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The paper reviews winder rope inspection procedures at the Non Destructive Testing (NDT) Unit of Western Australian School of Mines (WASM) and outlines measures taken to adopt the world's best practice. The measures include acquisition of a new type of rope tester, adoption of comprehensive rope rejection criteria, adoption of a standard rope inspection procedure and formal training of the wire rope inspectors.

Jan 1, 1995

By R Piper

The Yabulu Nickel Refinery commissioned in 1974, processes lateritic ore via a modified Caron process to produce high quality nickel and cobalt products. The Greenvale orebody provided the sole source of feed to the plant until 1990 and with well-blended mineralogy, it resulted in stable and predictable plant performance, allowing the operating focus to be on reducing energy consumption and increasing ore throughput. This approach provided better economics than pursuing increased reduction efficiency. From 1990, increasing quantities of lateritic ore were imported from Indonesia, Philippines and New Caledonia. This introduced considerable variation in ore blends and instability in plant operation but also provided the opportunity to treat higher grade ore blends which yielded higher reduction efficiencies. Ore reduction is conducted using 12 Herreshoff multiple hearth reduction furnaces, using heavy fuel oil as reductant. The æROASTERÆ Project was approved in November 2000 with the primary objective of improving Nickel reduction efficiency by: Stabilising Roaster Operation via a structured program including focused maintenance efforts, capital equipment upgrades, new process measurements, process re-design and improvements to operating skills and process troubleshooting. A structured technical program including laboratory and plant studies using one plant furnace as a pilot unit to develop improved knowledge of how the reduction process proceeds in the Herreshoff furnace. Armed with this knowledge, optimised process conditions and a reduction process model were developed contributing to a significant demonstrated reduction efficiency improvement. Technical input to the project was provided by QNI with Hatch providing the engineering and project management for the $8.5 M capital work. Execution of the work included extensive consultation with the plant operators and close cooperation between the Hatch project team and QNI operations personnel ensuring installations were completed with minimal production disruption. A strong focus on safety management resulted in a number of brownfields project relevant safety initiatives being implemented resulting in project completion without a serious injury.

Jan 1, 2002

The pyroclastic-filled Voorspoed kimberlite pipe has a low grade due to significant internal dilution which translates to a marginal business case. The site, with excavations, tailings dumps and buildings remnant of mining from 1906 to 1912 is to become De BeersÆ benchmark mine in South Africa. In a climate of skills shortages and lean structures, a geological service to optimise exploitation of this complex resource was established. As historical mining removed the higher-grade centre of the pipe, initial production was in the weathered upper benches along brecciated pipe margins. Trenching and blasthole logging before blasts helped to mitigate the effects of the drastic contact deviations that occur when working with an inferred geological model. However, identification of unfamiliar weathered kimberlite and delineation of unmodelled internal waste posed challenges. Efficient grade control by demarcation and allocation of individual truck loads will be vital to continue profitable mining at Voorspoed. Further challenges arose across disciplines. The first yearÆs planned production of mostly weathered kimberlite was processed through a plant designed for VoorspoedÆs unusually competent ore. The high clay content of the weathered material led to clogged chutes and overloaded fines disposal, hampering efforts to commission the plant. Resolving this problem involved mining æout of planÆ to provide a blend of fresh and weathered kimberlite. The calculation of an accurate mine call factor was hindered by a lack of haul truck monitoring, process stoppages and stockpiling in the plant during commissioning. Updating of the geological model to incorporate the contact changes observed in the pit was slowed by the need to first understand how 40 years of exploration data was integrated to create the model. A plan, involving focused mine geology practices, is in place to upgrade a portion of the resource from Inferred to Indicated level of confidence. These challenges are not limited to new mines but will be ongoing as new information is constantly gained at Voorspoed and many mining operations.

Jan 1, 2009

Oceana Gold CorporationÆs (OGC) Frasers underground (FRUG) transitioned into production in early 2008. The mine uses a relatively unique yielding pillars mining method that takes its lessons from empirical coal mining practices more so than hard rock techniques. Being a low-grade, flat-dipping resource hosted in the highly structured relatively weak Otago schist in central South Island in New Zealand, meant a number of iterations were undertaken to find the right mix of mining cost and resource extraction. Mining is on the down dip extension of the active Frasers open pit at the Macraes site (that extracts the full shear zone package at a head grade of 1.5 g/t). The challenges for the FRUG feasibility study team was to deliver an net present value (NPV) positive operation that would exist as a coproduct with OGCÆs other New Zealand operations, allowing it to make use of the high throughput low cost refractory ore treatment facility.Key factors in the successful project design were: Net capital costs kept to less than NZ$30 M by realising significant gold revenues from mine development from month four onwards. Virtually eliminating waste development by putting all key capital infrastructure in the low-grade ore adjacent to panels and maintaining the option of extracting this resource on retreat from the mine. Targeting a specific higher grade halo ore package within the entire mineralised shear zone. Applying a mining method that accepted a higher degree of dilution, ore loss and resource loss (in yielding and non-yielding pillars) to the flat-dipping resource. Thus providing an acceptable margin per tonne and resource tonnes mix, as the resource could not support a conventional low-cost caving operation, nor a higher cost room and pillar or open stope and backfill operation. 2008 has seen increasing tonnes and grade performance with a corresponding decrease in cost per tonne and cost per ounce as the mine has reached nominal capacity and is producing an operating surplus. The challenge will be to maintain and improve.

Jan 1, 2009

By E Topal

There are presently no suitable underground mine production scheduling optimisation models available for application to sublevel stope mining. Scheduling underground production for maximum return is therefore still a manual process, which generally involves scheduling production from the next available highest cash flow stope within the operational constraints of the project. In most mining operations, the scheduling problem is too large and complex to guarantee truly optimal results through manual scheduling. This paper reviews some general optimisation studies that have been proposed for underground hard rock mining. Furthermore, an example of a mixed integer programming model is presented for a small conceptual sublevel stoping operation. Comparative results of a schedule generated by a mixed integer programming (MIP) production scheduling model and a manually generated model on a nine stope example is presented. Results indicate that the potential benefits of the MIP production scheduling model for the purpose of maximising NPV are significant. Finally, a new constraint was formulated to limit multiple exposures of fill masses for use in an existing MIP production scheduling model. Testing of the formulation took place on the central stope of the nine stope example, which showed that the formulation performed its task without breaking other operational constraints.

Jan 1, 2007

By A Riles

"Three issues of relevance in a modern tailings storage facility (TSF) are:geotechnical stabilitymanaging acid rock drainage (ARD) from pyritic tailingsmanaging the tailings from cyanidation of gold ores. Drawing on examples from both copper porphyry flotation and sulfide-hosted gold ores, this paper demonstrates that giving some weight and importance to the process tails properties upfront can influence the flow sheet and not only improve tailings management effectiveness but also impact positively on economics. In the case of a typical copper porphyry ore with moderate pyrite content, the rougher tail in a conventional high pH selective flotation step is usually classified as potentially acid generating (PAG). To avoid the generation of ARD within the tailings and the requirement for a costly plastic lining, subaqueous deposition is recommended, which in turn has negative implications for tailings stability, consolidation and closure. Adopting a neutral pH rougher stage rejects silicate gangue but recovers pyritic material to the cleaners for a subsequent selective flotation stage, often after regrinding. This effectively quarantines the PAG pyritic material in a much lower volume cleaner tail, which can then be appropriately encapsulated within a larger non-lined flotation tails facility. It also facilitates cyanide leaching of the cleaner tail for gold recovery, with the encapsulated tailings facility being suitable for cyanidation tails storage. A case study from Europe is examined. For gold ores where the gold is sulfide-hosted, but not refractory, a flotation route with cyanidation of the concentrate can similarly produce the majority of tailings as a benign flotation tail and again quarantine the low volume concentrate leach tail in a small encapsulated cell with appropriate residual cyanide management measures applied. Overall economics for intensive leaching of a low volume concentrate stream can also be surprisingly positive. A feasibility study design example of the process and TSF is presented. CITATION: Riles, A, 2016. An Integrated Approach to Optimising All Concentrator Products, Including Tailings, in Proceedings The Third AusIMM International Geometallurgy Conference (GeoMet) 2016, pp 341–346 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Jun 15, 2016

By E Haren, A Winchester

The CSA Mine has a long and varied history from initial discovery in 1871 through to the present. Lead-zinc mineralisation was mined historically near the surface. Today copper and silver are extracted from the deeper regions of the mine. The mine has passed through a number of owners over this time, each with a unique operating philosophy and understanding of the mineralisation. Cobar Management Pty Ltd re-opened the mine in 1999 and has undertaken extensive drilling programs to expand the resource and gain a better understanding of the mineralisation characteristics. Presently mineralisation has been located over a strike length of 1.2 km and to a depth of over 2.0 km with over 30 mineralised lenses from four identified ore systems. The refinement of geological and mineralisation models led to further discoveries and prompted a review and modification of resource modelling processes. Advanced statistical analyses prompted the implementation of ordinary kriging as a grade estimator. Improved stationarity from enhanced geological domaining has been supported by variography and kriging neighbourhood analysis studies. Resource models at CSA are now quantifiable in terms of mineralisation style and estimation reliability. The new techniques are assisting the definition of more mining fronts, which are creating new opportunities to increase mine output.

Jan 1, 2006

Lower Silesia Coal Basin/SW Poland/ is adjacent to highly gas saturated igneous massiv and since the beginning of this century more than 1500 outbursts have occurred in four existing mines, including 1295 in the most hazardous mine Nowa Ruda. Prevailing part of these are carbon dioxide/coal outbursts of ejected masses 50-5000 tonnes/av.200/t and gas volume released from 200 m3 to 800,000 m3 Magnitude of these phenomena is growing with the depth and for present extraction levels/ 375-753 m/ may be expressed by a formula: M = 4.25/H-400/, where M-masses ejected, t and H - depth of extraction, m. Regulations obligatory hitherto call for gas pressure measurements to be made in 3 m long and 42 mm dia. boreholes spaces not more than 25 m along the longwall face and taking sample of drillings for desorption testing. Criteria of a hazard are following: pressure higher than 30 kPa /for C02/ or 80 kPa /for CH4/ and desorption more than 1,44 cm3/g. These criteria are not satisfactory because many outbursts occurred in spite of low values of parameters measured and for several times no hazard was evident after very high values were obtained. Moreover, observations show that a huge majority of case outbursts occurred in coal weakened by local geological distortion.

Jan 1, 1980

A Presidential Commission of Enquiry into the conservation of South Africa's coal resources was appointed in 1970. This Commission, in co-operation with the Chamber of Mines of South Africa, established a national inventory of South Africa's in situ and extractable resources and reserves of coal of various types and grades by several mining methods. South Africa's future demand for coal by all market sectors and the specifications of coal required, were also established by means of econometric models. A comparison of potential supply and anticipated demand indicated serious defi- ciencies of certain types of coal and the need for the conservation of others. This paper describes recommendations for alternate strategies for the optimum utilization of available resources. Con- sideration was given to various policies relating to pricing, exports, taxation and incentives, and to the possibility of the substitution of higher grades of coal by lower grades. The steps so far taken to develop a national coal policy in South Africa are described.

Jan 1, 1977

By Mazandarani M, Chabot L, Vichion K

Pitch-steering models have been developed for discretely advanced mining machines (such as heading machines and coal shearers) using small-angle geometry and there are illustrative examples of simulator predicted performance. Although simple linear models result from the analysis of open-based machines, sledge mounted machines require execution of a Linear Programming energy minimisation to determine the attitude of the machine base at each advance over the previously cut floor steps. An analytical approach is based on elastic beam concepts developed for such applications as longwall face conveyors, caterpillar tracked machines such as continuous miners and longhole drills. Simulation results for longhole drills show the expected performance of an automatic guidance system and the destabilizing effects of sensing deviation too far behind the drill bit. Certain drill bit boundary conditions are expected to assist TBM. steering studies in three dimensions.There is a real role in mining machine steering for the mathematical models used in flight simulators.

Jan 1, 1991

By R Kahnt, S Jahn, D Baacke, M Eckart

Relocation into the Lichtenberg open pit mine of about 110 million m3 of sulfide-bearing and ARD-generating waste rock piled up on the surface is the most important and cost-intensive single surface restoration project conducted by WISMUT GmbH at the former Ronneburg uranium mining site. The waste rock comprises for the most part Palaeozoic shales, limestones and diabases with pyrite contents of up to seven per cent. Waste pile relocation began in 1992 and is scheduled to be completed by 2007. The approach used for relocation has been extensively described elsewhere (Jakubick et al, 1997; Hockley et al, 1997; Chapman et al, 1998; Paul, 2003). Following completion of the backfill that will be up to 60 m above the initial ground level, a dry cover will be placed on top of the backfilled mine wastes. The area to be covered amounts to about 220 ha. Design planning for the final cover placement of which is to begin in 2004 had to be based on a comprehensive cost-benefit analysis over and above compliance with legal requirements. The crucial question to be answered in this respect was to determine û in addition to the expenditure required to ensure reuse, radiation protection and soil protection û the extent to which additional time, effort and money were justified in order to minimise contaminant release from the unsaturated portion of the backfilled pit contributing to total releases into the ground water and possibly achieve savings in long-term operating costs for the on-site water treatment plant. Optimisation was based on contaminant balance modelling for the entire site reproducing dominant physical and geochemical processes. Among the specifics underlying the cover design is that contaminant release from the backfilled open pit must not be considered independently of that from the adjacent flooded underground mine and that a major part of the backfilled open pit will also be submerged. Following weighing of cover-related short- and long-term costs it was found that higher construction costs for the various cover options will not be offset by cost savings in the long-term water treatment. As a consequence of pit flooding, even a costly multiple cover including an impermeable layer will only insignificantly impact on concentrations and loads at ground water spill over points. As a result of comprehensive studies and investigations, a combined cover of cohesive soil material from on-site excavation overlain by a 0.4 m thick storage layer to restore natural soil functions for revegetation was derived and submitted for approval. Together with hydraulic measures, this approach is to meet any requirement in terms of radiology, water protection, stability, erosion protection, and reuse.

Jan 1, 2003

By M R. Davidson, M P. Schwarz

A model for column bioleaching is investigated to identify and understand aspects of bacteria in bioleaching applications, which have implications in heap bioleaching operations. The model is used to simulate scenarios that would otherwise be time consuming to perform experimentally. This study uses a model of bacterial transport and attachment/detachment to ore particles, with a bioleaching model for the depletion of a copper-sulfide, also accounting for liquid and gas flow and gas/liquid oxygen mass transfer. The model includes aspects such as oxygen and ferrous ion consumption, coupled with leaching of a copper-sulfide via the shrinking core model. The model is used to investigate how the rate of leaching is affected by the bacterial concentration in the columns, by the bacterial regeneration of the leaching oxidant ferric ions. The model is also used to assess the impact of oxygen limitation and inoculation method on the copper leaching. Some comparison of the model with experimental data will be shown.

Jan 1, 2004

By K Kuganathan, Y Potvin

Enterprise Mine at Mount Isa is to expand ore production from the current 1.4 to 3.5 mtpa by mining the 3500 Orebody, from which production is scheduled to start in February 1998 making this the deepest underground mine in Australia with its lowest mining horizon at nearly 1.6 km below surface. The following fill requirements were defined for the 3500 Orebody during the feasibility study: a minimum filling rate of 250 m3/h, a curing time of 28 days, and minimum free fill water. This paper mainly describes the investigation of high density and paste fills for the 3500 Orebody. The investigation covered all the key issues relating to fill option selection, including design criteria, material supply and demand assessment, drainage modelling, tailing dewatering method, mix design and a pump loop test. Results of the investigation indicate that both high density fill and paste fill are technically feasible. The investigation has led to the selection of a blended tailing paste for the 3500 Orebody as the paste option has significant advantages over high density fill in stope filling rates and fill reticulation. The blended tailing for paste fill is finer than Isa deslimed tailing but coarser than full plant tailing. The paste fill selected has minimum binder and tailing dewatering requirements while a relatively high filling rate is achieved.

Jan 1, 1998

SPOT imagery acquired in May 1986 of the areas that include the Dugald River lead-zinc lode, northwest Queensland, Australia and the Ngwenalekau copper deposit, Botswana has been evaluated and compared with LANDSAT MSS imagery of the same areas. The data have been processed using band combinations, band ratioing, principal components analysis and classificatory techniques and the outputs compared with those of geobotanical, geochemical and biogeochemical data as well as geological information. For both study areas the image processing techniques cited have successfully distinguished discrete vegetation associations related to discrete surficial and bedrock geological units; and, notwithstanding the sharp contrasts between the nature of the geobotanical anomalies that in both areas occur over mineralised bedrock in Proterozoic sedimentary sequences, they have successfully identified the areas of anomalous vegetation over the mineral deposits. Greater vegetational and geological detail is revealed than on outputs generated from LANDSAT MSS data [see Cole, 1977, 1982(a) and (b)]. The additional information yielded by SPOT imagery compared with LANDSAT MSS imagery results from its greater spatial resolution - 20 metres as against 79 metres - and from ti fact that the three SPOT MSS spectral bands - 0.50 0.59um, 0.615-0.68um and 0.79-0.89um - respectivelc cover those sections of the electro-magnetic spectrum in which leaf pigments, notably chlorophyll, absorption for photosynthesis and leaf cell structure strongly influence reflectance. This accords opportunities for the detection of reflectance aberrations caused by stress due to drought and/or metal toxicity as well as for the identification of anomalous vegetation communities of moderate sizr These cannot be accurately discriminated on LANDSA I MSS imagery on which only very large geobotanical anomalies like that over the Lady Annie phosphate deposit in northwest Queensland [Cole, 1977, 1984; Cole and Owen-Jones, 19771 can be detected.

Jan 1, 1988

By J C. Furness, F S. Cannon

Metal casting operations are a significant source of hazardous air pollutants. In particular, high production iron foundries emit significant quantities of volatile organic compounds (VOCs) during pouring, cooling and shakeout of iron castings made in green sand molds. End-of-the-pipeline capture and destruction methods to reduce VOC emissions add crippling costs to foundries. Alternately, the incorporation of advanced oxidants (AO) into metal casting green sand systems has been shown to reduce emissions from high production iron foundries in the US, and at the same time reduce operating costs. Cost savings are driven by the benefits of AO in clay recovery systems. Emissions reductions are the direct result of cascading AO-based reactions taking place in green sand molds. This sustainable greening of the metal casting process is a prototype for the development of other AO and non-AO process-based solutions for sustainable high temperature processing of materials. Fundamentals of AO technologies will be discussed along with the performance characteristics of AO processing systems in the metal casting industry and the breadth of other processing and remediation applications for which AO technologies have the potential to be successfully employed.

Jan 1, 2002

By Jelenich L, Murray J. Rantanen J

The experience gained in the development of an Operator Guidance System (OGS) for on-line process control and fault diagnosis in a commercial scale sintering process will be discussed in this paper. The OGS development started with the specification of feasible control and support tasks, eg ratio control scheme, mass balance calculations. Next, minimum requirements for fault diagnosis and process control were defined and the adequacy of existing instrumentation was assessed. The OGS knowledge base consists of both quantitative and qualitative diagnosis methods. Quantitative models based on fundamental engineering principle are used first and any gaps in such quantitative knowledge are then filled with heuristic rules. The diagnostic rules for the knowledge base was developed based on the knowledge acquired from experienced operators and operations engineers and validated with plant data. A real time reasoning program was written using C language and data base software. The OGS has a human-computer interface which is the primary means of interaction between the OGS and process operator. The OGS development has been successful in assisting operators in decision-making in their routine tasks. Further enhancement to the existing system is currently underway.

Jan 1, 1995

By Woods PW

Consulting Engineers have been used in the mining and metallurgical industries for many years. The traditional role of the consultant overseas has been one of assisting with conceptual design right through to con- struction and commissioning as well as on occasion acting solely in specialist fields. This role developed because mining companies wished to concentrate on building up the permanent organisation they require to operate their mines and treatment plants without the traumas of increasing staff for the design and construction period and reducing it on completion. In Australia where there have been few individual minerals projects of magnitude (until recently) companies have looked after their own detailed engineering and construct- ion management employing consultants mainly in specialised fields.

Jan 1, 1975

By N Ross, N Goldup

In recent years the heavy mineral mining industry has started to look more closely at the feasibility of mining moderate to high slimes deposits. During the initial stages of orebody evaluation the primary purpose of the pilot plant is to produce heavy mineral concentrate for metallurgical evaluation. Hence, generally little consideration is given to the disposal of the waste material (slimes and tailings). This paper suggests additional, simple, low-cost, tests that can easily be incorporated into an initial pilot plant operation. With this data a more definitive evaluation of available waste disposal options can be made during the early stages of the project. Thus, permitting better project focus and utilisation of resources. These tests include free settling of slimes, natural slimes drying and consolidation (undrained and drained), tailings stacking angles, and particle size distributions of input and waste streams, etc. The objective and method of each test is summarised, together with its relevance to possible waste disposal options. The results of this preliminary testwork can later be used to expand upon and define further tests for the second phase of pilot plant operations, which will enable a more definitive evaluation of a proposed waste disposal solution.

Jan 1, 2001

By McDonald K. J, Flann R. C

A liquid phase sintering (LPS) process for preparing basket anodes from nickel powder has been scaled-up and the innuence of compact green density and sulphur content, as well as sintering conditions (period and syngas now.rate) on the perfonnance of anodes has been evaluated. The product anodes have been tested in an industrial electroplating tank. It is concluded that if anode residues are to be minimised, then with a sintering temperature of 960"C, compact green density needs to be as high as economically achievable (85 - 87 per cent density of solid nickel) and the sintering period approximately 40 minutes. With these constraints, if residual sulphur contents of anodes are to be kept as low as those of commercial anodes, then the sulphur content of the green compacts would need to be less than 1670 ppm. At the same time, it is also found that residual sulphur concentrations as high as 2000 ppm are beneficial to anode pcrfonnancc and not detrimental to the quality of the electroplate. The ability of the LPS process to produce marketable nickel anodes for the electroplating industry is clearly demonstrated.

Jan 1, 1993

By Smith G. A

The scope and complexity of the Melbourne Underground Rail Loop Project and the budget restraints on the planning, design and construction of the works necessitated sound manage- ment procedures for control and co-ordination. Project Management Procedures formulated by the Principal Consultant to the Authority, John Connell - Mott, Hay 9 Anderson, Hatch, Jacobs, ensured that the Authority retained overall control of the project at all times.

Jan 1, 1981