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By Sulanto J, Talonen T

In the mid 1960's Outokumpu considered building a lead Flash Smelter on the basis of Flash Smelting technology developed first in the late 1940s for smelting copper concentrates. Pilot scale tests were carried out and the process was found technically sound. The project was however not economically viable under Finnish conditions and it was cancelled. In 1981 pilot plant tests were restarted after many enquiries from the primary lead producers. All the know-how and development made in copper and nickel smelters was applied to the Lead Flash Smelting process and the tests were successful. Outokumpu has so far tested several types of lead concentrate with lead contents ranging from 28 to 75 per cent. The concentrate is oxidized and smelted to metallic lead and slag directly in the Flash Smelting Furnace using high oxygen enrichment of tonnage oxygen. Fossile fuel is used in the Flash Smelting Furnace in cases when the feed material does not contain enough latent heat to smelt the furnace products even though pure oxygen is used for oxidation. Thus the process results in a low consumption of extraneous energy. Use of oxygen results in a small gas flow but it is rich in sulphur dioxide. The gas treatment facilities and sulphur recovery plant will be small in size and low in investment cost. The process is flexible and can produce stable quality of products from different types of raw materials. Quality of lead bullion especially the sulphur content can be regulated over wide a range, from 0.1 per cent upwards according to the needs of the refinery.

Jan 1, 1984

By W Stange

Assessing the risks in a mining project is a key aspect of project evaluation. This is an exacting and demanding task because of the complexity due to the need to deal with uncertainty over long time periods. The way risks are assessed and managed is critical to the long-term success of the projects and the business. Discounted cash flow (DCF) analysis is commonly used for project and risk evaluation. A discount rate is selected that accounts for uncertainties in the cash flows. However, it is difficult to determine an appropriate discount rate due to the large number of factors that need to be considered and the complex relationships between risk sources. Using a proven framework, ævalue at riskÆ (VaR), this paper proposes to rigorously model and quantify ærisk at sourceÆ. The approach was first employed to assess financial market risks and is now widely used in the banking sector for risk assessment. In project evaluation, all risk sources are identified and estimated separately to ensure the overall project risk is quantified accurately. A bottom-up approach has been proposed. Estimates are first carried out for risk factors at the bottom of the project structure. The assessment is then applied at increasingly higher levels until the overall project risk is estimated. Value at risk is a versatile methodology and can be used in a local or integrated manner. The final value is objective and the calculation steps can be easily justified and followed. Four case studies have been included to illustrate how the proposed approach can assist management in decision-making.

Jan 1, 2009

By Pollmans GJ, Hoberg H, Schneider FU

The Institute of Mineral Processing at Aachen University of Technology has been engaged in fine and ultrafine comminution for several years. Former investigations had been dealing with the mechanical activation with the aim of increasing the solubility of highly resistant oxides such as tantalite and niobite while research on the product of ultrafine powders is of major importance at the moment. Materials of that kind are of increasing interest in the production of extremely resistant ceramics, in the development of new raw materials, in powder metallurgy and in the production of fillers (extender pigments) and pigments. The creation of ultrafine powders is difficult and very expensive. They can be produced by means of condensation or dispersion methods. One important method of dispersion is mechanical comminution. Due to long and intensive research and development all over the world important advances have been achieved but still a great number of questions and problems occur especially in producing materials of submicron and nanometer grain sizes which could be answered or solved only insufficiently up to now. These mentioned difficulties refer especially to: ò the required energy input into the feed material, ò the forming of strong agglomerates and wall stickings, ò the required product qualities, and ò the entire and reliable characterisation of the products. Basic investigation aim to clarify the micro and macro processes of ultrafine grinding and work towards solutions to the difficulties mentioned above. The aim of the Institute's research is the development of a new grinding device for producing ultrafine powders. First results of a laboratory scale mill of that type will be presented in this paper.

Jan 1, 1993

By Watters R

Modem open cut and underground mining in the tropics inevitably expose partially weathered and unweathered rocks to oxygen and water, leading to weathering and the release of solutes and often acidity as well. Historical monitoring data can demonstrate these phenomena. Three case studies from open cut mines in the north of the Northern Territory illustrate the deterioration in quality of pond water receiving drainage from waste rock dumps. The potential for deterioration of water quality was not recognised in many mine Environmental Impact Statements prepared and accepted in the 1980s. The examples documented indicate the importance of adequately planning for this near inevitable process. Retrofitting a mine water management system to 'no' or minimal release can be very difficult and expensive, and may not be feasible, leading to downstream pollution. The characterisation of acid and solute production potential of ore and waste rock, and improved dumping strategies and water management are very important to minimise the environmental impact of mining in the tropics.

Jan 1, 1994

By P Gnnther, A M. van Niekerk

Coal mining operations in the Upper Olifants River Catchment in the Mpumalanga Province of South Africa are challenged with the increasing production of excess mine water that cannot be fully managed by existing practices of pollution control at source, recycling, and reuse on mining sites, storage and limited release to the natural water course. In contrast to this, the Olifants River Catchment is experiencing water stress and insufficient water is available to satisfy all water quantity and quality requirements for future industrial and municipal growth. It is estimated that the catchment has a deficit of 192 million m3 per annum if the reserve water requirements are taken into account. The future increased water requirements can be met by water transferred to the Olifants River Catchment from adjacent catchments. The cost of transferred water is likely to be substantially higher than the current cost of water supplied to local municipalities, commerce and industry. BHP Billiton and Anglo Coal Corporation are working together to jointly implement water management strategies that will contribute to the achievement of in-stream and dam water quality and aquatic objectives for the catchment. Consideration is now being given to the treatment and beneficial use of excess mine water. This will inaugurate a new era for the coal mining industry in South Africa, in which a pollution threat to the water resources in the Upper Olifants River Catchment is converted into a water source for beneficial use. Three potential mine water reclamation and reuse schemes have been identified and this paper details the technical, institutional, legal and financial considerations in the implementation of these schemes.

Jan 1, 2006

By Pinter R

Several major routes connecting Northern and Southern Europe or Asia run through Austria. These highways have to surmount the alpine range which traverses Austria from west to east. In order to ensure safe driving conditions even in winter, tunnels, at times quite long ones, are necessary. Austria now has tunnels totalling 160 km in length. These tunnels are either already in use or just about completed. The Plabutsch tunnel near Graz will be one of the longest tunnels in the world: approximately 10 kilometers in length. It will be put into operation in the summer of 1987. Before construction could begin, soil and rock conditions had to be investigated by means of a test tunnel. Afterwards, excavation was begun to the full 100 m' cross section. The new Austrian tunnelling method with conventional blasting was used for the major part of the tunnel. It was necessary to have such a large tunnel cross section because a fully transverse ventilation system is installed for environmental reasons. In order to avoid air pollution from the tunnel, exhaust fumes are not allowed to escape from the tunnel portals but from two shafts, each with a diameter of 8.5 m. In this way, exhaust fumes must rise 90 meters or 240 meters before they reach the open air and will thus not affect the city. The ventilation system influences the size of the excavation, and especially the size of the ventilation caverns and the air shafts. All these factors directly influence construction and maintenance costs, and an economical optimisation leads to the appropriate dimensions for the excavation.

Jan 1, 1987

Welcome to this 13th Congress of The Council of Mining and Metallurgical Institutions. It is twenty one years since The Australasian Institute of Mining and Metallurgy last hosted this congress and it is a privilege and a pleasure for The AusIMM to have that responsibility once more. The theme of this congress "The Twenty-First Century - Mining for Mankind" stimulates many thoughts. The first thought that it generates in me relates to the reference to the 21st Century. We are still 14 years away from it and already consideration of the beginning of the next millenium is becoming something of a cliche. If we feel like that about it now, how will we feel at the 14th Congress of the CMMI in 1990, or the 15th in 1994 or the 16th in 1998? If we do all the crystal ball gazing about the 21st Century this week, those poor devils in the 1990s will in fact have nothing to talk about. Of course that is not the case. This is a very appropriate time for those of us concerned with mining and metallurgy to contemplate the next century. Fourteen years is about the extent of forward planning necessary in the mining business. I sometimes feel that most people do not take seriously the need for long range planning in our industry. Politicians, investment fund managers, and others under severe short-term pressure to perform in our hyperactive world may nod in apparent appreciation of our long term plans but their actions in the interests of expediency often betray-them.

Jan 1, 1986

In the late 1970's Western Mining Corporation, Exploration Division considered the purchase of a major multi-element spectrometer as an adjunct to our existing atomic absorption spectrophotometers. The analytical work proposed for the unit included barium, uranium and rare earth elements from Olympic Dam, uranium, sulphur, vanadium and strontium on Yeelirrie type deposits, major element and whole rock analysis, multi-element analysis of samples from the laterite, chromium and manganese exploration programmes and tin and arsenic analysis. These were all analyses that were not readily or easily performed by flame atomic absorption or were where we expected that a simultaneous multi-element instrument would be an advantage. Also the turnaround times for the commercial laboratories was considered unacceptably long for some determinations. Other factors, important when considering the spectrometer were the ability to ensure confidentiality of results and the ability to assign our own priorities and not to have to rely on commercial laboratories. The two techniques considered were X-ray Fluorescence Spectrometry and Inductively Coupled Plasma Optical Emission Spectrometry. The decision was made in favour of the ICP unit for several reasons. The ICP fitted in with our existing methodology, ie samples digested for atomic absorption or colorimetric techniques would also be suitable for ICP analysis and vice versa. The technique was suitable for water samples and for major element analyses and for rare earth elements. X-ray fluorescence spectrometers were installed at the Kambalda and Belmont laboratories and would be available to us for routine checking and for elements not suitable for ICP analysis. The final consideration was price. ICP was considerably cheaper than XRF.

Jan 1, 1987

Kambalda Nickel Mines (KNM) currently have eight operating underground mines, three on care and maintenance and other orebodies at various stages of development. Each operation differs greatly in scale, ore grade, milling characteristics and cost structure. The optimum number of mines operating at any one time and their level of production, within the constraints of mill blending requirements and overall mill capacity, is the key to maximising profit in a climate of fluctuating nickel price. Cost models are developed for each mining operation which relate ore tonnes mined to total cost per pound of nickel produced from that mine. Aggregating the mine cost models provides a composite cost model for the entire operation. The cost models provide the operating levels necessary for each of the mines and hence Kambalda as a whole, to operate at the lowest cost per pound of nickel produced. However, lowest operating cost does not necessarily lead to maximum profit. The level of nickel price above operating cost can dictate maximum profit positions which are contrary to the lowest cost position. In addition, the decision to temporarily shutdown mines or reopen mines in response to nickel price movements comes at a cost. In considering the optimum operating position, the price of production capacity flexibility needs to be taken into account. This paper describes the process used to assess all these factors in arriving at the optimum operating position for Kambalda Nickel Mines for varying nickel prices. The same methodology can be used by corporate management in managing multiple mine sites as well as mine management managing multiple orebodies or stoping blocks for maximum profit.

Jan 1, 1995

By M McLean

This paper deals with change strategies on brownfield and greenfield sites in extractive industries. It draws upon contemporary experiences across Australian, Indonesia and Papua New Guinea (PNG). Change strategies can be used when owners of an extractive industry operation want to optimise their resource. This paper draws upon many tried and proven theories and practices, including the findings of the Tavistock Institute (Trist, Emmery, Bamford, Jaques), as well as the concepts of Adult Learning espoused by Malcolm Knowles and is supported by learnings of Australian based management consultants. This paper reviews a range of approaches that have succeeded in the integration of systems, machines and people, with the key corporate objectives of: increasing productivity; decreasing cost; improving on-time delivery performance and achieving long-term survival. Such integration needs to be measured to show the outcomes from the change strategies and the authors have worked within many measurement regimes and metrics but for the most part, found that JaquesÆ set of metrics being æquality, quantity, resources and timeÆ has gained currency across many Australian operations. This paper contends that investing money in machines alone without a commensurate investment into the people side is counter-productive. Further, if there is not an understanding of processes, ie stable and capable, core and support processes, then all that new technologies will do, is to make what is done badly, only quicker. Recent interventions for the most part, have been cognisant of this balanced approach towards change management. The change strategies described are across extractive industry implementations, using a number of tools and techniques drawn from Continuous Improvement and Six SigmaÖ (registered trade and service mark of Motorola Corporation, USA).

Jan 1, 2006

The Mammoth Mine is located some five kilometres from the town of Gunpowder which is approximately 120 km north-west of Mount Isa in Queensland.

Jan 1, 1993

WHEN reading reports on reefs and lodes, one often comes across the statements "short shoot," "narrow shoot," "wide shoot," & c.From a number of reports in the writer's possession, some by members of the Geological survey, it is plain that the words "short," "narrow," "wide," "long;" &c., are used somewhat carelessly.In one official report on a certain field, for instance, the reefs are described as having "short, rich shoots"; another report on the same field states that "the reefs were characterized by narrow shoots, rich at the surface." Again, Charters Towers is described as having "wide shoots"; another writer says they are "long shoots. "The writer has read again of "short shoots which went down like pipes," and of "narrow shoots of limited extent." No doubt one can make out what is really meant, but the language is mixed. It is apparent that "narrow" is meaning the same as "short," and that the shoot has not much length in a horizontal direction. Nothing is said about the thickness or width of 'said shoot, or its depth. The "wide" shoot is evidently a "long" one; its thickness 01' width and depth is not specified. When we consider these terms, it is seen that only a few words are needed, and that these few should (as they do) have a definite meaning. In the course of his mining experience, the writer has seen shoots of almost all sizes, and some have been very long (in horizontal measurement), and have been followed down for great depths, these shoots being the best type-Charters Towers, Walhalla, &c., are examples.

Jan 1, 1909

By G C. Lukey, J S. J van Deventer

The disposal and subsequent encapsulation of mine tailings in a cost-effective and environmentally secure and responsible manner is one of the principal issues facing any modern mining project. A careful assessment of all options available for the capping and subsequent remediation of tailings is important because it can result in large capital, operating and closure cost-savings. For these reasons, the technology of geopolymerisation is receiving increasing attention for the stabilisation and solidification of waste materials produced from mining operations. The first part of the current study investigates the application of geopolymer technology to the capping of hypersaline mine tailings. It has been found that suitable geopolymeric materials which have satisfactory compressive strength, durability as well as low permeability, can be formed using between 60 - 75 per cent of mine tailings as the main ingredient. It has been established that geopolymeric materials have the ability to suppress dust generation and prevent salt precipitation on the surface of the mine tailings. The slurry-like consistency of geopolymers would promote efficient application procedures through established tailings disposal techniques. This is a possible close-out technique for hypersaline tailings storage facilities such as those commonly found in Western Australia, which meets both regulatory requirements and community expectations. The immobilisation of contaminant metals within geopolymers has been investigated in the second part of the present study. In particular, the leaching characteristics of Cu and Pb from geopolymeric matrices derived from different fly ash sources have been examined. Potential breakdown of each geopolymer containing metal contaminants due to the leaching of Si and Al from the geopolymeric matrix has also been investigated.

Jan 1, 2000

Timestudy analysis of mining operations at North Broken Hill Limited has been carried out by dissecting operations into small elemental components, and accurately timing these elements. Over a wide range of observations, this has enabled standard time values to be calculated for all underground work.The application of the standard values is in calculating performances as a measure of work output and Performance Controls are kept on approximately two-thirds of underground employees. Through the Controls it has been possible to stimulate supervisory action to improve low performance, and to reduce delays and lost time.The values are used to calculate contract" prices, and anomalies in previous prices have been adjusted on work values and not on arbitrary standards. In out-of-the-ordinary circumstances, the request for a timestudy investigation has been made by both operatives and foremen, and the contract set following the timestudy analysis has been to the satisfaction of both parties.The range of values enables contracts to be applied to work which was previously performed on a day basis, resulting in improved performance.A natural corollary of timestudy is the analysis of methods, and in some cases method improvements have been introduced.It is anticipated that further investigations will be made on methods.INTRODUCTIONIn 1953, a Timestudy analysis of mining operations at North Broken Hill Limited was commenced under the guidance of management consultants. Its aim was, to determine standard time values for specific operations, which would provide management with a measure of productivity beyond the existing measures of tons or feet of advance, and also to determine whether increased output was available under existing operating conditions.

Jan 1, 1956

As a basis for my address to you tonight I thought it might be opportune if we considered the great history of the mineral industry in Australia, and the contribution it has made to the development of the country. While it is perhaps interesting to review the achievements of the past there is also the opportunity to examine the developments of the future.The names generally given to the three periods of man's life on the earth-the Stone, the Bronze, and the Iron Ageand to which should perhaps now be added the Atomic Age, imply the vast importance of the progressive steps in 'man's discovery of minerals and the means of working them. They tell the story of his advance from the flint knife to the bronze celt, and then to the keen-edged iron weapon, and now to the possibilities of the peaceful application of atomic energy. Not only have the stories of gold, iron, copper and tin told a great deal of the history of the progress of mankind, but they have also traced the commercial and industrial growth of Australia over the last century.Gold in the 1850's was responsible for the most significant period of immigration Australia has ever had-when the population almost tripled in the ten years to 1860. Minerals were also responsible for opening up Australia and determining the pattern of settlement. As mineral finds were made, railways were constructed to these fields, then agricultural development followed.Then, as the industrial era started, minerals provided the raw material for Australia's rapid industrial expansion, and they have all contributed to the extent that they have made...

Jan 1, 1960

By Hanley J

Coal winning in the Latrobe Valley exceeds 45 mtpa uses a small number of Bucket Wheel Excavators and high speed conveyor systems. While this equipment offers many advantages in the production cycle, incorrect use can lead to low productivity and risks to the safety of the operators and equipment. The mining equipment is of high capital value and easily damaged when used outside the correct operating range. In the extreme case, this can result in total machine collapse, having major implications for personnel safety as well as production and costs. With an active productivity improvement program in the Latrobe Valley in the last two years resulting in a 50 per cent reduction of personnel, many experienced operators have retired. Mine management are facing the urgent need to rapidly train new operators to maintain high productivity levels and reduce the risk of accidents to personnel and high capital cost plant. With the assistance of the Central Gippsland College of TAFE a Certificate Level course has been developed for open cut operators. The course covers all essential training needs for the Latrobe Valley mines. The training is developed from National Competency Standards, allowing transfer of skills, and is flexible to suit other enterprises. It has been written for self-paced learning with the total job understanding, and to have competency-based learning outcomes, training tasks and assessments built-in to modules. With the introduction of this new training program, management is convinced that the element of risk within the mine will be significantly reduced. For these reasons it is an ideal training model for other enterprises.

Jan 1, 1994

By T J. Napier-Munn

This paper proceeds from the premise that process improvement is a key part of the mineral engineer’s role, and one in which he/she can make a significant contribution to shareholder value. It presents four tools to help with process improvement projects. Two are designed for process monitoring, to determine as soon as possible whether there has been a true change in performance: the cumulative sum (cusum) control chart plot with V-mask, and the control chart using a process model. The other two are used for process optimisation: simplex self-directing evolutionary operation (SSDEVOP), and a response surface model developed using a central composite rotatable experimental design (CCRD). These methods are robust, have a rigorous theoretical basis and are easy to implement. They also promote project continuity which increases the chances of success, particularly in fly-in/fly-out (FIFO) operations. Variants are used in other industries, but they are rarely if ever applied in mineral processing to-day for reasons which are unclear. The paper gives examples of the application of each method in concentrators which demonstrate that they have the potential to be useful additions to the mineral engineer’s professional toolbox.CITATION:Napier-Munn, T J, 2014. Cunning solutions to process improvement, in Proceedings 12th AusIMM Mill Operators’ Conference 2014, pp 5–10 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

By G J. Jameson, A Agarwal

This paper is concerned with the observation and analysis of bubble clusters in a laboratory flotation cell. A device was used in which bubbles were allowed to rise in clean water containing the same frother and collector concentration as in the cell. Bubble clusters were recorded using a high speed camera and analysed using an image analyser. Dodecyl amine was employed as a collector to float silica. The effect of impeller speed on the cluster behaviour was investigated. The results were interpreted in terms of cluster diameter and shape factor. The sizes of the bubbles forming the clusters were also measured and compared to the sizes of the independent bubbles in the cell. It was found that there was an optimum impeller speed in which the cluster diameter was a maximum. Higher agitation and the consequent higher power inputs resulted in cluster break-up while lower shear rates promoted cluster formation.

Jan 1, 2005

By B Indraratna, A Dey

The surface geometry of a rock bolt plays a very important role in the rock/resin/bolt load transfer mechanism. Very little work has so far been reported on the influence of the bolt surface geometry on the bolt/resin interface failure mechanism. This paper examines the behaviour of bolt surface roughness under constant normal stiffness condition in the laboratory. To study the shear behaviour of the bolt/resin interface a series of shear tests with an initial normal stress between 0.1 to 7.5 MPa has been conducted on the flattened bolt surface of two most popular bolt types currently being used in Australia. Bolts with deeper ribs offered better shear resistance at low initial normal stress conditions whereas bolts with shallow and closer ribs offered better shear resistance at high normal stress conditions. The maximum dilation occurred at a shear displacement of 60 per cent of the rib spacing irrespective of the bolt type and depth of the rib.

Jan 1, 2000

By L. Gilbert

Recent changes to environmental legislation and trends in the environmental regulation of mining in the Northern Territory are being driven by (among other factors) Federal Government policies and international agreements on the environment. These trends are discussed and the expected application of the NT Water Quality Management Strategy (based on the National Water Quality Objectives) over the next few years is examined with respect to mine environmental management practices. Some of the potential conflicts and changes in approach which may develop are identified and examples discussed. Proactive means of integrating trends in environmental legislation with mine planning and waste management are discussed.

Jan 1, 1994