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By J Rutter, D La Rosa, P Walters, M Scott, L Keeney

Bulk ore sorting technologies, whether surfaced based or penetrative, have seen an increased uptake by the mining industry for preconcentration application. As with all technologies, going through the technology validation process is key to de-risking the operationalisation of the technologies and to demonstrate and confirm predicted value propositions. The ability to laboratory calibrate cross-belt bulk sensors is standard practise for sensor vendors, however transitioning the technology from laboratory to real-world application is a non-trivial process. The industry has taken two main approaches to trialling and validating bulk sensing technologies in operational environments, namely:  Construct an off-line pilot facility at scale, or  Install bulk sensing systems on production conveyors Each of these two approaches have significant advantages and disadvantages and require different experimental design programs and analysis methodologies. Consideration of material movement, heterogeneity degradation, logistical requirements, and financial investment all factor into which approach is most suitable for an evaluation scenario. CRC ORE in partnership with mining companies, have conducted several bulk sensor pilot trials utilising different sensor technologies employing each of the two main approaches outlined above. This paper describes the challenges faced, learnings obtained and outlines a position on how to transition bulk sensing technologies from the laboratory into the operating environment. The case studies presented cover a range of commodity types in both open pit and underground operations.

Nov 10, 2020

By X Hu, J Björkvall, L Sundqvist Ökvist

The metal production industry is a significant contributor to global CO2 emissions due to the use of fossil fuels such as coal and coke. To mitigate these emissions and meet climate goals, innovative and sustainable technologies are required. Molten salt electrolysis is a promising technology that directly produces metals from their precursor sulfides or oxides using electricity. When combined with renewable electricity and an inert anode, the electrolysis process can be carbon neutral. This paper presents the results of two pilot-scale studies on the electrolytic reduction of metal oxides and sulfides in molten salts. The first study focuses on the electrolytic reduction of chalcopyrite in molten NaCl-KCl salt. The results demonstrate that in situ separation of copper, iron, and sulfur is possible, enabling the extraction of all valuable elements without CO2 emissions. Furthermore, the findings underscore the capability to eliminate impurities like zinc, antimony, arsenic, and mercury from the electrolysis product. The second study investigates the electrolytic reduction of pure/synthetic chemicals of wüstite, hematite, and magnetite, as well as a magnetite-type iron ore in molten NaOH salt. The findings reveal a stepwise reduction of iron oxides from high valence to low valence, ultimately leading to the production of metallic iron electrolytically. Notably, this study underscores the challenges associated with the selection of an economically viable and durable inert anode material for efficient oxygen generation. These results indicate that molten salt electrolysis provides a sustainable and green route for base metal production. The use of this technology has the potential to significantly reduce CO2 emissions in the metal production industry, contributing to achieving climate goals.

Jun 19, 2024

By L O’Connor, S C. Dominy

"Geometallurgy is an important addition to any evaluation project or mining operation. As a discipline, it seeks to maximise the net present value (NPV) of an orebody while minimising technical and operational risk. It also aims to promote sustainable development and initiatives by ensuring that all stages of extraction are performed in an optimal manner from a technical, environmental and social perspective. To achieve these goals, development of innovative technologies and approaches along the entire commodity value chain are being established (Glass, 2016). Geometallurgy has been shown to increase operational stakeholder collaboration, creating an environment for knowledge sharing and improved data acquisition and interrogation, with the end result being the integration of such data into mine planning and scheduling. All of these aspects create better business optimisation, utilisation of staff and targeted and realistic key performance indicators.The mining industry faces numerous challenges including, but not limited to:declining ore gradesgeometrically and/or internally more complex depositsdeep-seated deposits, with potentially high in situ stress regimesincreasing quantities of mine waste that needs to be managed appropriatelyhigher energy, water and chemical costsprocessing of more challenging and refractory ores – textural complexitiesstricter environmental/permitting conditions – so-called ‘licence to mine’increasing demand for specialist metals (eg rare earth elements, In, Ge, Te, Rh, Se, Ga and Li)commodity market volatilitya difficult funding environment.Given these challenges, geometallurgy provides the opportunity to control or at least manage some of them.CITATION:Dominy, S C and O’Connor, L, 2016. Geometallurgy – Beyond Conception, in Proceedings The Third AusIMM International Geometallurgy Conference (GeoMet) 2016, pp 3–10 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Jun 15, 2016

By T Elms, R Beckman, M Sampson

"In today’s mining industry, the pressure of reducing costs and increasing production while maintaining high safety standards is at the forefront of operational endeavours. A combination of specific mining knowledge and technological advances has helped enable this notion. Fleet management systems have been developed to enable sites to better measure and manage production to improve operational efficiency.The integral part to managing production is having accurate, readily accessible data. This empowers key stakeholders in the management team to drive production reporting, materials tracking and budget forecasting.If a site does not run a fleet management system, manual input is heavily relied upon for production data, which introduces increased risk of human input error. Errors can drive outcomes that don’t achieve increased production at a reduced cost. Alternatively, a fleet management system can have improved accuracy but involves a high monetary investment. Such an investment is not always feasible for smaller mining operations subject to current industry cost pressures.The Emeco Operating System has been developed in alliance with sites such as the Mungari White Foil Operations by satisfying the criteria of a low intensity hardware installation, material tracking data validation processes, remote monitoring, identification of metrics to improve overall operating efficiency and providing the right information to key stakeholders.Citation:Beckman, R, Elms, T and Sampson, M, 2016. Getting Accurate Mine Information to the Right Teams to Drive Production Improvement, in Proceedings Ninth AusIMM Open Pit Operators' Conference 2016, pp 203–211 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Nov 15, 2016

By E Vargas, A Egana, M Alarcon, X Emery, A Barberan, A Lopez, N Morales, C Friedrich

"As the cost in time and money of data from sensors and small-scale tests has reduced, additional challenges have arisen. Although many mine data sets are not big relative to those in other disciplines, they are complex in other ways, and becoming too large to manage efficiently on personal computers. In order to take advantage of the opportunity offered by increased data, a diverse team from Universidad de Chile and CSIRO Mineral Resources has developed a virtual geometallurgical laboratory to support the computational requirements linking data acquisition with data-driven business decisions. A particular focus to date has been the development of user-guided workflow ensembles to enable comparison between plausible geometallurgical hypotheses.A case study has been undertaken using publicly available data from the Rocklea Dome iron deposit in Western Australia. A hypothetical mining schedule was produced from geochemical and hyperspectral drill core/chips data via the following steps: data preprocessing, exploratory data analysis, geochemical interpolation, block modelling, ultimate open pit design and scheduling. The key outcome of this study was the integration of workflow stages through new plug-in methods or modification of existing software. Outcomes from this study will be described in the paper in terms of geological and metallurgical data quality, analytical software support and ongoing computing infrastructure requirements.CITATION:Lopez, A, Barberan, A, Alarcon, M, Vargas, E, Ortiz, J, Morales, N, Emery, X, Egana, A, McFarlane, A and Friedrich, C, 2016. Progress towards Data-driven Mine Planning via a Virtual Geometallurgical Laboratory, in Proceedings The Third AusIMM International Geometallurgy Conference (GeoMet) 2016, pp 287–294 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Jun 15, 2016

As a result of cheap Maui gas and plentiful hydro-electricity, over the past few decades New Zealand has enjoyed some of the cheapest energy of any OECD country. The situation is changing; at best we are facing some radical changes in energy use, at worst we are facing a crisis resulting from the following:   Cause 1: Maui gas will be exhausted by 2012. Distorted pricing and supply contracts; resulted in Huntly Power Station, a coal mine mouth generator running on 70 per cent Maui gas until very recently!   Cause 2: Investment in new generating capacity (and transmission) is woefully inadequate; as a result hydro lake levels are being continually pushed to the limits.   Cause 3: Distorted thinking is everywhere, for example; æWe will find more cheap gasÆ. æGas is clean û coal is dirtyÆ. Hot air  û ægreen alternatives such as wind generation will save usÆ. æNo NuclearÆ. The outcomes of the distorted thinking will be price increases, then shortages (there is nothing like "black-outs" to focus national thinking) and finally recession.   But what can NZ do? - Mine Coal. Coal jump-started the industrial revolution, it can provide the transition to post-gas and oil. NZ has the second highest reserves of coal per capita in the world, yet we use less that any other country with significant coal reserves. Our exports of our best coal have increased threefold, yet out own consumption has remained static at about 1-1.5 Mtpa for the last 30 years. Our coal is NZ owned and inexpensive relative to other energy sources, even allowing for infrastructure and environmental costs.   What can we do? We as mining professionals can promote informed responsible development and investment in the country's mining and energy business. We can galvanise public opinion on issues such as æunbundlingÆ our entire energy chain from mine-to generator-through transmission, even if the nuclear issue has to wait! With oil above US$70/bbl substitution is feasible. For individuals, there is always solar!

Jan 1, 2006

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

Jan 1, 2004

By A T. Spathis, K E. Leslie, K R. Blay

Many open pit mining operations seek to control blasting-related movement of ore and waste to minimise loss and dilution. Tracking the movement of ore boundaries can result in the maximisation of ore recovery and minimisation of waste sent to the mill, thereby optimising the economic performance of the operation.A novel solution for tracking the ore–waste boundary location before and after a blast uses subsurface markers placed along the boundary with all measurements and scans conducted remotely from the blast block. Upon system activation, user-operated equipment on the surface determines the three-dimensional (3D) location of the subsurface markers.The patented system concept combines two electromagnetic mechanisms, magnetic positioning and radio frequency through-rock communications to enable remote battery-powered markers, buried within the rock to be accurately located in 3D space.Field trials at a quarry have demonstrated the system can comfortably handle over 100 subsurface markers with a complete scan, including set-up, taking less than an hour. Location accuracy for each marker in 3D space is better than 0.5 m at a range up to 50 m from the magnetic source, and the system has an overall operational range in excess of 75 m.CITATION:Blay, K R, Spathis, A T and Leslie, K E, 2015. A remote, rapid and accurate three-dimensional ore waste boundary tracking system, in Proceedings 11th International Symposium on Rock Fragmentation by Blasting, pp 297–306 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 24, 2015

By M J. Nugus

The structural models developed by exploration and mining geologists are most commonly concerned with the ‘main structures’ or key constituents that pertain to the associated mineralisation. To this end, it is recognised that the geological and exploration models, which are developed, are essentially ‘fit for task’ and the scale-related variances are not always realised at an early stage. In fact, in many cases anomalous intercepts along different trends and of variable apparent continuity have often been neglected as ‘back scatter’ and not important. Recognition of the importance of subordinate structures as mineralising hosts suggests that additional opportunities exist outside the primary and main structures. History shows that opportunities are often not realised where gold is hosted in orientations not parallel to the predominant trend of the schistosity, main fault or shear zone.Another reason for the importance of subordinate structures can be understood from their roles in a percolation network. Subordinate structures can access the large fluid fluxes provided by backbone elements, but, as dangling elements, they provide greater opportunities for gold precipitation mechanisms and hence may constitute essential parts of the resource. Therefore, the role, understanding and consideration of the smaller-scale and orthogonal structures should be considered during all facets of exploration, resource development, delineation and mining.

Aug 22, 2011

By N Murthy

Alumina is a major impurity in Australian iron ores and as the higher grade ores become depleted there will be a stronger focus on treating lower grade haematite/goethite ores and developing suitable beneficiation techniques to reduce the alumina content. High alumina in iron ore is deleterious in that it can:• produce slags with lower desulfurising capacity,• reduce sinter/pellet strength and quality, and• produce higher slag volume and increase slag viscosity.Meeting iron ore quality specifications for alumina by blending ore from different sources will eventually be insufficient. Hence, innovative flow sheets based on new and commercially available technologies will be required. Their advantages and disadvantages, the testing methodologies and the challenges and diffi culties involved in reducing the alumina content of iron ores are presented and discussed.

Jul 11, 2011

By R M. Krek

The haulage system used to convey ore from an underground mine to a surface stockpile at the mine process plant is a vital component of the mine’s overall infrastructure and economic viability. The system selected has a significant impact on the set-up of the mine and the access to the underground mine. In turn, the set-up of the mine and the access to the underground mine have a significant impact on the system.A number of haulage technologies are available to transfer the ore from the underground workings to the surface stockpile, including hoists, conveyors, rail and trucks.This paper focuses on the shaft hoisting and inclined conveyor haulage technologies. These technologies have been used consistently to deliver ore from at depth and/or at high tonnage. Previous reviews of the appropriate vertical haulage systems have nominally been restricted to the respective systems only, with no consideration for any other scope or issues that may affect the selection. The selection of the appropriate vertical haulage system, whether shaft hoisting or inclined conveying, needs to consider numerous key factors.CITATION:Krek, R M and Northcote, A E A, 2014. A holistic viewpoint for selecting the vertical haulage system – shafts and conveyors, in Proceedings 12th AusIMM Underground Operators’ Conference 2014 , pp 289–296 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Mar 24, 2014

By T Baumgartl, D Bradshaw, B Forsyth, M Edraki

In a tailings storage facility, the chemistry of pore water is a function of oxidation and dissolution of sulfide minerals, containing metals and metalloids, the neutralising effect of gangue minerals and the geochemical processes controlling solute equilibria such as pH, redox potential, precipitation, ion exchange and adsorption. On the other hand, the changes in geochemical composition of tailings feed over time is a function of spatial variability within the orebody and modifications in processing method. Tailings properties such as pyrite content, pH, concentration of deleterious elements, surface chemistry, pore water chemistry and particle size are already shaped in the dynamic environment of a process plant.To engineer desired environmental outcomes, a new research framework is needed. The new approach should follow the physical and geochemical processes of tailings feed and construct models that can be used for the prediction of seepage water quality and dust propagation and evaluate the potential re-processing of tailings or production of tailings with desirable surface chemistry, particle size and internal structure. The challenge of developing tailings engineering model is not in laboratory techniques, but more of the overall communication of results and establishing the link between disciplines. It requires investigating geochemistry across mining and processing for improved environmental outcomes at tailings storage facilities.The paper reviews the current tailings management practices by comparing the geochemistry and mineralogy of tailings and the chemistry of seepage water from three Australian case studies in the context of geology, mineral processing and climate. Some alternative methods of tailings management are also reviewed and it is concluded that a proactive multi-disciplinary approach is needed with respect to tailings management, based on a novel integrated research framework.CITATION:Edraki, M, Forsyth, B, Baumgartl, T and Bradshaw, D, 2012. Geochemistry of tailings and seepage from three tailings storage facilities in Australia - Uncapped, capped and active tailings, in Proceedings Life-of-Mine 2012 , pp 269-278 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 10, 2012

By S Thomas, E Grimsey

Mining education in Australia has undergone another cyclical downturn over the past five years and several departments have been discontinued while others are still teetering on the brink of destruction. During this downturn Curtin UniversityÆs WA School of Mines (WASM) has managed to stay alive and well, but this has not been by accident. This paper outlines some of the strategies and experiences that have kept WASM in a strong position and offers hope to other departments and schools elsewhere that are still experiencing difficulty. This paper is also directed at all mining departments and schools that are certainly going to see it all happen again after the next mining boom turns to bust.

Jan 1, 2004

By P J. Hawke

Within the Mesa J pisolitic iron ore mine, clay is distributed unevenly throughout the deposit and often forms as pods and channels less than 10 m in width. The mine resource model, based on 50 m + 50 m spaced drilling, has been unable to accurately delineate the clay for scheduling and mining purposes. Therefore, alternative methods for mapping the clay-contaminated ore were sought. Predictive clay mapping will significantly reduce production costs at Mesa J through improved selective mining practices, more accurate scheduling, reduced wear on mining equipment and minimising the need for maintenance of haul roads and ramps. High lateral resolution electromagnetic (EM) surveying using a Geonics EM31 instrument can quickly and inexpensively delineate the extent and orientation of the clays. Preliminary results indicate that a block model based on the interpretation of the EM data can accurately predict the distribution, volume and tonnage of ore and waste material. While rip-line mapping, infill drilling, ground penetrating radar and gravity can delineate clay with various degrees of success, none were as efficient as EM31.

Jan 1, 2002

By N LaBranche, G Callinan

There has been a reduction in overall workforce in the mining industry during the current downturn; a corresponding reduction in fatalities and high potential incidents (HPIs) has not been observed. The same contributing factors can be seen in the vast majority of these incidents. These include inadequate supervision and lack of adequate risk assessment. How management structures, trains and leads an operation can have a great impact on eliminating these factors and reducing the risk of fatalities and HPIs.Contractors now account for 41 per cent of full-time equivalent employees in the Queensland mining workforce, and are disproportionately represented in the majority of fatalities and HPIs. Having a clear strategy for how contractors are integrated into the workforce is crucial. This talk will include a discussion of the data as collected in the Department of Mines and Natural Resources department database, and offer solutions based on this data.CITATION:LaBranche, N and Callinan, G, 2016. Organisational factors in fatalities and high potential incidents, in Proceedings International Mine Management Conference, pp 201-206 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jun 22, 2016

Byproduct coking is practised in three of the major Australian ironmaking centres, the Newcastle and Whyalla works of the Broken Hill Proprietary Co. Ltd. and the Port Kembla works of Australian Iron & Steel Pty. Ltd. Coking first commenced at Newcastle in 1915 and at Port Kembla in 1938. The installations established at these centres include coal cleaning facilities and com- plete byproduct streams. The Whyalla plant, because of its location is somewhat less extensive, having no coal cleaning plant and a comparatively restricted byproduct section. As new batteries have been built every opportunity has been taken to incorporate modern design features and improved operat- ing techniques. This has included the provision of equipment to reduce atmospheric and water pollution. A marked reduction of markets for byproducts has had serious repercussions on the profitability of this section of the Industry.

Jan 1, 1972

By Pak DL

Over the last decade computers have become an essential element in assessing the economic feasibility of mining new mineral deposits and in assisting a variety of related support functions. A broad overview is given of the many technical application areas where computers are contributing to the mining industry with reference to work being done on the evaluation of drill hole information, mineral inventory modelling, ore reserve estimation, financial analysis, process simulation, process control, workshop job scheduling, PERT applications, and com- puter aided drafting. In all these areas the computer has greatly reduced the manual effort involved in looking at alternatives. It has had a significant effect in eliminating delays in revising calculations, or rescheduling activities to incorporate new data or cater for changing conditions, while at the same time providing more accurate and prompt information for the management decision making Process.

Jan 1, 1980

By Moritz P

Thiourea has been recognised for a long time as an acid-stable complexant for gold. Generally, the use of thiourea has been shown to exhibit enhanced leaching kinetics compared to cyanide but suffers the disadvantage of excessive reagent consumption. Thiourea leaching is particularly com- patible with the extraction of gold from refractory ores. This is due to the need for an oxidative pretreatment to liberate the gold. Such pretreatments typically result in the production of an acidic residue. The application of novel thiourea leaching technologies to the extraction of gold from a bioleached pyrite concentrate was investigated. The interac- tion of leach variables with thiourea consumption and gold extraction was established. An economic assessment of thiourea leaching was compared with conventional cyanidation. The results indicated that gold leaching of the bioleached residue using thiourea compared very favourably with cyanidation.

Jan 1, 1991

By Coates D. F, Neil T. J, O&apos

A proper economic analysis of pit slope design must reflect the trade-off between the benefits and the increased risks of slope fail- ure inherent in steeper slope angles. However, no formal framework for a proper analysis existed to date. This paper describes the results of the past four years' effort in which a formal eco- nomic analysis framework was developed and tested through a case study. This framework, in essence, consists of the availability of tested procedures and com- puter programs. The procedures as well as the programs are divided into two broad functional categories; (1) the first category related to assessing the economic benefits and costs associated with various pit slope angles and (2) the second category that determines the overall financial impact which the assessed benefits and costs exert to the mine operator's overall economic stature.

Jan 1, 1977

By Clifford C. E

The Black Star and Racecourse orebodies below 15 level contain a major portion of the primary silver-lead-zinc ore reserves of 56 million tonnes at 150 g/t Ag, 6.4% Pb and 6.5% Zn at Isa Mine. Extraction from this area is scheduled to begin in the early 1980's. Mining in this block will be quite com- plicated as the ore is contained in a dozen separate orebodies varying in width from 3 m to 20 m with only narrow barren pillars between them in some cases. Mining objectives which consider metal recovery, costs, environmental and safety factors, operating requirements and rock mechanics are used to compare proposals. The planning work involved in formulating mining proposals considers disposition of reserves, scheduling factors, sequence of extraction, extraction methods, haulage set-up and ventilation requirements.

Jan 1, 1979