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By Bisshop J. P W

Maximum recovery of sulphide minerals by flotation is achieved over a limited size range. Valuable particles above and below this range have a smaller probability of being recovered. In the normal grinding-flotation operation, not all valuables are reduced to the optimum size range, and therefore sub- stantial losses occur. A significant improve- ment in the size distribution is not usually possible within the conventional circuit, and a more complex arrangement may be necessary to obtain optimum recovery of the valuable mineral. This problem is considered with refer- ence to the Mt. LyeZl concentrator. The performance of the existing circuit is dis- cussed, and it is shown that losses in recovery occur in both coarse and fine sizes. Laboratory tests indicate that regrinding the coarse particles results in an increase in recovery of up to 4%. Redistribution of plant grinding capacity to reduce initial grinding power by 6% and use this capacity to regrind coarse particles was considered. It is con- cluded that overall plant efficiency would be increased by 2% provided that overloading of the regrind mill could be avoided.

Jan 1, 1977

By M Neurohr, B Wacker, D Mensing, C Murphy, W Kitz

Mining operations have large power requirements. The biggest consumers of energy are the drives for the mills located in the concentrators. Assuming that the decision is made on how many mills are needed and how big these mills will be, it can be determined how these mills should be driven. The decision as to which drive should be applied depends on design limits for different mechanical or electrical drives, anticipated operation modes, capital expenditure optimisation and lifecycle cost optimisation.The task for the engineer specifying the drive equipment is to select a drive solution that can debottleneck the operation, avoid interruption of production and enhance the reliability of the process. At the same time, the engineer must choose a design that enables cost optimisation either in a single investment or in relation to the total cost of ownership (TCO).This paper outlines different mechatronic or electric drive alternatives for tube or horizontal mills applied in the mining industry, along with their advantages and disadvantages. The paper covers a wide range of applicable drive systems and provides a background to the benefit of applying integrated drive systems.CITATION:Wacker, B, Kitz, W, Murphy, C, Neurohr, M and Mensing, D, 2015. Application of different drive systems for horizontal mills, in Proceedings Iron Ore 2015, pp 205–216 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

By G H. Park, Y J. Jun, J H. Park

The carbon solubility of the CaO-Al2O3-FeO-SiO2-MgO slag, the main system formed in the Ruhrstahl-Heraeus (RH) vacuum degasser, was measured at 1873 K to understand the effect of slag compositions on the carbon contamination in the ultra-low carbon (ULC) steels. The stable form of carbon was demonstrated to be carbonate by plotting the log [(wt%C)/aC] ratio against the log p(O2) which ranged -11 < log p(O2,atm) < -9. The carbon solubility of the CaO-Al2O3-FeO-SiO2-MgO slag can be estimated using thermodynamic model. The distribution ratio of carbon increased with increasing concentration of FeO due to the FeO reduction reaction and increased basicity of slag. The carbonate capacity of the CaO-Al2O3-FeO-SiO2-MgO slag can be expressed as a linear function of the activity of lime and the optical basicity.

Jun 19, 2024

By C G. Sweeney

The underground mining industry is seeing unprecedented shortages in skilled labour. Migration to Australia being at an all-time low is a leading concern, with pandemic-induced border closures and lockdowns only exacerbating the skills shortage, not causing it. The skills shortage is forecast to peak in 2023 and remain high beyond 2025. With this skills shortage in mind, mining companies throughout Australia are trying to deal with stricter protocols around Health and Safety (H&S) legislation, as well as more stringent controls on quality assurance, particularly as underground mines are reaching greater depths and extending into ‘unchartered territory’. The cumulation of this is proving to be a major hurdle in ‘effective’ operational geotechnical management. The drive for automation in mining is bringing another level of complexity. However, ‘once automation is up and running, it presents the opportunity to access talent pools that may not normally be available. There is also a change in skillset that will be required to drive automation. ‘The top two emerging roles that will be critical for the future of the mining industry are artificial intelligence and machine learning (AI/ML) specialists, and process-automation specialists’ (Writer, 2021). If anything positive has come from the pandemic, it has shown that remote working can be effective and that the drive for automation and critical evaluation of skills required on-site should be given greater priority. UQ acknowledges that the industry is changing, and that digital technology is required to be offered in mining related disciplines. Industry and academia need to do more to promote geotechnical engineering in mining and balance the curriculum to suit the future of mining and make it more enticing. The average cost of a geotechnical failure is about $5 million in coalmines and can be into the hundreds of millions of dollars if production is affected (Cartledge Mining and Geotechnics, 2020). The cost of a good geotechnical design far outweighs the potential losses if a failure were to occur. This alludes to the growing importance of experienced geotechnical consultancies playing a pivotal role in managing mine site geotechnical hazards, while the industry is developing the next generation of geotechnical engineers.

Nov 29, 2022

By P Mitchell, S Pushpan, G Ferres, K Bobbermien, L Hudson

"Falling commodity prices and a rising supply surplus have ushered in a period of restraint in capital project investment across the global mining and metals sector. Competition for capital project funding has seen fewer projects progress through investment gates and a stronger focus on projects that deliver gains in capital productivity and strategic outcomes.Over the course of the 2015 financial year, EY conducted a study of 108 projects in the global mining and metals sector (EY analysis; Larsson and Ericsson, 2014; SNL Financial, 2015). The projects studied were at various life cycle stages and related to the development of copper, iron ore, gold, coal, nickel and other commodities. Each individual project investment exceeded US$1 B, and the studied group represented a cumulative investment value of US$367 B.The research found that the majority of projects were delayed and/or over budget when measured against the initial estimates made during the early stages of the project life cycle. Of the surveyed projects, 69 per cent were identified as facing cost overruns with an average overrun of 62 per cent above the initial estimate and 50 per cent reported schedule delays, even after remedial acceleration initiatives.The analysis found that budget and schedule overruns could be attributed to five key causes:project management factorsstakeholder conflictsresource constraintsregulatory, and policy-related challengesunfavourable external environment.Improving project delivery performance starts with successful planning, followed by rigorous management during delivery. From global experience on large and complex capital programs, EY has observed a consistent theme of underinvestment and a lack of focus in three often-overlooked but critical areas:implementing effective governance and reporting frameworks with lead indicators that reliably flag emerging risks while they can still be mitigatedallocating adequate cost and time contingency to account for risks across the life cycleenhancing the value of contingency by aligning contingency plans with scenario plans.This paper explores the surprising findings of the study, proposes a root cause model and examines key considerations in applying these critical enabling techniques.CITATION:Hudson, L, Mitchell, P, Ferres, G, Bobbermien, K and Pushpan, S, 2016. Are your megaproject schedules and costs under – or out of – control?, in Proceedings Project Evaluation 2016, pp 75–85 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Mar 8, 2016

By J D. Bryant

The Ernest Henry Copper-Gold mine, the third largest copper deposit in Australia, is located 35 km NE of Cloncurry in the Mt Isa-Cloncurry mineral district of NW Queensland. Ernest Henry Mining Pty Ltd (EHM), a wholly owned subsidiary of Xstrata Copper Australia, operates the mine. Approximately 10.2 Mt of ore grading 1.12 per cent Cu and 0.56 g/t Au were processed during the 2001 - 2002 financial year. The Ernest Henry plant produces copper-gold concentrate, which is trucked to Mt Isa for smelting. The Ernest Henry deposit is a member of the diverse Fe-oxide-(Cu-Au) class of deposits. The orebody is hosted within a sequence of moderately SSE-dipping, intensely altered Paleoproterozoic intermediate metavolcanic and metasedimentary rocks. Copper (chalcopyrite)-gold mineralisation occurs mainly within the magnetite-biotite-calcite ¦ pyrite matrix of a 250 m + 300 m pipe-like breccia body. The breccia pipe comprises two anastomosing lenses separated by a lower grade, clast-supported breccia zone. Several anastomosing brittle faults affect the macro-geometry of the orebody. Copper grade is proportional to the degree of matrix support in the breccia. The July 2002 Ore Reserve was 88.7 Mt @ 1.0 per cent Cu and 0.5 g/t Au. Resource estimation at Ernest Henry is based on a large database of predominantly diamond drill hole information. Drill spacing is typically 50 m + 50 m. Ordinary kriging is used to estimate Cu, Au, SG and IST (oxidation indicator) into model parent cells of dimension 20 m E + 20 m N + 16 m RL. The block model is comprised of five geological-geochemical domains represented by 3D wireframe surfaces. Zonal control, where samples and blocks are assigned the same domain number, is used to control grade estimation. The geometry of the domains defines hard grade boundaries across strike and soft boundaries along strike A Deep Drilling Project was initiated in August 2002 with the initial aim of testing the down-plunge extension of the orebody to a vertical depth of over 1 km. The encouraging intersections to date have resulted in a significant increase in the mineÆs open pit Mineral Resource together with the identification of an underground Mineral Resource. Added benefits of the project included an expanded and updated geological legend and an improved understanding of the host geological sequence.

Jan 1, 2003

By R Berry, S G. Walters, J A. Hunt, D Collett

The texture of an ore type is fundamental in understanding the metallurgical behaviour of an ore. This study will show examples of how quantified textural attributes (mineral shape, grain size and mineral association) can be obtained from automated and scanning electron microscope (SEM)-based microscopy and utilised using advanced image processing techniques. Examples will be shown of integrating quantified and semi-quantified meso- and macro-scale textural attributes as well as how they relate to texture-based visual logging systems. The implications of texture for processing behaviours such as comminution, liberation and recovery will be discussed. This research is part of a major collaborative geometallurgical project undertaken at the Centre of Excellence in Ore Deposits (CODES, University of Tasmania) and the Julius Kruttschnitt Mineral Research Centre (JKMRC, University of Queensland). The authors wish to acknowledge financial support and permission to publish from the sponsors of the AMIRA P843 GEMIII project.

Jan 1, 2008

By P Marianelli, J Theiler, B Beamish, A Spillman

The presence of reactive pyrite in waste rock contributes to the hazard of spontaneous combustion in emplacement facilities as it acts as an initiator of self-heating at low ambient temperatures. Organic carbon also present in the waste rocks acts as a fuel at elevated temperatures above 120&#176;C and can lead to thermal runaway resulting in eventual ignition. A new laboratory test method (adiabatic incubation testing) is now available that can identify the presence of reactive pyrite and quantify the self-heating behaviour of the waste rock. McArthur River Mine has a waste rock profile that contains pyritic shale units, which have created spontaneous combustion events in the past. A systematic sampling and testing program is underway to characterise the spontaneous combustion hazard likelihood of the McArthur River Mine waste rocks to provide a sound database for future mine planning of the waste removal and emplacement. This paper presents some initial outcomes of this program and shows the leading practice in spontaneous combustion hazard assessment and management that has been adopted at McArthur River.CITATION:Beamish, B, Marianelli, P, Theiler, J and Spillman, A, 2018. Spontaneous combustion hazard assessment of McArthur River Mine waste rock, in Proceedings Mine Waste and Tailings Stewardship Conference 2018, pp 422–426 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 23, 2018

By G McCullough, J Bassan, d P. Knights, C T. Farrelly

By 2045, carbon-neutral mines will be economically producing products that are vital for the world’s transition to renewable energy. After overcoming significant technical challenges (and the investment of significant capital), leaders have successfully eliminated the use of diesel and other fossil fuels by introducing a wide range of new decarbonisation technologies. These leaders will be reaping the benefits of lower production costs (resulting from elimination of diesel), stable and predictable operations, and easier access to capital for their future projects. This paper describes a future scenario of how a net zero carbon and zero-entry mine could operate by taking maximum advantage of technologies in development or already proven in other industries. Some miners have been unsuccessful in their efforts to reach decarbonisation targets. Instead, they have been forced to close or offload their assets to be acquired by operators with better sustainability credentials, or, in some cases, to indigenous or community-based enterprises with vested interest in making operations viable and sustainable. Regardless of ownership structure, all successful mining operations will have fostered strong and positive community relations that bring education, health, security and economic development opportunities to the communities while respecting their traditions, land-uses and culture. As shallow, easy to mine deposits have become scarce, the majority of new mines are underground. Advancements in electric underground technology and the feasibility of ‘zero entry mining’ (with no personnel in active mining zones) has made it increasingly possible to economically operate underground mines, even at shallow depths. The newest mines have a near zero footprint on the surface, produce no harmful by-products, and are employing in-place or in situ methods of extraction that are efficient and low impact. Surface land-uses, such as agriculture and renewable energy generation, continue in the immediate vicinity of the mine, with no significant ground disturbance, community impact or environmental footprint.

Sep 1, 2024

By F Kock, Y Sulianto, T Trott, B G. Putland, D Morgan

"Northparkes installed and commissioned a secondary crushing circuit in 2010 to debottleneck the semi-autogenous grinding (SAG) mill constrained grinding circuits. Following further improvements to the circuit (inclusion of a double deck vibrating screen), the project successfully delivered finer feed to the SAG mill. The result of this project was an increase in the milled tonnes from 5.6 Mt/a in 2012 to 6.0 Mt/a in 2013.The increased throughput rates introduced new challenges with the circuit becoming power limited. How to best optimise the available comminution power, while delivering the optimal particle size to the flotation circuit was made the key optimisation objective. To achieve this objective, Northparkes initiated a project that included engaging comminution experts. Recommendations included changes to the SAG mill including mill lifter design, increased grinding media charge levels and reduced grinding media size with aim of producing a finer grind size.Northparkes implemented these recommendations along with some other changes to SAG discharge grates and the mill discharge vibrating screen. This achieved a substantial reduction in the flotation feed particle size distribution (approximately 20 microns) by utilising increased average SAG power utilisation, in turn resulting in a two per cent increase in copper recovery.With power utilisation now maximised, the next phase of optimisation has moved to the throughput-grind-recovery relationship and the cost benefit analysis of installing additional grinding power.Citation:Sulianto, Y, Trott, T, Morgan, D, Bell, T, Kock, F and Putland, B, 2016. Optimisation of Installed Mill Power Post-installation of Secondary Crushing Circuit at Northparkes Mines, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 331&ndash;338 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By A M. Avis

This paper presents an overview of recent developments in the Environmental Impact Assessment (EIA) process to provide the background for a more detailed analysis of environmental and social constraints that the Heavy Mineral Mining industry has encountered over the past decade. Four cases studies are reviewed to provide a context for further analysis and identification of cross cutting environmental and social issues that either resulted in the projects not proceeding, or in the Australian case study, places existing operations under significant pressure from anti-mining lobbyists. The Xolobeni project, from the Eastern Cape in South Africa, is presented as the primary case study because it is recent, topical, and accessible; and raised numerous issues related to mining in a sensitive environment. A proposal to mine an area adjacent to the Okefenokee swamps in 1997 was also met with strong opposition from various environmental groups in Georgia, USA. This case study is briefly reviewed to further understand what ultimately resulted in the project not proceeding. Opposition to mining at North Stradbroke Island is reviewed to identify current issues more applicable to a developed country. A further review of a strategic assessment undertaken at Wavecrest, Eastern Cape, South Africa is provided in support of possible solutions to the challenges identified in the case studies. Important common themes were identified, including in some cases unfortunate timing of the environmental studies, but in all cases opposition was due to ecological sensitivity, landscape quality and sense of place. In one case study limitations to the EIA process included inadequate detail in the specialist investigations and insufficient information on mitigation. In all cases public participation was a limitation. It was either insufficient; flawed through possible bias; too ‘top down’ and required engagement with mobilised, motivated lobbyists. There was also insufficient investigation of social impacts, particularly amongst rural communities directly affected by a project. Generally alternatives were inadequately considered, a recognised limitation of project level EIA. It is concluded that the EIA process should be started as early as possible (at prefeasibility), and that investigations should be expanded from a typical fatal flaw assessment to one that applies methodologies used in strategic assessment. In particular, opportunities and constraints of the natural and social environment should be assessed in the context of the mining option as well as other options, to allow for a more meaningful assessment of alternatives. Public participation must form an important part of this initial study, despite the potential risks associated with public engagement at an early stage in the project. The application of the IFC Performance Standards; and expanding the scope of the EIA into an environmental, social and health impact assessment will lead to a more rigorous procedure, and result in more defensible products which could successfully unlock the key to the resources in these sensitive areas.

Oct 5, 2011

By J Sigda, T Jones, D Staggs, J Ewing, C Cheng, J Pickens, S Paulka

Mine-derived solutes from Energy Resources of Australia’s (ERA’s) Ranger uranium mine have been closely monitored for decades. Ranger is surrounded by the Northern Territory’s Kakadu National Park and is upstream of Ramsar convention wetlands. Modelling of groundwater flow and solute egress from mine wastes to surface waters has helped ERA successfully assess closure options and secure intermediate regulatory approvals during the site closure process. Potential environmental impacts were assessed using groundwater modelling in support of three ERA applications involving disposal of tailings-derived mine waste. Model results were an important part of the basis for obtaining regulatory approval. Three case studies are presented describing the three applications and how the groundwater modelling supported approval of the applications. For case study #1, INTERA supported ERA in addressing stakeholder concerns in 2017 regarding two aspects of tailings deposition in Pit 3. The first was the potential for flow of tailings fluid into the surrounding formations during tailings deposition. The second was the difference in post-closure magnesium (Mg) loading to surface water for two tailings deposition scenarios. INTERA developed a two-dimensional (2D) model that showed excess tailings pore pressures would not cause outflow and solute egress from the pit during deposition. INTERA’s three-dimensional (3D) models demonstrated that post-closure Mg loading to creeks for both tailings scenarios differed marginally and would be a small fraction of natural creek Mg loads. The modelling results helped avoid delays in completing tailings deposition driven by stakeholders’ environmental concerns. Case study #2 consisted of supporting ERA’s 2019 request for approval to change the tailings deposition method and final tailings level in Pit 3. INTERA’s model results for the permitted and proposed deposition methods showed minimal differences in post-closure Mg loading to creeks. The model results helped ERA obtain the needed approval for the tailings deposition method and water and tailings levels in Pit 3. For case study #3, INTERA modelled the comparative impacts from leaving the entire contaminant plume from the temporary tailings storage facility (TSF) in situ or excavating a portion of the contaminated material from beneath the TSF floor and placing it in Pit 3. The modelling results supported an approved TSF contaminated material application important for ERA to stay on schedule and minimise both closure costs and environmental impacts.

Jul 1, 2021

By S Bright, M J. Masamvu, E K. Chiwandika, S Dandi, S M. Masuka

The depletion of high-grade hard and lumpy chrome ores has forced Zimbabwean ferrochrome producers to resort to low-grade friable ores that have an average of 28 per cent fines against a set limit of 12 per cent. Submerged open arc furnaces currently in use are associated with eruptions within the furnace because of the high amounts of fines, high energy consumption, as well as high SO2 and CO2 emissions. Traditionally employed agglomeration methods such as pelletising and the use of coke in the furnace have been discarded because of the pressure to lower operational costs and to achieve higher profit margins. This research aims to develop a method to incorporate lowgrade friable ore fines and unprocessed coal into production while lowering CO2 and SO2 emissions through a closed direct current (DC) arc furnace. The closed DC arc furnace could incorporate the friable ores and coal while maintaining above 90 per cent reduction rates. Preliminary findings also show that energy consumption could be reduced by up to 35 per cent by incorporating a pre-heating and pre-reduction system using the flue gases from the furnace. In the proposed circuit, the cost of production per ton of ferrochrome might be potentially lowered by an average of 30 per cent.

Jun 19, 2024

By M W. I Visser Æt Hooft, R C. Schimmel

Until recently the Corus IJmuiden pellet plant produced approximately 4.5 Mtpa of pellets. Corus IJmuiden is currently running a program to increase its pig iron production to 6.4 million tonnes HM per annum. The burden of the Corus IJmuiden blast furnaces consists of approximately 50 per cent high basicity sinter and 50 per cent acid pellets, both produced in-house. To accommodate the increased pig iron production, the capacity of the pellet plant needed to be increased to 5.0 Mtpa. The productivity was increased by modifications to the plant layout, which were implemented during the 2006 cold maintenance stop. In addition, the composition of the ore blends is optimised to gain productivity.

Jan 1, 2007

Samples weighing 0&#183;5 g are fused with sodium hydrogen sulphate, leached with 5 ml. of 4 M nitric acid and diluted to 10 ml. with water. An aliquot of the clear solution is boiled with concentrated nitric acid and then 2 ml. of a phosphotungstate solution are added. After dilution to 10 ml. with water, the solution is heated in a boiling water-bath for not less than 10 min. When cold, the solution is extracted with 2 ml. of iso-amyl alcohol and the yellow phosphotungstovanadate complex is compared with a standard series. Concentrations down to 4 p.p.m. may be analysed at a rate of 100 samples per man-day of 8 hr.

Jan 1, 1971

By Grant BPM

The lower levels at the CSA Mine have been developed to mine reserves between theNo.7 level and No.9 level.Work on major excavations for the project began during 1982 with the develop-ment of the crusher chamber, on No.9 level. The brows and walls were pre-dowelled to improve stability before mining by mass blasting techniques.At the same time work commenced on theextension of No.2 Shaft from No.7 level toNo.11 level. The shaft was stripped, using hand held drilling, to a raise bored holeand concrete lined to a diameter of 5.5 metres. Plats were developed at No.8 level, No.9level and the loading station.

Jan 1, 1985

The low grade Mount Charlotte orebody was first mined with minimum capital expenditure by mechanised cut and fill stoping. The lower block was prepared simultaneously for open stoping by shaft sinking and installing another crusher and services. Similar development for the third block was discouraged by economic factors and reduced tonnage. Decline develop- ment required less capital and opened up ore reserves commensurate with advance, providing flexibility to stop operations without commit- ment: A 1 in 7 decline measuring 4.25m x 5.5m to accommodate standard Euclid 25 tonne dump trucks was developed south of the orebody. A fleet of four trucks average 12 loads each per shift over a haul distance of 700m.

Jan 1, 1973

By Hodkinson I, Slight M

Over the last five years Mt Leyshon has matured into a sizeable gold mine by Australian Standards. In the later part of 1990, after commissioning of the 3.5 mtpa CIP Plant upgrade, experience indicated there was potentially additional Mill capacity beyond that being utilised at the 3.5 mtpa rate. Overall throughput was limited by crushing plant performance and high operating costs resulting from the age and condition of the main crushing plant.In addition, mining was being carried out using a mining contractor who utilised relatively small, high cost mining equipment, and on-going exploration success was also indicating that the then current mine plan would result in only a portion of the available resource being exploited.

Jan 1, 1992

Until the early 1960s the world aluminium industry was dominated by six principle pro- ducers with integrated activities from bauxite mining to aluminium production. The growth in consumption of aluminium since that time and the emergence of additional producers has broadened the market for bauxite. In addition the increase in the optimum size of alumina refin- eries has influenced competing metal producers to unite in large joint ventures to minimize alumina costs. From these bases the paper examines present and likely future markets for Australian bauxite; differing marketing phil- osophies for serving those markets; factors influencing successful marketing; and the sources and relative strength of competition which Australia faces.

Jan 1, 1974

In a coal mine there are many substances capable of ignition under certain circumstances, which can be placed in the following groups: ordinary combustible solids, dusts, liquids and vapours, gases, metals and plastics. There are many factors influencing ignition, including temperature, minimum ignition energy, particle size, explosion pressure level, rate of pressure rise, specific energy content and also explosive limit. Not all are applicable in every case. Frictional ignition of methane is an accident statistic of increasing concern and is considered in some detail. Practical measures that can be taken to reduce the incidence of frictional ignitions are considered, and also possible ways of ignition suppression.

Jan 1, 1981