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By T Kojovic

"The index A*b, determined from the Julius Kruttschnitt Mineral Research Centre (JKMRC) drop weight tester (DWT) results, has become well-known in the mining industry as a reliable measure of ore hardness in impact or crushing, having the inferred units of t/kWh. This index evolved from a long history of comminution studies at the JKMRC, including the development of the now superseded JKTech twin-pendulum, the industry standard JK Drop Weight Tester (JKDWT) and the faster alterative JKMRC rotary breakage tester (JKRBT). A reduced version of the DWT, the semi-autogenous grinding mill comminution test (SMC test®), also provides estimates of the A*b though the testing of only one particle size at five specific energies. Experimental determination of A*b using the above devices/tests requires samples, with sufficient mass, to be sent to designated laboratories, registered to conduct such tests. This protocol is fine for bankable and commercial testing, where material characterisation data is used in conjunction with machine specific data in modelling and simulation, and power based calculations. However, for comparative testing, where results are required at the time of sampling (eg for plant troubleshooting or spot-surveys), or for rapid ranking of geometallurgical samples, these existing tests simply do not provide a timely, viable and cost-effective solution. In order to address this critical void in the realm of comparative testing, a new device has been developed, exploiting a central feature of single particle impact testing – that the A*b can be reliably estimated using one precise low energy test. This device, for which a patent is currently pending, called the HIT (Hardness Index Tester), has been precision engineered to allow users to break narrowly sized fragments at a set specific energy, in a safe and easy manner. The manufacturing materials have been chosen carefully to ensure compatibility with the intended use and portability to any site, whilst minimising cost. The device is supplied with a novel quality assurance / quality control (QA/QC) feature, to ensure that the targeted potential energy is consistently delivered. The product from the HIT breakage test can be quickly sized using a single screen to determine the mass per cent undersize, from which the A*b index is calculated directly at site – eliminating the need to send the raw data off-site for analysis. On presized fragments, a single test using 20 fragments takes less than five minutes to complete, and the results are immediately available. The HIT is currently being tested at a major mining laboratory in the US and the results to date have proved it can deliver on all fronts. This paper describes the new prototype device, which offers users a low cost in-house mechanism for estimating the A*b at any mine site, with potential applications on fragments up to 25 mm from drill core, blast chip rejects or the grinding circuit feed. It also outlines the results of field tests carried out by an objective third party mining group and compares the results with those from current industry standard tests conducted on the same material.Citation:Kojovic, T, 2016. HIT - a Portable Field Device for Rapid Testing at Site, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 9–16 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By F van de Venter, J Monama, T Kale

For a multitude of years fine iron ore, -1 mm, across the world has been deposited as discard material in tailings facilities. This contributes to environmental problems, decreases plant yield and increases the cost of processing. Fine iron ore recovery processes are often deemed unfeasible or uneconomical, due to the complexity of the reclamation thereof in comparison with high-grade ores. However, recent advances in the recovery of fine iron ore using the Optima Classifier® has shown great promise. The Optima Classifier® is a new hindered settling separator that makes use of an upward current of water for density separation. It’s unique design combines three different separating zones for increased efficiency and recovery. In this study the potential of the Optima Classifier® to produce a +63 per cent Fe concentrate from -1 mm feed material was evaluated from a standalone and process perspective. It was found that a +63 per cent Fe product can be produced from a single stage, using the Optima Classifier®. Fine iron ore feed with an average head grade of 50 per cent Fe was upgraded to average concentrate grades of 63.2 per cent Fe. Displaying upgrade ratios of up to 1.26 in a single stage. A three-stage, rougher, cleaner and scavenger system did however show the best performance with recoveries of up to 70 per cent, yielding 56 per cent of a 63 per cent Fe product. Furthermore, the dewatering of the product and tailings was evaluated using the UltraG ultra-fine dewatering screen ensuring dry, stackable material. The tailings could be used in codisposal, while loads on thickeners and filter presses are significantly reduced. The high throughput of the Optima Classifier® ensures a small plant footprint, minimal civil and structural requirements and low operating utility consumption such as electricity, minimising the carbon footprint of a fines beneficiation plant. The Optima Classifier® in combination with the UltraG dewatering technology has provided a platform for economical recovery of fine iron ore, both current arising and historical. Providing opportunity to lower plant operating costs, reduce environmental liability of tailings facilities and increasing immediate process water recovery

Sep 18, 2023

In seeking to improve the economic performance of mines, the management or human aspects are usually seen to be quite seperate from, and more significant than, the technical aspects. There are obvious aspects of industrial relations, man-management, skills training and supervision that are currently the focus of efforts to improve the productivity and quality of the mining process. However technology also has a lot to offer. Analysis of the costs involved suggests that innovations leading to improvement in the productivity of the excavation and transport of overburden and the recovery of coal (both in the mine and preperation plant) can lead to improvements in the economic performance of a mine that may outstrip the obvious non-technical or management opportunities for improvement. While there are some innovations currently being investigated within the industry that relate to the design of mining equipment, the type of machinery being used in open cut mines has not changed dramatically over the last twenty five years. It is also likely that mining equipment will remain essentially of the same form in the forseeable future. If significant improvements to mining performance are to be achieved other than by futher increases in the scale of machinery, then we need to seek ways to operate these same types of machines in a more productive and controlled manner. This paper discusses the identification of mining processes the improvement of which is likely to have a significant effect on mining costs and performance. Some areas of current research are discussed and potentially fruitful areas for future development are identified.

Jan 1, 1991

By Wharton C. L

This paper describes a new computer program which can significantly increase the Net Present Value of either an open cut or underground mine by optimising the cut-offs used during the operating life of the mine. It was developed over a period of about three years by Whittle Programming Pty Ltd of Melbourne, Australia. Several authors have contributed to the theory behind this work, but the ideas were further developed, consolidated, and clearly explained by Lane (1988). It was this book that triggered the development of the new program. The paper starts with an explanation of the theory behind this type of optimisation, and then goes on to describe the computer methods used to optimise the different parts of the problem.

Jan 1, 1995

By M Spleit

A long-term production schedule for the LabMag iron ore deposit in northern Quebec, Canada is derived using stochastic integer programming. The optimisation formulation maximises the schedule’s net present value while simultaneously managing the risk of deviations in production tonnages and qualities by considering stochastic simulations of the orebody instead of a single deterministic model. The formulation also smooths and minimises haul truck requirements and ensures that as mining progresses, space is created within the mined out pit for the return of waste material.CITATION:Spleit, M, 2014. Production schedule optimisation – meeting targets by hedging against geological risk while addressing environmental and equipment concerns, in Proceedings Orebody Modelling and Strategic Mine Planning Symposium 2014, pp 397–404 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 24, 2014

Traditionally, the development of a mineral resource project goes through a fairly set pattern of decisions from what commodities to search for; where to look; how to locate; what are the reserves; how can they be exploited with optimum returns for all stakeholders; where are the markets and what will be the price received; what financing arrangments? However, due to the unique nature of most mineral resource properties, the relative significance of individual parameters on the ultimate development decision will vary from project to project. Sensitivity analysis in its formal sense is most frequently related to the economic analysis of a project particularly in conjunction with the ultimate development decision making process, and acknowledges the uncertainty of the actual values with their impact on the corporate decision making yardsticks. In many cases, this analysis merely adds more values to confuse the decision makers who may well opt for some subjective rationale to overcome the numeric confusion. However, sensitivity analysis should be used more frequently to exploit the development dollar to its maximum, THROUGHOUT the phases leading to the development decision. It is essential to identify the critical inputs to the various decision tiers in a project as early as possible and direct the funds to ensure that these parameters are determined as accurately as possible. Examples are used to illustrate the need for an even-handed quantification of the parameters which affect the outcome of decisions en route to the final one while minimising the risk in making an optimum assessment in relation to development funds Available.

Jan 1, 1983

By Sarkar B. C, Sen A. K

India is well endowed with vast reserves of banded hematite ore, about 12 billion tonnes, estimated by some conventional methods. Various authors have assessed this huge reserve using some advanced geostatistical methods. A Banded Iron Formation (BIF) belt named the `Singhbhum-Keonjhar-Bonai' belt in India has been chosen as a case study. In this paper, the experiences of Chiria iron ore, in particular, have been described. This study will finally create a dynamic mineral inventory after standardising the geostatistical parameters which will help to cater for the needs of the stringent quality requirements of the Indian steel industries.

Jan 1, 1995

By Kuwasaki N, Mitsune Y

Many activity measurements of components in liquid oxides have been reported in the field of slag chemistry. However, very little is known about the thermodynamic behavior of compo- nents in oxide solid solutions. In the present paper, e.m.fs. of the follow- ing galvanic cells employing solid electrolyte Zr02(CaO) were measured on the entire range of composition of the solid solutions. Pt/Ni-(Mgl-x ix)O/ZrO2(CaO)/Ni-NiO/Pt Pt/Ni-(Mgl-xNix)2SiO./ZrO2(CaO)/Ni-NiO/Pt Pt/Ni-(Mg l-xNix)Si03/ZrO2(CaO)/Ni-NiO/Pt. Activities of NiO in these solid solutions of (Mgl_ Nix)O and (Mgl_ Nix) 2Si0a(where 0

Jan 1, 1980

By B Beamish

The concept of a ‘critical velocity zone’ in the longwall goaf environment for the development of a spontaneous combustion event has been supported by numerical modelling. However, there is no experimental data available for Australian coals to show ventilation effects on the self-heating incubation behaviour of broken coal in the longwall goaf. A preliminary study using incubation testing has been completed on three high volatile bituminous coals (A, B and C) with R70 self-heating rate values of 3.86°C/h, 3.15°C/h and 2.09°C/h and moisture contents of 11.3 per cent, 3.9 per cent and 4.7 per cent, respectively. Mass to flow rates used in the adiabatic oven reaction vessel have been selected to be indicative of a sluggish, natural air leakage and medium ventilation environment. Under a sluggish ventilation flow rate all three coals incubate to thermal runaway in minimum time frames of 2.8–3.1 years, 34–42 days and 79–95 days, respectively. When the ventilation flow rate is increased to natural air leakage, coal A with the highest R70 value and highest moisture content selfheats to 28°C above mine ambient temperature before heat loss takes over due to moisture evaporation. However, both Coals B and C at this flow rate incubate to thermal runaway in a shorter time frame than under sluggish flow. At the medium ventilation flow rate, only Coal B incubates to thermal runaway, albeit after a significant extended period of time. These results show how important it is to determine the heat balance between the coal intrinsic reactivity (as indicated by the R70 value) and moisture content. The results also have implications for the possible location of the ‘critical velocity zone’ and subsequent hotspot development and migration.

Oct 12, 2022

By M Erskine, R Mills

This paper approaches tailings dam risk management from the perspective of how other high hazard industries approach the management of their catastrophic event risks, with the aim to provide recommendations from these learnings for the industry to adopt.

Jul 1, 2021

By M G. Hawtin

The Rocklands copper project is a multilode, iron oxide copper gold (IOCG) + cobalt mineralised system located in the Eastern Fold Belt of the Mt Isa Inlier. Rocklands orebodies cover a range of oxidation zones from oxide, to supergene and primary. Each zone contains different economic minerals of interest. The supergene zones contain significant amounts of native copper and the primary zones are dominated by chalcopyrite. The juxtaposition of these oxidation zones and minerals make it an interesting mineralisation system.Current mine production sampling collects a nominal 3 kg drill chip sample from a 1 m composite, RC drilled interval. A site specific sampling procedure was needed to quantify introduced sampling error when taking grade control samples. Due to oxidation and mineralogical variation in ore zones we needed to develop a practically achievable sampling methodology that ensures minimum sample mass and sample error requirements are achieved to ensure ‘representative’ samples for all ore types.These issues are planned to be resolved using an experimentally derived method using principles from the Theory of Sampling. This method uses an experimental calibration of parameters K and a for Gy’s fundamental sampling error formula using a modified 32-piece sampling tree experiment to compile sampling nomograms for the primary and supergene ores. This paper demonstrates the process undertaken to improve the quality and standard of existing mine production sampling procedures at the Rocklands operation.Results indicate a sample mass of 5 kg for RC drill chips is appropriate for both the primary and supergene ores to achieve a fundamental error below 0.01 or 10 per cent relative error, which is slightly higher than the existing sampling protocol of 3 kg. An additional experiment is recommended to compile sampling nomograms using the exact laboratory comminution and mass reduction stage information to assess the use of a 3 kg sample. The results also indicate no changes are required to existing sampling protocols when sampling RC drill chips in primary and supergene ore at Rocklands.Sampling nomogram results also provide a useful ‘rule of thumb’ reference guide to other mining and exploration companies to help understand minimum sample mass requirements and sampling error during exploration drilling, resource evaluation and mining production stages when targeting similar IOCG mineralised systems. A sample mass of 5 kg is recommended when RC drilling similarly IOCG mineralised prospects and deposits in the Cloncurry area. Future test work is recommended when additional open cuts become active as well as including resource drilling drill core to provide better three-dimensional sample representivity.CITATION:Hawtin, M G, 2017. Minimum sample mass from reverse circulation grade control drilling at Rocklands copper project, in Proceedings Tenth International Mining Geology Conference 2017, pp 337–346 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 20, 2017

A new watersoluble binder for mineral ore pellets has been developed by the sulfonation of bituminous materials. A highly effective binder for iron ore pellet making is obtainable from bituminous materials produced in the hightemperature cracking of crude oils. This paper deals with production process and basic properties of this binder as well as new applications in the field of iron ore pelletizing.

Jan 1, 1974

By P Pieterse

Kumba Iron Ore Ltd is currently commissioning the Sishen Expansion Project (SEP) û a brownfields project on the Sishen Iron Ore Mine located in the Northern Cape Province, South Africa. SEP is designed to produce 13 Mtpa of product from 21.7 Mtpa of ROM feed. The beneficiation section of SEP employs jigs to process narrow size fractions in the 25 x 0.8 mm size range. The -0.8 mm fraction is screened out ahead of the jig plant and rejected as waste without any prior beneficiation. The processing of this fraction was not included in the early stages of SEP development because no suitable beneficiation or dewatering technologies could be identified within the time-frame required to implement SEP. This paper presents the SEP 1B project, ie the metallurgical and process engineering study that was done to evaluate the techno-economic viability of processing the -0.8 mm material of SEP. To support this evaluation, metallurgical bench scale testwork was done on selected samples characterising the material types used in the SEP for gravity concentration beneficiation. Subsequently, pilot testwork on a 300-ton bulk sample demonstrated that an integrated teeter-bed/spiral circuit could be used to successfully beneficiate the -0.8 mm fraction. The study has established the viability of the proposed process and has concluded that approximately 390 000 tpa could be produced and added to the SEP fine ore product without violating the applicable product specifications. The proposed process has been designed to be implemented in modular units in order to facilitate implementation and ensure future expandability. Based on the recommendations of the study, approval has been granted for the detail design feasibility study. Production is scheduled to commence in the first quarter of 2010.

Jan 1, 2008

By S S. Kanchibotla, I Brunton

Most blast fragmentation models assume the rock mass properties, explosive properties and blast design variables to be constants and uniformly distributed within a blast. However, in reality all these input variables vary within a blast resulting in variation in the resulting fragmentation size distribution. A stochastic modelling approach is introduced in this paper to quantify this variation. This technique takes the input variables as statistical distributions rather than constants and through several thousand iterations, generates a statistical representation of the expected fragmentation resulting from a production blast. A case study of three production blasts from a large open pit mine are presented and the modelled fragmentation æenvelopeÆ shows good agreement with the fragmentation æenvelopeÆ estimated from Split image analysis. The various blast-related parameters influence different parts of the fragmentation distribution, eg rock strength and explosive velocity of detonation have most impact on the fines. The technique is used to identify the parameters that have the greatest influence on various size fractions. Such an analysis will be useful to direct resources to efficiently minimise the variation.

Jan 1, 2001

By D Kentwell

For deposits where a full assay suite of elements/oxides is available and where several variables are critical to the evaluation of the deposit, it is desirable for the estimated block values of all elements/oxides to sum to 100 per cent of the weight per cent. This is difficult to achieve in practice and the estimation methods used need to be designed to minimise bias of the key elements/oxides by ensuring that block estimates are consistent with the individual assays and that the estimated totals are as close as possible to 100 per cent.This paper presents a case study of two domains within a magnetite hematite deposit, one with a high level of drilling classified as Measured and one with a lower density of drilling classified as Indicated. Several estimation methods were tested to evaluate their ability to maintain consistency of the proportions of each element/oxide and sum to 100 per cent. The following methods were evaluated: ordinary kriging, co-kriging, inverse distance and min/max autocorrelation factors (MAF) all as implemented in the Geovariances Isatis software.The comparisons showed that the MAF method produced the most robust estimates in terms of block totals and that grades and tonnages at the reporting cut-off were not significantly different between methods. At an individual block scale all methods produce artefacts that are less than desirable but can only be remedied by additional drilling.CITATION:Kentwell, D, 2015. Comparison of min/max autocorrelation factors, kriging, co-kriging and inverse distance block totals – a magnetite hematite case study, in Proceedings Iron Ore 2015, pp 465–474 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

By A Suwandhi, H Utama

PT. Indo Muro Kencana (PT.IMK) is a gold mine that is located in Central Kalimantan, Indonesia. Drilling and blasting activity is applied in order to support mining production. Drilling and Blasting (D&B) planning is conducted by its engineers. A drilling and blasting contractor conducts drilling and blasting activity. The objective of this paper is to evaluate the implementation of the scaled depth of burial (Chiappetta and Treleven, 1997) in explosive charging sheet application to increase blast efficiency. The function of the scaled depth of burial is to maintain stemming height above explosive charge in order to prevent the ‘over energy’ condition, to reduce the excessive fly rock possibility, to maintain rock fragmentation (digger’s productivity) and to increase blast efficiency. The focus of this paper is to implement the scaled depth of burial as a reference in D&B planning and practice, especially in designing stemming height. The purpose of this paper is to validate that the scaled depth of burial can be used as an engineering tool in D&B practice in PT.IMK. However, scaled depth of burial cannot applied as an engineering tool to determine stemming height above explosive charge for trim blastholes and secondary blasting area. In general, the implementation of the scaled depth of burial in PT.IMK is applicable for production blastholes (ore and waste blasting). In conclusion, it is clear that scaled depth of burial can be used as an engineering tool to create explosive charging sheet and also to increase blast efficiency (ore and waste blasting) in PT.IMK.

Jun 22, 2022

By F Cesnik

The past few years has seen a concerted effort to improve the recovery of gold along with its co-product copper from the æhigh-gradeÆ Ridgeway concentrator at Newcrest Mining LtdÆs Cadia Valley Operations. A number of initiatives were identified and implemented, culminating in a sustained improvement in recovery of approximately three to four per cent for both metals. The key projects that contributed to this improvement included the installation of a 355 kW Metso stirred media detritor (SMD) to create a regrind circuit, installation of froth crowders on the scavenger circuit, installation of a Falcon SB2500SE gravity concentrator as part of the regrind circuit to improve gold recovered to bullion on-site and the optimisation of the grinding circuit to reduce the 80 per cent passing size (P80) of the primary grind from 160 to 121 ¦m for the same throughput via process control, cyclone and ball charge optimisation. This paper will focus on the supporting test work, where applicable, that was used as the design basis for the project, but more importantly the plant data before and after the changes to clearly identify the improvements to plant recovery.

Jan 1, 2007

By A J. Moore

Blasting operations in open cut mines results in airblast, ground vibration and rock movement with the potential for wild flyrock. In some mines there is a trend towards blasting closer to established infrastructure as extraction boundaries alter with increased resource prices and changed economic circumstances. Mine infrastructure in close proximity to blasting has the potential to be damaged by ground vibration and wild flyrock especially. To provide guidance for the determination of appropriate buffer distances and blast specifications, this paper describes methodologies that may be used to determine the potential for damage to infrastructure by predicting:dynamic blast;near field ground vibration levels;dynamic blast strains induced in infrastructure by consideration of ground vibration,ground strain and response amplification;potential for damage by comparing induced strains with allowable working strainsfrom structure design codes and serviceability requirements; andflyrock throw distances based on models developed from flyrock investigations.This report demonstrates the use of strain prediction methodologies developed during Australian Coal Association Research Programme (ACARP) Project C14057 for infrastructure such as conveyor belts, transmission poles and towers, buildings and bridges.

Nov 8, 2011

By Reichardt Y

Fine feed fractions in the size range from 1 to 40 ¦m of materials with different hardness as limestone and silicon carbide have been stressed in two different devices. A tungsten-carbide-blodc allows a single stressing with a pressure up to 2000 MPa and a 4-piston-block enables a multiple stressing procedure in which the material bed is stressed in alternating directions with a pressure up to 700 MPa. The experiments show energy absorption as the major factor for the interparticle breakage of hard material, like quartz, zircon silicate, silicon carbide and smelted oonindum, pressure, however, does not influence the results within the investigated range from 100 to 700 MPa and even up to 2000 MPa for corundum. But the breakage of the middle-hard limestone depends on the pressure so far as more fineness can be produced if the same energy is introduced at a lower pressure level. The creation of very fine and microfine fragments decreases strongly with increasing hardness of the feed materiaL The energy consumption for producing microfine material with a multiple stressing procedure on a particle bed is much lower than that one of a usual milling process. But this procedure needs a classification with a seperation cut at a couple of microns, which is not easy to accomplish.

Jan 1, 1993

By L R. Sousa, M He

Rock burst is common in deep underground excavations and is characterised by a violent ejection of block rocks from excavation walls. It is critical to understand the phenomenon of rock burst and particularly the failure mechanism. Laboratory experiments are one of the ways. For that purpose, a rock burst laboratory test system was developed at the State Key Laboratory for Geomechanics and Deep Underground Engineering at the China University of Mining and Technology, Beijing. A true triaxial test system, designated the Deep Underground Rock Burst Analogue Test Machine, was developed, which can transfer a stress state from three-direction-compression on six surfaces to the compression on five surfaces with one set free. The rock burst experimental system comprises an acquisition of acoustic emission signals, a high-speed recording in order to accurately record the kinetic characteristics of rock fragments ejected during a rock burst event and the possibility of infrared thermography showing the surface temperature of the samples. In this paper, analyses of typical results from rock burst tests are presented with a description of the obtained results. The mechanisms of rock burst are illustrated, and a rock burst classification is proposed based on these laboratory tests. For the control of rock burst, the constant resistance, large deformation (CRLD) bolt or anchor is presented for accommodating the large displacement of surrounding rock masses and absorbing the impact of the sudden release of rock burst while outputting a constant resistant force in response to the external load. The CRLD bolt or anchor has had practical applications in underground mines. Finally, in situ tests performed in a tunnel at Qingshui coalmine, China, are analysed in detail.CITATION:He, M and Sousa, L R, 2014. Experiments on rock burst and its control, in Proceedings AusRock 2014: Third Australasian Ground Control in Mining Conference , pp 19–32 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 5, 2014