumps rather than the more costly positive displacement pumps, which also require greater management of tailings deposition. Process water can also be recovered from the tailings storage facility (TSF) decant. Tailings water that is not recovered from the plant or the decant will be lost to entrainment within the tailings, seepage to the foundation or through the wall, or evaporation. However, tailings water is not always suitable for reuse in the plant, particularly when it becomes contaminated by the processing, and it may simply be stored on the TSF. This will exacerbate the seepage of contaminated water to the environment, and will limit the densification of the tailings that would otherwise occur due to desiccation of the tailings on exposure. If a larger tailings footprint were developed early, cycling of tailings deposition in thin lifts between a number of cells could occur, maintaining the dormant cells dry to enhance desiccation and densification, and ultimate rehabilitation. The end result would be a much reduced stored volume of tailings, the potential for upstream raising, and ease of rehabilitation to a high level. The higher initial capital cost would be overtaken by reduced ongoing capital, operating and closure costs.CITATION:Williams, D J, ?2014. An alternative whole-of-life approach to tailings management, in Proceedings Life-of-Mine 2014 , pp 285–298 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 16, 2014

By Leahy G. J, Moxon N. T, Nicol S. K

Experimental work is described in which extremely dilute aurocyanide liquors are treated with novel surface-active complexing agents to produce a hydrophobic aurocyanide species. Subsequent aeration of these liquors causes accumulation of such species at the air-water interface and the aurocyanide complex is transferred to a froth concentrate. A detailed performance assessment of this process is made and this knowledge used in the design of a pilot plant facility. Early results indicate the feasibility of the selective recovery of aurocyanide ions from reclaimed residue dam water (approximately 0.2ppm Au) with upgrade ratios of the order 180:1. A further study was made applying ion flotation to the recovery of gold from a carbon-in-pulp (CIL) feed liquor (approximately 1.0ppm Au). The probable economics of this process compared to conventional CIL processing is also described. Successful development of countercurrent ion flotation for concentrating solids-free gold solutions may offer a lower cost alternative to existing gold ore processing technologies, or in more secondary applications such as concentrating dilute gold solutions or heap leach runoff. The technology may also have more generalised applications to other heavy metal process- Ing.

Jan 1, 1991

By Ariti J

The mineralogy and extractive metallurgy of platinum and palladium in ores and residues is examined and the relative reactivity of Pt, Pd, PtS and PdS in cyanide and chloride media at 20¦C is discussed. Electrochemical measurements establish that Pd is readily leached in chloride media but more slowly in cyanide media due to a passivating PdO film. The passivating oxide film on Pt prevents leaching in either system at ambient temperatures. The results of leaching Au, Pd and Pt from an iron oxide residue obtained from the Sherritt Gordon Process using CN/air and Cl-/H202 are compared. It appears that passivation is overcome either by roasting at ?600¦ or by leaching at >_100¦C.

Jan 1, 1991

By M Mohammad Khani

An economic block cave is dependent to the characteristics of the rock mass at stages of caving. These are cave initiation, propagation and ore flow. In this research, the rock engineering system (RES), first established by Hudson (1992) to solve complex rock engineering problems, is introduced and verified against the well-established caving parameters established by Laubscher. There are two types of factors influencing caving and these are natural (cannot be controlled) and induced (operator controlled). A RES based interaction matrix is developed by determining the rating parameters required to reproduce the caving database using Laubscher’s caving parameters. This provides the relative importance of the parameters in the interaction matrix. After discussing the rock mass caving process and identifying all the effective parameters, an interaction matrix is introduced to study the cave initiation of rock masses. The expert-semi-quantitative (ESQ) coding method is utilised to assign the numerical value to each parameter’s interaction. Thereafter, the interaction intensity and dominance of each factor in the system is determined to classify these factors. Finally, all the parameters affecting caving operation and their weights on the RES system are identified. This new application of RES in block caving is very efficient and useful for any stage of caving studies and helps experts to make decisions more accurately.CITATION:Mohammad Khani, M, 2016. The application of rock engineering systems to block caving to identify the effective parameters, in Proceedings Seventh International Conference and Exhibition on Mass Mining (MassMin 2016), pp 853–860 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2016

By M F. Lee

In order to make good decisions, as to whether large diameter raise bored shafts can be constructed in blocky rock at a particular location, mine planners, management, geotechnical engineers and contractors must understand and consider a range of geotechnical issues. Firstly, mine management must ensure that adequate time and resources are available to find appropriate shaft sites. Deep weathering, adverse structures, groundwater, etc might mean that the most desirable location, with respect to other mine development, might not be suitable. Special site investigation drilling, etc may be necessary. Even then, alternative construction options might be necessary, other than just reaming through to the surface. A site investigation borehole should then be drilled to investigate specific and general ground conditions along the raise alignment. Often, only small sections of weak blocky rock dictate raise stability. While the empirical McCracken and Stacey method is typically used in Australia to assess raise stability and assess geotechnical risk, until recently it had no published performance data.An Australian database of raise performance now exists and is presented below, courtesy of an industry survey by the Eastern Australian Ground Control Group. Raise diameter and ground conditions (in terms of a lower bound Qr value) is presented for 50 cases versus raise performance.

Jan 1, 2008

By Woodhouse M, Drew GJ, Andrews DL

The Honeymoon nickel sulphide deposits are located 45 km south of Wiluna in the 2.7 Ga old Agnew-Wiluna greenstone belt in the NE of the Yilgarn Craton (Figure 1). Both disseminated and massive nickel sulphide deposits are present within the deformed and metamorphosed Honeymoon Well ultramafic complex and are hosted by distinctly different komatiitic lithologies (Gole et al, 1996). The deposit styles and host rock lithologies reflect formation in markedly different volcanic settings. Metasomatism has affected parts of the ultramafic complex, including sections of the sulphide deposits, and has had a marked impact on mineralogy and bulk sulphide compositions. The present indicated resource is 158 Mt at 0.71 per cent Ni in four deposits (0.4 per cent Ni cut-off, resources above 300 m depth, December 1995). This includes a massive sulphide resource of 2.5 Mt at 3.36 per cent Ni.

Jan 1, 1996

By R West

The Olympic Dam smelter facility processes copper concentrate feed using direct-to-blister smelting technology to support the current site production rate of 225 000 t/a copper. The metallurgical control of the Olympic Dam smelter is largely managed from a single central control room. Control room operation and management is therefore a key function in ensuring safe and reliable operation of the smelter, including identifying and initiating control of abnormal events. As part of a consolidated smelter reliability improvement program, a team consisting of process and control system engineers was formed. The teamÆs charter was to address and resolve the alarm flooding issues being faced by the control room technicians and the lack of an up-to-date base of supporting functional documentation. The project was successfully resourced with WorleyParsons metallurgists, Citect PLC technicians and the on-site technical team. Implementation was conducted over a 12 month period with the goal of achieving best practice alarm levels. The goal was achieved through a systematic process of alarm design review that analysed every configured alarm versus best practice design standards. Innovative concepts such as group-based alarms, first-up interlock displays, graphic only alarming, alarm help and alarm shelving were developed and implemented in conjunction with improved alarm masking. Total configured alarms were reduced from 20 000 to 5000 while the alarm rates were reduced from in excess of 200 alarms per hour per controlling technician to best practice levels of less than 12 alarms per hour per controlling technician. Completion of this program has provided a firm foundation for implementing further control optimisation and was a key activity in supporting sustained smelter reliability levels.

Jan 1, 2005