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By R Dunne, W McCallum

Continuous improvement might be defined as seeking incremental improvement over time through improved equipment, processes, technology and the efforts of people. Most people working in ore processing facilities embrace the general principles of continuous improvement. However, given the industry-wide issues with skilled personnel and the constantly changing environment in ore processing facilities, it is often difficult to identify improvements in a facility over a given time period. The driver for these outcomes is the use of basic principles and technology to achieve best practice targets. The process involves four stages: develop standards of practice to define best practice in specific areas; write procedures to guide the organisation towards these best practices; implement the procedures and develop a review process to provide a method of measuring performance against best practice.By reviewing performance against best practice on a regular basis, the organisation measures progress towards the best practice targets and the incremental improvement between these regular reviews is a measure of continuous improvement.This paper provides the background for developing standards of practice for metal accounting, metallurgy and metallurgical management. The paper also describes how standards of practice can be used to develop continuous improvement and the skills set of the departmentÆs leadership team.CITATION:McCallum, W and Dunne, R, 2012. Metallurgical management tools for continuous improvement, in Proceedings 11th AusIMM Mill OperatorsÆ Conference, pp 225-230 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Oct 29, 2012

By S W. Houlding

The Certificate in Mining Studies program at the University of British Columbia, Vancouver, Canada is a collaborative initiative between mining schools and industry to provide accessible, cost-effective, accredited continuing education and training, designed to address the future needs of the global mining community. Content is provided by industry specialists and delivered through an integration of online learning, short courses and interactive webcasts. Accreditation is provided by a network of mining schools. In 2011, the program will deliver close to 100 short courses and interactive webcasts and provide 24/7 access to more than 130 online courses in six mining streams, to participants from as far afield as Tanzania, Argentina and Mongolia. The program is proving adaptable to corporate and mine site engineer-in-training and graduate-development programs, as well as providing accessible professional development opportunities for individuals. It also provides opportunities for cross-training from other disciplines and integration with mining school curricula.

Nov 22, 2011

By D Reid

Run-out analyses of tailings storage facilities are typically undertaken using methods based on rheological theory. These are reasonable techniques to model the behaviour of tailings that, through significant run-out and possibly mixing with supernatant water, are generally acting in a fluidised manner. Such modelling often follows on from two-dimensional continuum analysis models where, if failure is predicted, grid failure often occurs when deformations begin to increase. This results in a disconnect between the prediction of failure and the modelling of the potential extent of the failure.Recently, rezoning methods have been incorporated into commercially available two-dimensional soil mechanics deformation codes. Rezoning techniques enable large deformations to be modelled within a two-dimensional continuum analysis framework; however, while promising, the use of such tools is not yet widespread, and a consensus is yet to develop on how they should be applied to tailings dam run-out modelling.This paper uses FLAC rezoning techniques to model the flow behaviour of two historic tailings dam failures. The purpose of these analyses is to critically assess the performance of rezoning against some available historic failures. The required data to undertake such an analysis is outlined, along with the inherent limitations and assumptions required. Parametric analyses are outlined to address some of these issues. In general, the analyses undertaken underestimated the flow distance observed in the historic failures by varying degrees; however, in some instances, the analysis reasonably reproduced the qualitative shape of the initial failure zone. A variety of potential reasons for the discrepancy between historical observations and the models undertaken are provided.CITATION:Reid, D, 2015. The use of rezoning techniques to model historic tailings failures, in Proceedings Tailings and Mine Waste Management for the 21st Century , pp 201–206 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 27, 2015

By Cottrell EC

Remote sensing has been used for many years but until recently its application has been limited by the resolution of the data available. High resolution airborne multi-spectral scanner data (MSS) has proven suitable for a number of applications including environmental management and monitoring. A shallow water mapping research. project completed on the Gold Coast has shown that- remote sensing can be used as a cost effective tool for environmental management and Monitoring.

Jan 1, 1987

By B Shi, Y Li, L Ma, F Zhou

Subsurface fires are a common threat to coal mining, as spontaneous combustion of coal can potentially result in gas combustion and explosion. Fire-proof techniques, such as grouting, foam, or colloid injection, are not in a position to function ideally, due to the limited coverage and stopping the extinguishment substance from reaching the fire location. Liquid nitrogen, as a kind of all-submerged fire prevention or extinguishing method, can rapidly extinguish fires, thus preventing gas explosion and minimising extinguishment time. Injecting liquid nitrogen through boreholes is an important way during the period of mine catastrophe. But liquid nitrogen is not effective enough in infusion; technical issues restrict the development and utilisation of liquid nitrogen fire prevention and extinguishing technology. Immediate infusion of liquid nitrogen is usually associated with ‘air slug’ (the balloons and bubbles in the pipeline which hinder the flow of low-temperature liquid), which blocks pipelines for liquid nitrogen injecting. Another issue is that the pipeline tends to be damaged due to freezing, which undermines the injecting efficiency of liquid nitrogen and its application result. In order to solve the problems of the low efficiency and some other related field issues in liquid nitrogen perfusion, the ground–underground high efficiency liquid nitrogen injection technology were developed. Implementation of liquid nitrogen infusion techniques in Chinese coalmines achieved the goals of fire prevention and air-cooling. The technique presented in this paper is efficient in absorbing heat, and consequently, displacing oxygen and combustible gases. Field tests at Rujigou and Yangchangwan Coalmine justified the efficiency of the technique. By using this technique, there was no waste left behind, which may impede the subsequent production. The presented technique is of great benefit to the social, economic, and environmental aspects of mining operations, and will have broad applications in fire prevention for large-scale coalmines.CITATION:Zhou, F, Shi, B, Li, Y and Ma, L, 2015. Key techniques and engineering applications of stereoscopic liquid nitrogen infusion for coalmine fire prevention, in Proceedings The Australian Mine Ventilation Conference, pp 291–298 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 31, 2015

An Ore Reserves and Exploration System has been under continuous development at Mount Isa Mines Limited since 1970. The task of re-engineering the system has now begun, and the first stage is operational. This paper describes how the application of data base concepts, and table driving techniques has resulted in a design in which the input documents, validation procedures and file data content are redefinable by parameters, thus allowing the system to be tailored to suit varying geological Environments.

Jan 1, 1977

By Kawatra SK

The incentive to control coal flotation circuits arises because of disturbances, from plant operating practices and variations in feed coal characteristics, which result in large amounts of fine coal being lost in circuit tailings streams and lower grade concentrates being produced. Additionally, the flowrates and compositions of con-centrates and tailings streams can have significant effects on dewater-ing brocesses. A universal control strategy for these circuits cannot be developed. Rather, three major groups of variables must be con-sidered during strategy development: coal characteristics; circuit design and operating practice; and the variables selected to control the process. The second. and third groups-are discussed in this paper and examples from studies in operating plants are presented.

Jan 1, 1985

By P Wilson

The Mt. Wright Underground Mine is located near the town of Ravenswood in North Queensland and is operated by Carpentaria Gold – a wholly owned subsidiary of Resolute Mining Limited. The establishment of the world’s first Sub Level Shrinkage (SLS) mine from a tradition Sub Level Open Stoping operation has proven to be a geotechnical challenge which has required tailored solutions to overcome unique issues. This paper will be broken into two distinct sections that will outline: a brief overview of the mining method and how the SLS method was chosen; and how the SLS is managed and key geotechnical learnings. The story of the world’s first SLS originated from the need of a bulk mining method to ensure the viability of Mt. Wright into the future. Traditional bulk mining methods such as; Block or Sublevel Caving were originally ruled out due to the low natural ‘cavability’ of the orebody and the proximity of the orebody to existing major infrastructure (Decline, Ventilation Rises and Egresses). The first section of the paper will outline the key geotechnical information that helped decide the SLS method in addition to how continuous backfill influenced the design. The second section is intended to address issues that the geotechnical engineers encountered since the inception of the SLS. The feature topic of this section is mining induced stress. Like most bulk mining methods, Mt. Wright had success when the production front was running parallel to the stress (production front being ‘shadowed’ from the stress). This was until a design change, forced by a splitting ore body resulted in this shadowing effect becoming harder to achieve. As a result, rehabilitation and production hole re-drilling become a regular occurrence, which teamed with a strict set of access controls made the production cycle longer and harder to complete. CITATION:Wilson, P, 2018. Mt Wright – geotechnical learnings from a sub level shrink, in Proceedings The Fourth Australasian Ground Control in Mining Conference (AusRock), pp 119–132 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 30, 2018

By G S. Beros, K M. Edwards

Over the past 20 years drum scrubbers have become a widely adopted technology within iron ore beneficiation plants. Generally, the drum scrubbers in use are considered high-capacity machines capable of accepting larger-sized feed material. Together with a water addition to a desired pulp density and a mild energy input, these large rotating machines effect an attritioning action that removes water soluble clays and other deleterious materials. Within the Western Australian iron ore industry, drum scrubbers have been successfully applied to Channel Iron, Marra Mamba, Bedded and Detrital orebodies. The introduction of drum scrubbers has enabled Western Australian producers to satisfy the substantial increase in demand for iron ore from Chinese steelmakers by making the lower-grade sections of the above orebodies economic. However, despite being a relatively simple unit process, the requirements for successful design and operation of these machines are not fully understood. This paper draws on the collective experience of both authors to provide some points to consider for incorporating drum scrubbers into iron ore beneficiation plant flow sheets.

Sep 18, 2023

The Telfer Underground sublevel cave (SLC) Operation is located approximately 850 m below surface. The cave was designed to propagate through an old decline which was initially used to monitor the cave. There was a requirement to install air blast plugs at two locations in the old decline in order to isolate any potential air-blasts from the active workings in the event of the rock mass collapsing into the cavity. There was a further requirement for an air-blast plug in another section of the mine where there was a risk of the cave intersecting an old workshop and providing an air-blast pathway through an abandoned incline. The design criteria for the plugs was that they should withstand the design air blast loading, be free draining, cost effective and easily constructed with the mining expertise available on site. A plug consisting of grouted mullock was considered robust and least challenging to construct. For the purpose of estimation of maximum air pressure on plugs, it is supposed as a worst case that the rock above a cave falls as an airtight piston onto the top of a muck pile, forcing air into it and also mine workings intersected by the cave. Airflow through the muck pile is governed by Ergun's equation for turbulent flow. In a time-stepping integration scheme, transient air pressures and velocities are calculated according to equations of thermodynamics, in the cave and at intervals along intersected drives by means of a finite difference spatial discretisation. The ability of plugs to withstand computed pressures is assessed by finite element elastoplastic analysis. This paper outlines the rationale for potential air blast loading, calculation of transient air pressures, plug design and analysis of plug behaviour. The plug construction method is also discussed.

Nov 25, 2010

By W Malone, J Garrett

FLSmidth (FLS) has spent the last 15 years, working with customers and engineering houses to deliver innovative improvements in crusher safety, coupled with the latest, maintenance friendly, crusher design. The key focus being to prevent service personnel from working underneath the crusher during maintenance and obviate the need for personnel to be exposed to suspended loads when performing tasks such as, main shaft installation, for example. Improvements include: full top-service capability to ensure the safest and fastest way to disassemble the crusher for maintenance purposes, which also removes the requirement for a service cart; a selfaligning main shaft which ensures remote assembly is now possible, keeping service personnel well out of harm’s way; And rotable shells, or the ability to perform relines off-station, allows for quick shell ‘swap-over’ without the downtime associated with removing, refitting and curing time associated with epoxy backing. The high flow spider improves large material entry into the crusher, reducing blockages and downtime and therefore maintains crusher capacity. Each size of crusher in the range comes with an option to increase the standard feed opening to a larger one if desired to compensate for ‘blocky’ or ‘elongated’ feed material, a common problem for Pilbara hematite iron ores. Power capability has also been increased with a maximum of 1500 kW, to match the higher throughput capacities being achieved. This due to uprated eccentric speeds and larger discharge annulus. Increased eccentric throws and mantle diameters are also now a reality, when compared to more traditional designed gyratory crushers. To keep up with the improved design features of the Mk V, digitalisation has also been upgraded to maximise performance capabilities to ensure that the most efficient reduction and throughput capacities are achieved, whilst utilising the higher powers now available as standard. Condition monitoring ensures that the crusher is at its optimum operating capability by monitoring and adjusting the crusher settings via feedback from additional sensors, ie main shaft spin, temperature and vibration. Camera monitoring capabilities are available as is an advanced oil contamination monitoring system. As a result of the above design improvements, it will be shown that the Mk V range offers benefits such as: enhanced safety features, increased availability, faster maintenance turnarounds, higher power utilisation, equivalent product size at higher throughput capacities and with Remote operation capabilities. All of which result in a gyratory crusher with higher levels of safety and a lower per tonne operating cost.

Sep 18, 2023

By C N. Hatton, K Ward

Tailings operations are inherently reactive as operations personnel continuously contend with a concentrator reject feed (tailings) transient in physical and engineering properties, which places a constant constraint on capital and operational spending. It requires a unique skill set to manage the prescribed distribution of tailings under unenviable conditions. Enter the tailings operator, an oftenundervalued commodity and untapped resource that can provide benefits beyond the rigors of dayto- day operational support. Experience consistently demonstrates that skilled and committed operators can serve a vital function in the safe construction of a tailings storage facility. It takes a village to raise a tailings dam. An important part of this process is establishing a culture of operational accountability and ownership. Operator development training is nothing new. However, we find that many of the intrinsic operator skills are left unexploited, and an operator's experiential knowledge base and creativity are commonly overlooked and underutilized. With proper training and guidance, these skills can be harnessed, contributing to safe dam operations. Operator engagement, when properly facilitated, provides tangible benefits ranging from improved tailings engineering properties to reduced closure costs. One important benefit is helping transitioning tailings management from reactive to proactive. There are many processes involved in the reactive to proactive transition process. One element of that process includes engaging operators in the tailings management process and facilitating legacy ownership. The core of operational legacy ownership is measured and described using five-stage operator engagement rubrics. Levels of operator engagement are presented with a description of the incremental benefits of each stage. An important part of legacy engagement is providing the tools to operators necessary for managing the tailings. Therefore, the approach identifies specific methods used by operations personnel to control tailings distribution and in-place properties. The end goal of leveraging operator engagement is to facilitate committed ownership and transition tailings management from an inefficient, reactive process to an improved, cost-effective, proactive practice.

Jul 1, 2021

By C Jacobsen, N Harries

Assessing and managing instability hazards is an essential activity when working with unstable natural slopes and excavated open pit mining slopes. Slope monitoring has become the standard technique for the management of geotechnical risks associated with mine slope instability hazards. In recent decades, a proliferation of new monitoring techniques such as terrestrial radar, satellite InSAR and LIDAR have become standard operational tools, complementing conventional survey-based monitoring solutions. A reliable monitoring system should identify and record incipient anomalous slope movement. Although the most obvious purpose of a monitoring system is safety related, slope deformation and performance monitoring also enhance the understanding of slope behaviour and assists in improving system design and implementation. For a monitoring system to be considered an effective early warning tool, it needs to operate in real-time and should be linked to the mine’s emergency communication systems. Terrestrial radar systems have been developed that can provide near real-time measurements, at a high level of precision and covering broad areas in all weather conditions. This has had a positive impact on the management of geotechnical risks in operational conditions. The technology adoption of RADAR in mine monitoring has significantly progressed in the last 20 years from technology enthusiasts, to visionaries, to pragmatists to conservative users. However, the increasing adoption of RADAR cannot reduce or remove other monitoring techniques that often have important benefits; even if these technologies cannot be used as a real-time operational tool. An increasing awareness on the importance of combining data from different monitoring techniques to develop a holistic picture of all possible geotechnical hazards is a current industry trend. This is proving to be an excellent foundation for managing hazards associated with slope instability in open pit mines, and is only expected to improve with time with the adoption of new technologies based on big data and Artificial Intelligence (AI).

Nov 29, 2022

Increases in mechanisation and mining at greater depths are leading to additional problems of heat and humidity in many mines. As a result there is now an escalating demand for temperature prediction simulations appli- cable to underground environments. After a brief review of the present situation with regard to world mining and the use of environmental programs, the paper goes on to discuss in moderate detail the mathe- matical modelling of the many parameters that govern the condition of the ventilating air in a mine. The development of a program that gives the temperature distribution for a mine ventilation system is then outlined. The practicality of the program is discussed and the presentation format for users is explained. Simplification of input data requirements and the acquisition of data from other planning programs are an integral part of the commercial application of this program.

Jan 1, 1977

By Walton DR

It is self-evident that the availability of well qualified and experienced people to manage mining operations is vital to the success of an individual mine and to the ability to develop new mines either in Australia or overseas. For larger operations the term "mine manager" is here used to denote a range of positions within an individual company. Thus "mine managers" may be people managing individual mines at one geographic location with overall management provided by other "mine managers" in the roles such as mine super- intendents, production managers, general managers, etc. Smaller operations may have only a single level of management nominated as "mine manager".

Jan 1, 1980

By D R. van der Meulen, P Ande, D J. Lunt

Pressure hydrometallurgy is becoming an increasingly common unit operation in the treatment of gold and base metal ores and concentrates. The design of an adequate and appropriate pilot-scale testwork program is, therefore, essential in order to minimise the risks associated with developing a project in which autoclaves form a key part of the operation. This paper identifies the approaches that have been taken in the piloting of oxidative and pressure acid leach operations. Particular emphasis is placed on the determination of scale-up ratios between the pilot and commercial plants and the pilot-plant run durations. The issues, both metallurgical and project-specific, that can impact these key parameters are reviewed.

Jan 1, 2004

The passage of a vast array of new State and Federal environmental legislation over the last couple of years has required many mine operators to sharpen their focus on environmental requirements. Established requirements, such as environmental impact assessment, minimising disturbance and rehabilitation must now be complemented by mine environmental management plans. These may not only require regular monitoring of mine operations and detailed forward planning to prevent or reduce environmental harm caused during mine operation, but annual updating. It is likely that in future these plans will be required to incorporate general principles such as pollution prevention, sustainable development, waste minimisation and conservation of biodiversity and ecological integrity.

Jan 1, 1993

By G Pizarro, O Miranda, D Rosales

In panel/block caving mines, large amounts of information are collected at the operations. This information includes grades and extracted tonnage, fragmentation, lithology, design of stopes and main infrastructure, geotechnical information, overbreak progress, seismicity, numerical modelling and many other mine variables. To improve the reliability of the production plan it is required to integrate the mine data into one platform. In this paper, the logic of a new technological platform is presented for analysis, modelling and design in panel/block caving mines. The platform includes an acquisition system for mine data and geotechnical information, a back-analysis module for calibrating statistical models and a module of visualisation of the results. The application and benefits of the platform is illustrated for mining induced seismic risk for panel/block caving mining operation. The platform can be used in the mine design and planning processes and is useful for reducing uncertainty in the mining business of panel/block caving operations.CITATION:Miranda, O, Rosales, D, Pizarro, G and Vallejos, J, 2016. Development of an integrated platform for the analysis, modelling and design in panel caving mines, in Proceedings Seventh International Conference and Exhibition on Mass Mining (MassMin 2016), pp 237–240 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2016

By M Revell, B Sainsbury, D Sainsbury

This paper extends the existing knowledge associated with the design and placement of prefabricated pastefill barricades through a consideration of asymmetric drive geometry and conditions. The load capacity of prefabricated barricades and their failure modes are considered in relation to abutment geology and barricade geometry that includes curvature and span and drive geometry that includes abutment angles, haunch angles and misalignment. Design charts are provided for typical barricade sizes to provide general guidance for design capacities and optimising location placement based on asymmetric drive geometry. A recent barricade failure is considered in relation to the drive geometry and the potential impact it had on the installed capacity.

Nov 29, 2022

By D A. Williams, P J. Chapman

Constructing upstream raises with tailings is an accepted and cost-effective practice in Western Australia, where the climatic conditions are favourable, desiccation (and hence overconsolidation) occurs rapidly due to air drying and there is a perceived low seismic risk. This is in contrast to many other settings, where there is either a positive water balance, high seismicity or a combination of both. In recent times, there has been an increased focus on seismicity in areas of Australia that have historically been considered to be of low seismic risk. The increased focus is driven by two recently published documents used by tailings practitioners and increased awareness from corporate entities, particularly those with mines in high-seismicity regions such as South-East Asia and South America (particularly Chile).The increased awareness has resulted in increased rigour being applied to seismic design of tailings storage facilities (TSFs) in general, and particularly upstream-raised TSFs. This paper compares the results of a seismic stability assessment for an upstream-raised TSF located in the Goldfields region of Western Australia, which has historically been considered a low seismic area, with a seismic stability assessment carried out for a crossvalley TSF containing similar tailings but located in a high-rainfall, high-seismic setting in South-East Asia. The influence of the adopted design earthquake values on the results of the assessments and the potential impact of the maximum design earthquake (MDE) on the design approach is presented for both cases. The results indicate that although the Western Australian site is located in an area thought to have low seismic risk, the screening level analyses suggest that the MDE could result in liquefaction of the tailings materials. Not surprisingly, liquefaction was also indicated for the South-East Asian site. The outcomes of the assessment are also presented.CITATION:Chapman, P J and Williams, D A, 2015. Seismic design of upstream-raised tailings storage facilities in a semi-arid, low-seismicity setting, in Proceedings Tailings and Mine Waste Management for the 21st Century, pp 157–162 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 27, 2015