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By F M. Weir, M Fowler

The design of excavations in rock must, implicitly or explicitly take into consideration the influence of small- and large-scale geological structures. For most sites the complexity of a fractured rock mass is best captured using a 3D fracture system model based on field data. A discrete fracture network (DFN) approach involves stochastic modelling of the ‘smaller scale’, nondeterministic structures. For slope stability or tunnelling projects DFN modelling provides a valuable geotechnical tool for characterisation of a rock mass and identification of likely failure mechanisms.This paper presents a suite of the DFN modelling undertaken for the design of a large open pit in Australia. The proposed pit is to encounter a 160?m thick, high strength, sheared shale unit, which overlies a crystalline basement. DFN modelling was undertaken separately for both the shale and basement units. While the model inputs and development for each unit are briefly presented, the focus of this paper is on the various applications of the DFN modelling.A key advantage of the DFN approach for design studies is its probabilistic application to structural analyses and results. Multiple realisations of the same model were generated for both the shale and basement units, with the stability analysis carried out on each iteration. The generation of a large number of DFN models and analyses allow assessment of wedge volume, factor of safety and proportion of unstable slope for a range of conditions. The DFN modelling at the case study site was also utilised for a number of other purposes. For example, investigation of likely fault lengths in the shale unit and combined rock mass and defect failure. The development of this tool has been influential in improving our understanding of fracture networks for excavation design.CITATION:Weir, F M and Fowler, M, 2014. Rock mass characterisation and analysis for excavation design – a discrete fracture network approach, in Proceedings AusRock 2014: Third Australasian Ground Control in Mining Conference , pp 445–456 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 5, 2014

By J V. Mehrabani, A R. Sayadi

Adequate estimation of equipment costs is a key factor in a feasibility study and in evaluation of design alternatives for mining and mineral processing projects. Inaccurate early cost estimation could lead to the elimination of investment benefits. However, this estimation is complex and time consuming because of data accessibility problems and consequently access to a rapid, up-to-date and accurate tool is desirable for carrying out cost estimations.This paper describes the development of models for estimating capital and operating costs for a jaw crusher, which is used as the primary crusher for a wide variety of mineral beneficiation plants, applying single and multivariate regression analyses, together with the design of experiment approach, based on principal component analysis. Explanatory variables include gape size, length of feed opening and power as numeric (quantitative) variables and toggle type (single or double) and the existence of extra heavy duty construction as categorical (qualitative) variables. The performance of each model has been investigated and comparing the estimated R-squared (R2) of each model, the best was selected and its validity examined. The cost models include the capital and operating costs along with the operating cost components. The results indicate that the suggested best cost model is sufficiently accurate for use in feasibility studies.

Sep 26, 2011

By W Z. Liu, Q Q. Shi, H T. Yang, X L. Zhang

In order to improve the cutting blasting effect of dimension stone mining, the water coupling directional cutting blasting technology was put forward. Based on the test apparatus and special charge configuration, the mechanism of directional cutting blasting was analysed. Directional device changes the initial equilibrium of the total energy of shock wave effect on blasthole wall. The initial directional crack first appears in the blasthole wall that makes contact with the directional device. Then, two cracks are connected along the direction of the blasthole centre line under the action of detonation pressure and water wedge. The plexiglass tests showed that water coupling directional cutting blasting technology produced cracks along with the predetermined direction completely. The cutting surface was smooth and only a few short cracks appeared around the blastholes. It proved the validity of this technology.CITATION:Liu, W Z, Zhang, X L, Yang, H T and Shi, Q Q, 2015. Directional blasting rock cutting technology, in Proceedings 11th International Symposium on Rock Fragmentation by Blasting, pp 815–818 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 24, 2015

By T Niitti, J Turunen, P B, A Rinne

In todayÆs marketplace, with high metals prices, many operations are faced with the challenge of improving recovery in the particle size ranges which are normally difficult to recover. This presentation focuses on the various methods used to alter the flow dynamics in a mechanical flotation cell, thereby improving metallurgical results. Modern computational fluid dynamics (CFD) tools have been used in the design phase, with subsequent validation at the plant. Some of the validated variables include mixing profile, power draw and local air hold-up. This presentation underlines how modern CFD analysis can be used to screen and select different approaches before commencing costly trial-and-error experiments at plant scale. Two methods of affecting flow dynamics are discussed û firstly, by altering the geometry of the rotor-stator area and, secondly, by fitting additional features in the tank. The rotor-stator area can be modified to provide more concentrated turbulent kinetic energy or, respectively, to provide more pumping efficiency with less attrition. The tank can be fitted with various additional features, aimed to create different particle suspension profiles. The benefit of both methods is that they can be applied not only to newly installed flotation technology, but also to existing plant cells, thus enabling potential improvement in the mixing profiles, solids suspension, tank sanding and metallurgical performance. Results of several sitesÆ tests are discussed in terms of flow variables measurement as well as metallurgy. This paper demonstrates the effects of different flow dynamics on the mixing profiles and metallurgical results of existing mechanical flotation cells.

Jan 1, 2006

Firedamp drainage has become an essential part of many mine environmental systems, and new applications are arising. Installations are evolving further to satisfy ever changing basic requirements, standards, and iniilny needs. In this paper, water seal, vacuum based installations are considered, as well as moni- toring, protective and control systems which have been developed for continuous, manless, and trouble free operation. Some factors affecting plant capacity and extractor per- formance are identified and assessed. INTRODUCTION Firedamp drainage applications are incr- easing world wide as mining engineers strive for improved safety and security, and further concentration of coal output. Fewer and fewer mines are able nowadays to satisfy coal prod- uction and firedamp control requirements solely by air dilution or by air dilution and underground firedamp extraction plants. As a result, dependence on surface extraction plants is increasing. This paper deals with som requirements and applications of such installations. I. DEVELOPMENT AND PRACTICE Firedamp drainage has existed for over 250 years following the early work of Carlisle Spedding at Whitehaven (1730). Some fundamentals of current firedamp drainage systems can be recognised in the

Jan 1, 1982

By English W, Poppit I

COALEX Pry Limited operates two underground steaming coal mines on the western edge of the Sydney Basin near Lithgow, New South Wales. Baal Bone Colliery uses longwall technology for an output of over two million tonne/year while Clarence Colliery currently uses continuous miners and breaker line supports for an output of two million tonnelyear.A computerised geological database and modelling system has been implemented to service these mines routinely, as well as several outlying prospects. The database is constantly upgraded for drillhole information, surveyed spot levels on the surface and underground, quality sampling details, surveyed mine workings and geological mapping. This information is edited on a routine basis, allowing dynamic modelling of key aspects of geology for ongoing operations.

Jan 1, 1991

By M Kim, J Park, I-K Suh, E Kim, J Lee

One of the key technologies in developing hydrogen-enriched ironmaking operations is the control of the carburisation, melting, and dripping behaviour of the iron ore burden materials. When a hot compacted iron (HCI) is charged in the blast furnace or the FINEX Melter-Gasifier, iron oxide reduction, the reduced iron’s carburisation, and the melting of iron and slag occur successively. This study investigated the reduction, carburisation, melting and dripping behaviour of HCI under a COH2 gas mixture using the high-temperature X-ray radiographic technique. Under 100 per cent CO gas atmosphere, the dripping temperature was 1410°C. When 5 per cent H2 was introduced, the dripping temperature slightly decreased to 1400°C. Furthermore, the dripping temperature gradually increased as the H2 gas composition increased. As 30 per cent H2 was introduced, the dripping temperature reached 1414°C. The carbon concentration in the drained metal samples gradually increased with increasing H2 composition. It is considered that H2 decreased FeO content in the slag, yielding the increased melting temperature and viscosity of the slag. On the other hand, H2 accelerated the carburisation of the reduced iron by CO gas, enabling the homogenisation of the oxide materials to form a liquid phase. Therefore, it is considered that introducing H2 in the reactor is helpful to increase productivity and energy efficiency by accelerating the liquid phase’s formation.

Aug 21, 2024

By C Fong

Compliance Planning is an active approach to ensure mining operations align more closely to their longer-term plans. Through Compliance Planning, operations can not only measure their performance on intervals as short as intra-shift, but they can then apply corrective measures to ensure they remain as close as possible to the plans. Compliance Planning targets short-term and execution level teams, as these are the shortest duration planning divisions commonly found in mining operations. Compliance Planning combines live information with intelligent planning capabilities to provide a framework that enables mining operations to realise a significant improvement in reconciliation of plan to actual movements.

Jun 22, 2022

By L Dyer, A Keith, G D. Corder

As mining activity moves to remote and less developed locations globally, a holistic approach to mine development is fundamental for achieving a balance between strong financial returns and corporate social responsibility and transparency. Key inter-related fundamentals such as social licence to operate, life-of-mine operational planning, minimising environmental impacts and, most importantly, attractive investment returns for the mining company all contribute to the viability of any new mining project.However, the typical practice in the mining industry is often to treat environmental and social/community aspects as separate compliance issues that are dealt with at minimum cost and disruption to the project and resulting operation. This often results in less than optimum environmental and social outcomes, and presents considerable liabilities at the time of closure when rehabilitation programs continue to require funding when all revenue has ceased.The five capitals model seeks to identify each of the key contributors to sustainable development as financial, manufactured/physical, social, human and natural to formulate a type of triple bottom line approach balancing these often competing project factors. The SUSOP® sustainability risks and opportunities framework, developed by the mining industry, bases its approach on the five capitals model and proposes an approach that breaks down enterprise silos to identify innovative solutions for life-of-mine sustainability. This framework has been developed with the nature of mining projects in mind in order to produce approaches and outcomes relevant throughout the life cycle from the planning phases, through project design and construction into operation and closure.This paper argues the need for a more holistic approach to the development and operation of mining projects, and presents case studies where a holistic approach has been applied, in whole or part, and discusses the lessons learned from these case studies.CITATION:Corder, G D, Keith, A and Dyer, L, 2014. A capitals based approach – leading innovation in planning for life-of-mine sustainability, in Proceedings Life-of-Mine 2014, pp 499–512 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 16, 2014

By I Lumsdaine

QNI Pty Ltd operates the Yabulu Refinery located 25 kilometres north of Townsville, North Queensland. The plant treats nickel laterite ores sourced from the Philippines, Indonesia and New Caledonia. The cobalt head grade and overall recovery expectations for the 2001/2002 financial year are 0.161 per cent and 53.8 per cent respectively. Cobalt is a valuable byproduct derived from the nickel refining operation which utilises the Caron Process. Any increases in cobalt recovery that are achieved from the existing relatively low level provide significant improvements to the bottom line of the operation. Towards the end of 2000, a project was undertaken to characterise cobalt losses with the sole purpose of improving cobalt recoveries using a variety of analysis techniques. The Time-of- Flight Secondary Ion Mass Spectrometry (TOF-SIMS û University of South Australia) method was used to verify the presence of surface bearing cobalt species, originating from either co-precipitation or adsorption mechanisms. Cross-section examinations were also performed using Scanning Electron Micrscopy (SEM) and Energy Dispersive X-ray Spectrometry (EDXS). These techniques indicated the presence of high cobalt concentrations (in the order of several per cent) within a select number of roasted and leached ore particles. The phenomenon of cobalt losses due to incomplete leaching within specific ore particles was not widely documented within the Refinery prior to these studies. In order to quantify losses via this mechanism, Mineral Liberation Analysis (MLA û JKTech Centre) was also performed on key samples. This paper serves to document a systematic approach in determining the source of significant valuable mineral losses in an established, operating plant. It discusses the use of a variety of analytical techniques, which have been adapted for the minerals processing industry, but are strongly relevant for plant investigations in the hydrometallurgical industry.

Jan 1, 2002

By A Sinuhaji, R Poedjono, G Flumerfelt

PT Freeport Indonesia is currently building the DOZ mine. It is a 25 000 tonne/day block caving operation which is scheduled to reach designed production levels by the fourth quarter of 2002. This paper describes some of the issues and challenges faced by the operation when introducing a new undercut method part way through the project. Advantages and disadvantages are discussed as well as the expected benefits of the new method.

Jan 1, 2002

Our ultimate resources come from the Sun and the Earth System. At this time we face a world crisis in energy, water and soil resources. Global pollution problems are increasing in almost all nations. There is an urgent need to use our vast knowledge with a new wisdom and this requires new integrated teams of experts to provide the best alternatives for the needed new development problems. These teams must include economists, engineers and a broad spectrum of scientists. Today it is possible to produce clean energy, stop soil erosion, clean water and reduce and use wastes of many types.

Jan 1, 1995

By MattelmSki M

Outokumpu Harjavalta Metals Oy has been producing nickel since 1962, based on conventional flash smelting technology followed by electrowinning of nickel. In the 1980s, a research project was initiated to develop a converterless direct smelting process to produce matte for further refining in the then existing refinery. The process was tested on a pilot plant scale at Outokumpu's research centre in Pori and was found to be viable. The process was named the Direct Outokumpu Nickel Smelting Process or the DON Process. At the turn of the 1990s, Outokumpu studied various options to develop its nickel business and the Harjavalta operations. As a result of this work, the DON Process was further developed to produce two mattes: low iron matte in the flash furnace to be leached in the existing leaching circuit and high iron matte in the electric furnace to be leached in the new leaching circuit. In Harjavalta's case, it was essential and important that the process could use the existing flash furnace and electric furnace without converters.

Jan 1, 1996

The role of a project metallurgist is diverse and covers input into the resource definition, mining studies, metallurgical test program development, process engineering and plant design, cost estimate preparation and financial analysis aspects of project feasibility studies. Mining project schedule and cost overruns can often be attributed to cutting short metallurgical test work, engineering and cost estimating leading up to commitment to development. In a significant number of cases this may result from the lack of understanding and commitment by the project proponent to the requisite metallurgical and processing studies required during the various pre-commitment stages of a mining project. Metallurgical test work, process development, engineering and cost estimating requirements for each stage of pre-commitment development are described together with a summary of the ongoing role of the project metallurgist during detailed engineering and commissioning of a process plant.

Jan 1, 2008

By S M. Gover

Estimating the probability of failure for embankments is not intuitive. It requires not only an appreciation of the strength of the embankment, but an understanding of the variability and uncertainty in the strength parameters as well. These additional aspects are, in themselves, relatively new to most practicing engineers, and therefore require some discussion.This paper discusses the concepts of probability and uncertainty, and presents a reliability-based numerical experiment, together with a literary study and collation of some of the author’s historical slope stability analyses, to investigate whether a direct relationship between safety factors and probabilities of failure exists for certain levels of uncertainty in strength parameters. In doing so, a useful tool is presented whereby knowing the safety factor of a simple slope or embankment with a consistent level of uncertainty, one can infer an approximate probability of failure.CITATION:Gover, S M, 2018. Linking safety factor to probability of failure, in Proceedings Mine Waste and Tailings Stewardship Conference 2018, pp 384–396 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 23, 2018

By A Atkins

Six recent case studies were selected based on the eight main causes of mine disasters (Table 1; Quinlan, 2014) and where credible information sources, such as Royal Commission Reports, Coronial Investigations and textbooks, were available. The six case studies are listed below. Details are available via this link or the conference PowerPoint accompanying this paper. 1. Beaconsfield, Tasmania – 2006 Fall of Ground/Seismic Event (Chandler, 2009; Melick, 2007; Wright, 2012). 2. Bingham Canyon, USA – 2013 Manefay Slide (Ross, 2017). 3. Bronzewing, WA – 2000 Hydraulic Fill Inrush (Hope, 2002). 4. Brumadinho and Samarco, Brazil – 2015 and 2019 Tailings Storage Facility (TSF) failures (Bowker, 2019; Darlington et al, 2019; Demajorovic, Lopes and Santiago, 2019; Morgenstern, 2016). 5. Northparkes, NSW – 1999 Cave Air-blast (Bailey, 2003; Hebblewhite, 2003). 6. Pike River, NZ – 2010 Methane Gas Explosion (Macfie, 2013; Panckhurst, Bell and Henry, 2012.

May 5, 2022

A general review of grinding mill steel liner evolutions/developments in recent times. The driving force behind these developments has been the mill operators desire to minimise the nett cost of their operation. These developments have resulted from a team approach between supplier, operators and reline crews. The move towards larger diameter high aspect mills, faster mill speeds, pebble ports and the use of large diameter grinding media has affected the traditional liner designs, which is placing higher demands on the supplier to meet these new working parameters and expectations. Operators are also taking closer ownership in the liners being supplied, as demonstrated by the development of their own mill liner specifications. This paper outlines some of liner developments and changes undergone at various milling operations around Australia and overseas (such as Cadia Hill, Kidston, Ok Tedi Mining, PT Freeport, etc) and where to in the future?

Jan 1, 2000

By S R. Williams

There is a sense of geometallurgy being new; a new methodology for mining project development and improved operational strategy. One of the main challenges that any ænewÆ technology faces is a validation of the value and the need to produce case studies. However, producing case studies can often be problematic particularly given the long cycle from mineral deposit project, through feasibility and construction to stabilised operation of a mine.However, the roots of geometallurgy go back quite some time. Successful practices with geometallurgy can be seen from as early as the 1980s. Many times those practices were not called geometallurgy but something else and, in other cases, what can be seen are various components of the geometallurgical ævalue chainÆ.This paper will analyse a selection of published past practices from a geometallurgical perspective to demonstrate the value realised from the application of this methodology. The paper will then make some general comments on where this history of work in geometallurgy has lead us to and what are the challenges today for the geometallurgical effort.CITATION:S R Williams, 2013. A historical perspective of the application and success of geometallurgical methodologies, in Proceedings The Second AusIMM International Geometallurgy Conference (GeoMet) 2013 , pp 37-48 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 29, 2013

By H Rossiter, A Maddever, J Market, P Jeanneau, A Virani

It is generally acknowledged that the head grade of the world’s copper resources is declining. Accordingly, there is an increase in the volume of resource material being mined and processed to maintain copper production. This has led to increases in cost base accompanied by reductions in Life of Mine (LOM) Net Present Value (NPV). The higher tonnages of material mined are driven by increased quantities of lower grade material required to satisfy the short term mine model. In turn, this has brought an increased focus on sampling and assay methods, since any error associated with estimating the grade of each block and determining its correct destination serves to magnify the losses that will occur. Presently most open-pit copper mining operations use blasthole sample assays to feed their shortterm model. The problematic nature of blasthole sampling is well documented (Engström, 2017), particularly the poor timeliness of the data and the significant errors that are inherent to the technique. Methods to improve grade control, such as drilling a separate grade control grid, have been proposed but come with their own cost, logistical, and accuracy shortcomings. A recent development in grade estimation is the Pulsed Fast and Thermal Neutron Activation (PFTNA) downhole logging probe. Deployed on an efficient semi-autonomous platform, PFTNA is being aggressively adopted in the Australian iron ore industry. The technology provides in-situ elemental analysis of the geological formation, delivering high accuracy, high efficiency, near realtime data from a sizeable measurement volume. In this paper we consider the application of the technology to copper. Whilst there are several operational components to such a value proposition, we focus on the benefits of improved gradeestimation. A simulated copper mine is used to model the quantum of improvement expected from a reduced grade-estimation error, which reduces the likelihood of misallocating material to the wrong destination, which in turn increases NPV.

Nov 10, 2020

By M Podreka, P Merry, L van den Berg

Anglo Gold AshantiÆs Sunrise Dam operation is located in Western Australia approximately 55 km south of the town of Laverton. Currently, the mine is producing from both its open pit and underground operations and is planning a significant step change in underground production as the pit phases out. The mine ventilation system is arranged in three independent ventilation districts: Astro, GQ and Cosmo. The future ventilation infrastructure requires significant upgrades to keep up with the increased tonnage. In the short term, increased production is planned for the GQ district as well as for Vogue, which is an extension in the Cosmo ventilation district. In the long term, however, Vogue is likely to become the centre of attention for mining activity.This paper explores several ventilation scenarios which include upgrading the existing fan stations, rentals, establishing a common ventilation backbone, and establishing new upcast infrastructure for GQ to support the short-term production increase. These developments were modelled using ventilation network simulation software to determine airflow distribution and fan operating points for each option. For the GQ area, with its short-term increase in production, each option is evaluated for total owning cost by considering capital and operating costs over a three-year period. For Vogue, which is to become the main focus of mining in the future, a different strategy is followed in analysing the ventilation requirements. Instead of considering different short-term options, a number of staged upgrades are considered to achieve the desired production rates.This paper summarises the planning criteria, airflow requirements, ventilation infrastructure requirements, and economic analysis associated with the conceptual ventilation system design. It highlights how the best short-term ventilation infrastructure upgrades can be selected when considered in isolation but highlights that long-term production planning can have an effect on the decisions made in the short-term.CITATION:van den Berg, L, Podreka, M and Merry, P, 2013. Sunrise Dam short- to long-term ventilation planning, in Proceedings The Australian Mine Ventilation Conference , pp 107-114 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 1, 2013