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By Little T. N, Bettess D

For many mining operations the challenge of equalling World Best Practices has become the key motivator for increasing mine productivities and for lowering total costs. In most instances this will only be achieved if mines optimise their total system rather than minimising specific costs within unit operations. In the past, drilling and blasting have been viewed as a cost to be minimised rather than operations which should have their impacts fully leveraged. Once a hardrock orebody is defined the activity which has the most substantial impact in determining the efficiency of a mining operation is the blasting. The output from a blast affects every downstream operation; only by understanding the extent and interactions can the mine be optimised. Substantial improvements to hardrock mining, quarrying and excavation operations are achievable. Instead of seeking the regular one to three per cent improvements based on reduction of consumables, mine operators would be well advised to go for much bigger targets of ten to 30 per cent by fully leveraging the drill and blast operations.

Jan 1, 1995

By Wang S

Fragmentation is the basic concern in rock blasting and serves as the main measure of blasting effectiveness. A good estimation of fragment size distribution before blasting is very useful and helpful for selecting the proper equipment for loading, transporting, and crushing rocks. A fragmentation model is presented that is based on a hole by hole analysis and correlates the rock properties, burden, spacing, and explosive column with the blasted volume and fragmentation obtained. The drill bench is divided into three separate areas corresponding to different breakage mechanisms. They are: 1) a main breakage or casting area, 2) a secondary breaking area, and 3) an overbreak area. The boundary of the main breakage area is found from the magnitudes of strains in the stress waves and the tensile strength of the rock. The secondary breaking area is determined by stress wave reflections at discontinuities and interactions between colliding stress waves from adjacent boreholes. The overbreak area is that beyond the main breakage area "where the reflected tensile waves no longer break the rock. This analysis is applied on a hole by hole basis to locate the breaking points. Then connecting the breaking points on each side of a borehole forms the triangle of the main breakage area. This is repeated for the next hole and the remaining area is the secondary breakage area. After the angle and area for each hole are found the Kuz-Ram model is used to predict the fragmentation size distribution for each hole. Then summing up the size distribution for each hole gives the total fragmentation distribution. This analysis has been successfully applied to field tests performed in a limestone bench where the entire spoil pile was screened to determine the fragment size distribution. Knowing the explosive and rock properties the breaking area was found for each hole, the strain and stress values, the breaking point, and angle of breakage (104 degrees). The fragmentation size distribution was then calculated and compared to the field data with excellent agreement.

Jan 1, 1990

By Marton A

The Readymix Group have a Quarry Improvement Program - 'Building in Quality (BIQ) which has many parallels to the ICI Explosives' total quality management - 'Quality Improvement Program' (QIP). Both companies have for some time recognised that the 'do it right first time' principle means less wasted effort and materials, that efficiency breeds profitability and so actively promote the quality culture. To install the principles and generate the culture requires considerable commitment and effort from the top down and invariably spreads to the suppliers and sub-contractors. Understanding the component processes involved with the quarry operation, analysis of those processes and gaining a breakdown of the cost of non conformance then allows the astute quarry operator to make the necessary changes to improve the process to realise profits. This paper outlines the steps in such a process and the profitable outcomes of the commitment to continuous improvement at the Nickol Bay Quarry.

Jan 1, 1994

In preparation of this Paper, the emphasis has been laid on the commercial rather than on the technical and scientific aspects of coal evaluation. It is intended to describe and comment on the principal factors which currently determine the selection and procurement of coking coal for the steel industry, and is not based on the results of any original research by the author. Evaluation of different coals for strictly thermal uses, for gas production or other chemical applications has not been attempted, and comparisons of coal with other fuels have been excluded: the paper is concerned only with coals for the production of blast furnace coke. The discussion is strongly related to, and illustrated by, British, and to some extent, other Western European practice, but it is hoped that the general conclusions may have a wider application.

Jan 1, 1975

The development of Mount Isa Mines Limited power supply is traced through the history of the mine operations. As would be expected, growth of the power supply system follows closely the increase in mine output, although it will be seen that total kWh. produced per ton milled shows a considerable reduction in later years when the mine output showed a more rapid rate of increase. That this reduction is not more marked is possibly due to the increased community and Shire Council power usage per head of population.INTRODUCTIONThe geographical position of Mount lsa, far from any large regional power supply Authority, dictated the policy that the Company be responsible for the production and suppiy of all power required for the plant operation. The Company also, in November 1937, accepted responsibility for the supply of a part of the power requirements of the township of Mount Isa. The history of power supply to the Mine may be divided into several phases.1. The supply Of lighting and power during the first plant construction period 1929-1931.2. The construction of the first section of the Mines Power Station, comprising Nos. 1 and 2 turbo alternators and boilers.3. The addition of No. 3 turbo alternator and boiler.4. The addition of No. 4 turbo alternator and boiler.5. The addition of No. 5 boiler.6. The addition of a. 2 turbo blowers for air supply to the Copper Smelter converters; b. 1 turbo blower for air supply to the L.ead Smelter; c. 2 turbo compressors for compressed air supply to the Mine and surface plant.

Jan 1, 1961

By Boyle L. A

A positive displacement pump is being dev eloped for pipeline transportation of coking coal to a -50 mm export specification, at a con- centration and velocity which will allow trans- portation in the plug flow region, minimising degradation of the particle structure, and pipe= line friction losses which will be lower than with turbulent or laminar flow. Pump operation is by hydraulic powered free pistons in a rota- ting cylinder block, with cylinders overlapped by stationary inlet and discharge ports in a water lubricated and sealed rotary valve. Before this development coking coal was not considered suitable for transportation in slurry form, for the valves in the double act- ing duplex piston pumps used for slurry pipe- lines, cannot be divorced from the slurry and require that the solid material must be reduced to a fines'consistency before introduction into the pump suction. The hydraulic transportation of 10 million tonnes of -50 mm coking coal, 50 km from the Bargo area west of the escarpment to an offshore shiploader at Port Kembla is feasible. Study shows that economic factors alone would dictate that the development of a pumping system for long distance transportation of coking coal is necessary. The greatest impact from the slurry transportation of coking coal would be the

Jan 1, 1976

By Sehic OA

One aim of testwork and flowsheet development is to ultimately provide a reliable and flexible plant that is simple to operate and maintain. Testwork can indicate amenability of ores to CIP treatment and provide a basis for process design and economic appraisal. Batch cyanidation and CIP tests are often sufficient for small projects. Continuous multistage test rigs can be operated to simulate plant operation and to provide data for flowsheet optimisation. Operating requirements, gold recoveries and potential problem areas can be anticipated at an early stage with more confidence. Subsequent project development involving decisions on the basic flowsheet, equipment types and general plant arrangements are based on practical considerations and experience. Computer aided process modeling and economic appraisal can be useful in analysing various tradeoffs, firming up the flowsheet and equipment sizes, and in specifying operating targets for the future CIP plant. INTRODUCTION Carbon-in-pulp (CIP) technology which has developed rapidly since 1974 is now accepted as an economically and technically viable process for the efficient recovery of gold. This paper describes testwork and flowsheet development procedures used for CIP evaluation and design.

Jan 1, 1982

By J E. Lynch

The Mt Leyshon gold deposit produced in excess of three million ounces of gold and considerable silver over a period of approximately 130 years. Most of this production occurred between 1987 and 2001. Mining commenced in 1872, however it was highly likely that Chinese miners were not only removing alluvial gold from the area but were also mining very rich æreefÆ gold. Records for early alluvial and hard rock mining do not exist, however gold production was probably considerable. In the early 1980s Marathon Petroleum (Australia) Ltd (MPAL) joint ventured into the Mt Leyshon area which had been held as a mining lease by Noranda Australia Ltd since 1968. Noranda at that time was concentrating its exploration effort on the Balcooma base metal prospect areas to the north of Charters Towers. In early 1982 MPALs parent company was taken over by US Steel. This led to an opportunity for MPALs Australian management to purchase all tenements and licences (except for coal, oil and gas) which were duly purchased for $US 1 million. At this time MPAL had a remarkable array of gold tenements (many of which were subsequently mined by other companies) and Mt Leyshon was considered to be the highlight. Early æseedÆ capital ($A 3.1 million) was raised with backers being the Bank of America, the NSW Government Superannuation Scheme, Westpac, private individuals and a Queensland grocery chain by the name of æJack the SlasherÆ.

Jan 1, 2004

By L E. Krause

This paper discusses the considerations for optimum maintenance of critical ore handling infrastructure in order to minimise the cost to the business of maintenance periods. As maintenance periods are a direct interruption to production, time is of the essence and careful management of shutdown periods is essential. The ore pass systems currently in use at Xstrata Copper û Mount Isa Copper Operations are up to 30 years old and have had significant wear over the years. The maintenance of these passes and their brows and chutes in a production situation is a challenge as it can potentially expose personnel to high risk situations in addition to the production interruptions. Some alternatives for mitigating the risk of working in ore passes including plugging and ballooning are described. Criteria are included for selecting a method for the safe entry into a given ore pass. Experience in adapting the method of ore pass plugs and some lessons learnt in the process are also discussed.

Jan 1, 2005

By H Arvidson, D Guibal

This paper presents updated interpretations of controls on mineralisation in C Deposit and highlights structural features that influence the geometry of mineralisation domains used in resource estimation. The Area C mining lease is located in the central Hamersley Province, ~100 km WNW of Newman, Western Australia, and contains resources of approximately 1100 Mt of Marra Mamba and Brockman iron mineralisation. C Deposit is located within Area C, on the northern limb of the Weeli Wolli anticline, and mineralisation is hosted predominantly in the Mt Newman Member of the Marra Mamba Formation. Production from C Deposit began in August 2003, following mining of a 950 000 tonne bulk sample in 2002. Recent mapping in the bulk-sample pit and updated interpretations by BHP Billiton geologists have highlighted the significance of structural controls on mineralisation in C Deposit and their influence on the thickness of mineralisation, which ranges from 20 to 80 metres. Structural controls on the geometry and continuity of mineralised domains include south-dipping thrust faults that developed along the Mount Newman/West Angela contact, folds associated with thrust fault development, steeply dipping stratigraphic contacts in the hanging wall of the thrust faults, and gently north-dipping stratigraphic contacts. Thrust faults and folds in C Deposit are significant for two main reasons: their formation resulted in the thickening of the main ore-hosting units in the Mount Newman Member; and faults and folded stratigraphic contacts provided conduits for supergene metasomatic-enrichment processes that produce high-grade iron mineralisation.The implications of this interpretation for the definition of the resource estimation domains are discussed, and suggestions are made for a better integration of geology into the data acquisition and estimation process.

Jan 1, 2005

By Kohra A, Shoji S

The amount of copper production by flash smelting process occupies about 17% (equivalent to 1.4 million t/year) of total free world production. In Japan, 650,000 tons of copper is produced annually by flash smelting. This is 65% of the gross copper production of Japan. To reinforce pollution control, promote energy saving, and enhance production efficiency by increasing the size of furnaces, conventional blast furnaces and reverberatory furnaces are being replaced with the flash smelters worldwide. The Ashio Smelter started copper production in 1884 and developed in association with the Ashio mine. In those days, the Ashio smelter produced copper by using the blast furnace process designed for the high-grade ore from the copper mine. At that time, this process was specialized in Japan. In 1956, for the first time in Japan, the Ashio Smelter introduced the flash smelting process developed by Outokumpu Oy of Finland (it is suitable for treating the copper concentrate, producing sulfuric acid and improving production efficiency). The flash furnace in Ashio, the first ever in Japan, had a capacity of 230 t/day for copper concentrate and was operated up to 1962. During this period, various operational troubles were solved, and further improvements were made; and, in 1962, a Furukawa-type flash smelting furnace was completed in Ashio. This improved version of a flash furnace had a capacity of 450 t/day. There was one flash furnace and one waste heat boiler, which were arranged in a unique pattern for that time. This furnace may be said to be the prototype of the present flash smelting process in the world.

Jan 1, 1987

By Weir D. R, Doyle B. N

The Sherritt Zinc Pressure Leaching Process is based upon the direct pressure leaching of zinc sulphide or lead-zinc bulk sulphide concentrates to produce zinc sulphate in solution and elemental sulphur in the leach residues. The zinc sulphate solution is compatible with conventional purification and electrowinning technology. The pressure leach residues can be treated for the recovery of elemental sulphur, lead and silver. With the conversion of sulphur to the elemental form, zinc pressure leaching allows zinc winning to be independent of sulphuric acid production. Direct pressure leaching of zinc sulphide concentrates was started commercially in October 1980. Continuing research and development studies have defined various pressure leaching configurations for integration with existing roast-leach operations, for grass roots plants, or for plants which are to have the roast-leach section completely replaced. These studies have included the treatment of zinc concentrates from various Australian producers and the development of process flowsheets for potential applications in Australia.

Jan 1, 1989

By Lynce AJ

A method has been developed for the prediction 'of 'the- . performance of a multi-stage grinding=cyclone classification circuit of any degree of complexity on any ore for a wide range `of operating conditions, The-.method involves ;the. s` inu ation b'f the circuit on a digital computer by means of. matheinatical' models ":bf the"' individual units:, the. development of which is- also discussed'., At present, in order to establish 'the!'" charac'teristtics of they ¦ore- and the machines. in mathematical terms;. it is necessary to know'the performance of a , simpl,.e. ; system on tri.e ore - for! one known ,,feed rate and.fe.ed s,l-zing, analysis. ' ,Fiiither work on :the- separate identification 'of the terms defining the characteristics of the ore and the machines may permit the method to be, applied directly to the cj.4ta,derived from small scale tests on ores,

Jan 1, 1964

By Parker C. J, Mikula P. A

The excavation for the Sydney Opera House Parking Station comprises a large donut shaped underground cavern with a central sandstone pillar. The maximum effective roof span is about 19 m and the rock cover is between 7 m and 8 m. Permanent support for the roof and the various services tunnels consists of a combination of tensioned anchors, and untensioned dowels, and mesh with shortcrete and fibrecrete as the final lining. Steel sets were installed at main intersections.Fundamental to the design philosophy for excavation of these spans at such shallow rock cover was the use of monitoring to check on the adequacy of the installed support. Prior to excavation, extensometers, inclinometers, piezometers and surface settlement survey stations were installed. Underground survey stations, anchor load cells and shotcrete pressure cells were installed as excavation proceeded. Excavation commenced at the crown using an initial heading and three widening stages. Geological mapping during excavation confirmed borehole expectations, namely sandstone beds 1 to 4 m thick interbedded with thin shale units. Bedding plane contacts varied over short distances from tight partings to thick brecciated seams. Jointing was subvertical and joints tended to be bed-limited.

Jan 1, 1993

By D Michaelsen, S Miller

The Grasberg Mine is a copper and gold open pit mine operated by PT Freeport Indonesia (PTFI) and located in the high equatorial mountains of the Indonesian province of Papua. The climate is alpine/subalpine with little seasonal variation in temperature or rainfall. The daily average temperature ranges from about 2¦C to 14¦C and the annual rainfall in the vicinity of the mine and overburden stockpiles is about 4000 mm to 5000 mm. Mining of the Grasberg open pit will continue until 2014 at which time approximately 2750 Mt of overburden will have been produced. Current overburden production rates are 200 Mt per annum. The current mill rate is 230 000 t/day from the Grasberg pit (190 000 t/day) and the underground operations (40 000 t/day). The acid rock drainage (ARD) issues associated with overburden from the Grasberg operations were identified early in the mining operation. Almost all overburden placed to date has been Potentially Acid Forming (PAF). Laboratory testing has identified four main overburden types: limestone and non-acid forming (Green waste), PAF low capacity (Blue waste) and PAF high capacity (Red waste), and Heavy Sulfide Zone (HSZ), which contains greater than 20 per cent pyrite. Waste type block modelling indicates that at least 30 per cent of the overburden production from 2003 to the end of Grasberg pit operations will be limestone. Strategies are being developed to maximise the beneficial use of limestone through strategic blending and placement for ARD mitigation and control.

Jan 1, 2003

By Henderson N, Schaap H

In large companies with mining operations spread over multiple sites, it is essential that consistency between sites is maintained in preparing and classifying resource and reserve estimates. The endorsement by The AusLMM and AMIC of the "Australasian Code for Reporting of Identified Mineral Resources and Ore Reserves" and the subsequent incorporation of reference to the code into the ASX listing rules for mining companies has provided a basis for the consistent classification of resources and reserves. However, compliance with other criteria more or less stringent than the Australasian Code can present some reporting difficulties. Examples include listing requirements for foreign stock exchanges, particular Acts of Parliament that may apply to individual leases, constraints imposed by individual companies on their own leases, and ultimately, reserves for short, medium and long term planning. Confusion can arise when any two or more sets of reserves for the same lease are compared.. To alleviate this confusion, a standardised procedure was developed for the calculation and classification of coal resources and reserves. The procedure which is geostatistically based incorporates a technique called "Irregular Block Kriging" where specific mining blocks are directly kriged. The procedure has enabled those engineers and geologists with only a basic understanding of geostatistics to apply the technique and not feel hampered by some of the complex mathematics which in the past has tended to inhibit and overcomplicate the use of geostatistics. The procedure has resulted in "cleaner" data bases and hence more reliable reserve estimates.

Jan 1, 1990

By Bronson B

The geotechnical and environmental aspects of heap leaching are very closely tied during design, operations and closure. Potential environmental impacts from heap leaching are mostly due to land disturbance and water quality issues, including both groundwater and surface water. Water quality issues are mostly related to containment design, which is primarily a function of proper sizing of the facilities and site specific liner design. Geotechnical analyses is the dominant discipline in providing cost efficient, operationally effective and environmentally sound heap leach facility designs. Much has been published on geotechnical aspects of heap leach design, for example Van Zyl, Hutchison and Kiel (1988) and Van Zyl (1987). This paper will emphasize a few specific aspects related to the geotechnical and environmental consideration for heap leach projects. These aspects are: ò site investigation; ò containment design; ò slope stability; ò heap flow dynamics; and ò closure design. Design of a heap leach project must consider not only the operating life but also closure and post-closure considerations. As a matter of standard practice, designing for closure is an extremely important concept. Not only is it important for environmental aspects, but experience also shows that projects designed for closure will be overall more economical for the total life cycle of the project. Closure considerations are also important during project feasibility evaluations to ensure that total life cycle costs are evaluated.

Jan 1, 1994

The far reaching consequences of designing pillars for coal mines, while retaining concern for safety and economics, are cause for the search for refinement of the existing engineering methods to continue. Coal pillars, while having various functions within the overall mine plan, are the basic structural elements that assure the stability of a mine. Reliable coal pillar design methods take into account criteria which the pillars should meet in specific applications. These applications include typical mining situations such as the partial extraction room and pillar method with and without subsidence considerations, high extraction rate room and pillar, longwall mining chain pillars, and barrier pillars. However coal pillars are onlyu one element of a three element roof-pillar-floor system, weakest element of which system usually determines the stability of the excavations; however, the mining engineer can ony change dimensions of a pillar, properties of the surrounding strata remain beyond his control. The state of the art approach in pillar design places emphasis on recent developments in research. A widely encountered problem in certain coal fields is where pillars are underlain by weak floor strata. The resultant pillar design constantly maintains the perspective of the reliability of the design.

Jan 1, 1991

By Mathews K. E, Willstead T. V C

Initial glory holing was followed by sublevel stoping, with a small proportion of total production mined by shrink and cut-and-fill methods.The sublevel stoping method was successfully modified to cater for altering ground conditions encountered at increasing depths. At present, 94 per cent of production comes from sublevel stopes. The evolution of this mining method and current techniques and practices is outlined. A combined shrink and,sublevel benching method was also developed to increase the mining rate of narrow orebodies over the standard stoping lift of 380 ft. Pillar recovery and stope filling operations have been continuously modified to suit the relIuirements of a rapidly developing mine.INTRODUCTIONOre production commenced at Mount Isa Mines in June 1931. Since then production has increased from approximately 2,500 tons of lead ores per mine day to the current 11,000 tons of sulphide ores per mine day comprising 3,100 tons of lead ore and 7,900 tons of copper ore. The early planners selected sublevel stoping with ring drilling for ore breaking as the most efficient and economical for Mount Isa conditions: This method satisfied requirements for:1. a low cost mining method for the comparatively low grade ores,2. a stoping sequence allowing development, stope preparation, breaking and drawing of ore to proceed concurrently,3. a method of extraction in which broken ore in the stopes would be kept to a minimum because of adverse effects of oxidation on mill metallurgy and...

Jan 1, 1961

By Wagland D. G, Guo H

The Mt Whaleback orebody is in a complex geological regime. A good understanding of geological structure is essential during the design and implementation stages. The amount of information on the rock-mass condition available at the design stage is considerably limited. It is essential to validate the rock-mass properties used in the design during implementation. It is important to achieve integrity of the final pit wall during development and to maintain the integrity until the end of its designed life for safe and economical extraction of ore. The original geological model is updated by way of on-going detailed geological face mapping. Original design is reassessed and is modified based on any significant variations to the previously evaluated geotechnical conditions. Information gathered during design implementation provide tools for effective management of the pit walls. Controlled blasting techniques are employed in the final limits blasting. Presplit blasting is used in most limits blasts. Presplit helps to maintain the integrity of the wall by venting excessive gases from the limits blast. This helps to reduce bedding dilation by gas penetration. Also, it helps to define the design batter for the operators for final batter trimming. Pyritic shale needs special attention during blasting due to its reacting nature. Cablebolting is applied in selective areas to secure small-scale potential instabilities. During the development phase, pit wall monitoring instruments are installed. These instruments are used to monitor the performance of the wall during and after excavation of the slope.

Jan 1, 1995