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By S Rogers, D Stead, E Eberhardt

The last decade has seen a major increase in use of the discrete fracture network (DFN) approach applied to cave mining problems, often integrated within more complex geomechanical simulations. Because the value of the DFN model directly depends on the quality and quantity of available field data, there is the need to apply dedicated mapping procedures to collect sufficient structural data at the required engineering scale. This paper attempts to address several key questions about DFN modelling; for example: are current methods for fracture mapping suitable for DFN modelling? What are the critical parameters that we need to measure and what do we need to change in the current practice? Particularly at the earlier stages of a cave project, engineers may have to account for the lack of appropriate data, which manifests itself in the form of increased uncertainty and the difficulty to characterise variability in an objective manner using a limited set of data. DFN models could in principle be generated using limited data by assuming statistical distributions for the sampled parameters; however, engineers would need to be aware of the implications that such limited knowledge (and increased uncertainty) would have on stability analysis, fragmentation analysis and mine design. When used correctly, a DFN approach offers practitioners the opportunity to:maximise the use of fracture data collected from mapping of rock exposuresgenerate more realistic synthetic rock mass modelsprovide estimates of natural fragmentation that also account for rock mass variability.CITATION:Elmo, D, Eberhardt, E, Stead, D and Rogers, S, 2016. Discrete fracture network modelling – importance of accounting for data uncertainty and variability, in Proceedings Seventh International Conference and Exhibition on Mass Mining (MassMin 2016), pp 845–852 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2016

By K George

The Dugald River lead-zinc-silver deposit is located approximately 60 km north-west of Cloncurry and 87 km north-east of Mount Isa. The development project is expected to turn operational in 2018. The resource is estimated to contain 61.1 Mt at 12.6 per cent zinc, 1.9 per cent lead and 34 g/t silver, with a projected mine life of 25 years. The evolution from exploration project to development project has presented multiple challenges for the technical team. Understanding and modelling the structural complexity of the deposit has been one of these challenges.Historically fault zones were logged as a lithology, with structural measurements recorded in a separate database table. When underground drill programs and development commenced in late 2012, it was recognised the deposit was more structurally complex than had been modelled. The extensive number of fault zone lithologies in core logging, made it difficult to identify fault trends and model faults in 3D software packages.In 2014, a structural project was conducted to produce a fault model for the deposit. The project highlighted that by logging the faults as a lithology, a shortage of fault characteristics was being recorded. Additionally, structural information could not be filtered to identify different fault sets due to the lack of information available to filter on. One of the major outcomes of the study was to change the methodology for the structural logging of drill core.Faults are now logged in a separate structural log. The structural log collects two types of information: interval data and point data. The interval data represents the damage zone of the fault in the surrounding rock and the point data the plane of movement for the fault. The faults are further characterised by their intensity on a scale of one to five, the type of fault structure (fault breccia, fault vein etc), the minerals present on the fault surface and structural measurements when available.The new data set allows fault data to be filtered based on fault characteristics, making implicit and explicit modelling of the faults more timely and accurate. The data set can be used to produce fault wireframes as single surfaces from the point data or hanging wall and footwall surfaces from the interval data. The logging method and how its applied in fault modelling form the focus of this paper.CITATION:George, K, 2017. A new approach to logging and modelling faults at the Dugald River Pb-Zn-Ag deposit, North West Queensland, in Proceedings Tenth International Mining Geology Conference 2017, pp 315–320 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 20, 2017

By Lloyd F, Arnold D. A, Hagan T. O

This paper investigates the problems that are encountered in mining at extreme depths. It looks into the rock mechanic aspects, especially the high stress levels that will occur, and the hazard of rockbursts. Furthermore, environmental problems are discussed, with refrigeration and reduction of neat loads being major methods of maintaining ,sorkable conditions. The paper concludes that it will be of tmost importance to have a planning team of Tne highest quality to ensure that conditions are maintained so that work can be carried out safely and under reasonable conditions.

Jan 1, 1986

By Falbo A, Quarestima S, Cozza C, Barbaro M

A new synthetic reagent of the mercaptobenzoxazole class, 5- methyl-2-mercaptobenzoxazole, has been studied. This reagent exhibits powerful selective collecting action towards copper sulphides present in several complex ores, as demonstrated both by laboratory and pilot plant tests. Industrial production is expected to start in the near future. The way this reagent reacts with pure chalcocite has been studied utilising in situ FTIR techniques, adsorption tests, electrokinetic potential measurements and Hallimond cell flotation tests. The FTIR studies have indicated the nature of the surface phase. Adsorption isotherms obtained by the rest method have revealed the quantitative evolution of surface products, permitting the determination of surface coverage at various reagent concentrations. The electrokinetic potential has been utilised to verify the stability of individual species in diverse concentration ranges. Correlation of the results obtained has provided indications on the chemical interaction of this reagent with the surface and on the surface Arrangement.

Jan 1, 1993

By D R Quick

The Goodall gold mine is located 30 km east of Adelaide River, within the Pine Creek 1:250 000 map sheet, at 8 525 000 mN: 750 000 mE, on the AMG grid. The first gold was poured in April 1988 and the mine closed in September 1993, having produced 228 400 ounces of gold from 4.095 million tons of ore, at a head grade of 1.99 g/t. Oxide and primary ore was mined from one large open cut and low grade oxide ore from three smaller pits. The gold mineralisation was discovered in 1981 by means of a helicopter borne rock chip sampling survey, which delineated 13 discrete anomalies. Systematic grid sampling of rock chips outlined an area of 1300 m by 300 m within the 2.0 g/t contour. Over 7500 m of costeaning was used to delineate the A and B-Pod mineralised areas. Geochemical soil sampling played only a minor role in the discovery and geophysics none at all. By the end of 1984, 40 diamond drill holes had been completed and a resource of 3.63 million tonnes at 3.0 g/t calculated. In January 1985, Western Mining Corporation Ltd became a joint venture partner and funded exploration to cam a 60 per cent interest. Additional drilling led to a feasibility study in 1987, based on a Measured and Indicated resource of 4.25 million tonnes at a grade of 2.35 g/t. The host rocks are quartzo-feldspathic wacke and interbedded phyllitic siltstone, of the Proterozoic Burrell Creek formation. The main zone of gold mineralisation, A-Pod, occurs in a sub-vertical vein array, up to 50 m wide and 800 m in length, of quartz and sulphide veins (5-20 mm wide), It is parallel to and on the east limb of an upright, north plunging anticline. Five types of veining have been recognised, with the bulk of the gold mineralisation associated with quartz-pyrite-arsenopyrite and chlorite-quartz-pyrite veins. The gold occurs as particles, from 1-20 micron, as inclusions and along fractures in pyrite and arsenopyrite and to a limited extent in chlorite. The mineralisation is epigenetic and structurally controlled by fractures developed during an earlier folding event. The gold is assumed to have been derived from the underlying sediments of the Koolpin Formation by hydrothermal fluids emanating from the deep seated northern margin of the Cullen Batholith. Precipitation of gold may have been controlled by variations in temperature and pressure.

Jan 1, 1994

By K Guilfoyle

AngloGold Ashanti Australia Ltd operates an underground mine below a large open pit at the Sunrise Dam Gold Mine near Laverton in Western Australia. Operations are based on an extensive mineralised zone which has very complex geometry, has a high ‘nugget effect’, and is difficult to interpret and model. Initial underground ore was produced from relatively narrow orebodies dipping from 15º - 70º. Open stopes aimed to selectively extract high-grade ore, using methods including jumbo stripping and longhole drilling and blasting. The complex geology makes it difficult to accurately locate development and stopes in the positions required for profitable production. In narrow stopes, rock mass damage and overbreak dilute ore grades and increase the cost per ounce of gold poured. In flat orebodies, several different techniques have been used to recover blasted ore but overall productivity is low. Thus selective mining can also be slow, costly and recovers only a portion of the available mineral resources. Large longhole open stopes with cemented paste backfill are used to extract multiple zones of mineralisation from the Cosmo and GQ orebodies. Bulk emulsion explosives and electronic detonators are used in all large stope blasts to reduce the risk of misfires and to accurately control blasthole initiation sequences and delay timing. Larger stopes improve productivity and significantly reduce direct mining costs, enabling the use of lower economic cut-off grades which increase the overall recovery of mineral resources. This paper reviews the evolution of open stoping at Sunrise Dam, the various mining methods and drilling and blasting practices used, the results achieved, and the lessons learned.

Nov 8, 2011

By J Shandro

This paper stems from recent multidisciplinary research between mining engineering and health researchers at the University of British Columbia and the University of Victoria, Canada. It considers the implications of a future state of sustainable mining development that places more emphasis on consideration of mine community health and sustainability within the definition of mine planning best practice. It reviews recently completed research studies on mining and other resource communities in British Columbia, Canada and a process undertaken by the research team to share research findings. It then examines the outcomes of this knowledge sharing process placing emphasis on the development of a more collaborative and enhanced mine planning process that integrates community- level indicators of health and sustainability to more effectively address mine impact-benefits. The paper concludes by discussing current initiatives that aim to benefit the mining industry, communities, and governments as they plan future mineral development projects.

Nov 22, 2011

By A H. Gray

Gekko Systems Pty Ltd engaged in the test work, design, manufacturing and commissioning of the pre-concentration plant at Silver Standard Resources Inc’s Pirquitas mine in the north western Jujuy province of Argentina. Testing of the ore at coarse feeds of between 2 and 12mm returned probable recoveries of up to a total of 95% silver into 50% of the mass fed to the InLine Pressure Jigs (IPJ’s). The plant has been designed and built based on the test results to include a preparation screen to bypass the fines that are naturally higher in grade and repulping of the coarse which is then pumped to three parallel trains of 2-stage IPJ roughing-scavenging. The target 50% yield to concentrate passes over a dewatering screen and the solids are returned back to the mill feed conveyor. The IPJ tails are transferred to a dewatering screen and solid rejects are stockpiled off the end of a transfer conveyor. All dewatered underflow products are processed via hydrocyclones to recover dirty water for use back into the IPJ circuit and return entrained fines to the fines bypass line.With the sulphide orebody being processed, the results from operations to date have shown that plant performance is matching the original laboratory sulphide ore testwork data. The objective of the pre-concentration step is to both reject gangue and achieve grades between 300-400g/t Ag to the float circuit as flotation recoveries are maximised within this range. The plant currently achieves overall upgrades of approximately 150% of feed grade with the IPJ only circuit producing an average 180% increase from calculated feed grade.

Aug 8, 2011

Using Dynamic Simulation Throughout a Process Plant's Life Cycle

Sep 13, 2010

By T Roberts

The transition of mechanical cooling refrigerants from their inception in the 1800s through to the current day has been driven by several factors. Original refrigerants such as sulfur and carbon dioxide, chloromethane and ammonia, whilst effective came with toxicity and/or flammability issues. In 1930 DuPont trademarked a new synthetic refrigerant known as Freon® 12, this development was the introduction of ‘chlorofluorocarbons’ (CFCs).Throughout the 1930s and 1940s additional synthetic refrigerants were developed, namely Freon® 11 and Freon® 22. Due to their non-toxic and non-flammable characteristics, synthetic refrigerants were extensively used for domestic, commercial and industrial applications for the next 60 years.In 1985, one of the first scientific papers suggested a potential mechanism linking CFCs and areduction in the density of the ozone layer. In 1987 the Montreal protocol is ratified; it is the first UN treaty to be ratified by every country on earth. Due to CFC’s ozone depletion potential (ODP), the treaty required the consumption of CFC’s to be reduced by 50 per cent over the next ten years. By 1996 the phase out of CFC’s (Freon® 12) is completed, the phase out of HCFC (Freon® 22) refrigerants comes into effect.On 1 January 2018 the phase down of HFC’s begins. Whilst having zero impact on the ozone layer HFC refrigerants have high global warming potential (GWP). As we transition through the HFC phase down (2018–2035) we are beginning to see the emergence of what some consider to be the fourth synthetic wave, hydrofluoro-olefins (HFO’s). HFO’s and their blends have zero ODP and low GWP’s, ranging from 150 to less than 1. The reduction in GWP with HFO’s typically comes at the expense of flammability, which is not ideal. Each refrigerant has its optimal application, therefor when considering refrigerant choices for mining systems, a complete assessment of the environmental, health and safety, efficiency and commercial impacts should be considered now more than ever.

Oct 12, 2022

By K J. Ward, C N. Hatton, J Scalia IV, C A. Bareither, D L. Spencer

The mining industry is experiencing change in the governance of tailings facilities (TFs). Guidance and regulations across many jurisdictions contribute to this amorphous change. The Canadian Dam Association, Mining Association of Canada, Australian National Committee on Large Dams, and the Global Industry Standard on Tailings Management, produced by the International Council on Mining and Metals, are establishing guidelines for more rigorous industry governance. Evolving guidance regarding TFs is developing concurrently with a shortage of experienced tailings engineers, which adversely affects the resource base available to support new governance. This paper presents an updated semi-quantitative estimate of the impending resource shortage of qualified tailings professionals. Updates are provided herein for the estimated number of TFs worldwide, which included available data on active and inactive TFs, as well as the estimated labor resources required to service these facilities. The tailings labor shortage is discussed in the context of academic and professional training currently available to increase the quantity of trained personnel. This paper represents a discrete moment in time as contributions to the available information and inventories accessed continue to improve, but as of today are incomplete. However, the data and information included provide insight into the resource deficiencies currently within our profession, training and education opportunities to address those resource deficiencies, and a snapshot of a recent professional training course offered on mine tailings.

Jul 1, 2021

By X Zhang, Y Zhu, P E. Ngoepe, P P. Mkhonto, W Xiong, L Han, L Lu

The triazine molecules have not been given much attention and they are potential collectors that may positively impact the mineral processing industry. The adsorption of triazine as collectors such as sodium 2,6-dithio-4-butylamino-1,3,5-triazine (SDTBAT) on pyrite form a basis in design of flotation collectors that may be applicable in a wide range of sulfide minerals. The SDTBAT collector was compared with the sodium normal butyl xanthate (SNBX) and sodium normal butyl dithiocarbamate (SNBDTC). All collectors were adsorbed in their neutral form containing sodium on the pyrite (100) surface. The computational calculations found that the adsorption energies followed the order: SDTBAT (-300.35 kJ/mol) > SNBX (-186.10 kJ/mol) > SNBDTC (-163.78 kJ/mol). It was observed that the SNBX and SNBDTC adsorbed through the S atoms, while the SDTBAT adsorbed through the S atoms and N atoms onto Fe atoms. It is clear that the SDTBAT had a strong binding energy which is attributed to the presence of the triazine group that is electron depositing to the active S atoms compared to the SNBX which possessed the oxygen that is electron withdrawing. Moreover, the SDTBAT collector was found to bind stronger than the xanthate. This was complimented by microflotation tests that showed fast floating and higher recoveries of pyrite when using the SDTBAT collector than the xanthate and DTC. This clearly demonstrated that the SDTBAT is a potential collector to replace the xanthate collector due to its high selectivity and flotation power.

Aug 24, 2022

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

By Davis RA, Wasp EJ, Cowper NT

The transportation of solids by pipeline is not new. In 1891 a United States patent broadly covering a method of pumping coal with water was granted to W. C. Andrews. His pilot plant was constructed on what is now the site of the New- York Public Library in Manhattan. His process was applied to pumping coal mine waste back into the worked out portion of coal mines. On October 26, 1967, the world's first long distance iron ore slurry line was put into service by Savage River Mines. The commissioning of this 5.0 million dollar installation climaxed three years of development, testing, and construction and proved the Company's faith in pioneering' this unique transportation method for iron ore. This paper will discuss some of the more pertinent items in connection with that three-year period. Also to be discussed will be the operation of this line during the past eleven months.

Jan 1, 1969

By B L. Dickson, E, M F. Lee, P A. Mikula

Computational techniques are needed to assist in the analysis and interpretation of the increasing amounts of geoscientific and mining related data and information that are routinely gathered at mine sites. New interpretation methods are needed to provide an integrated approach so as to establish relationships (cause and effect) or to be predictive about possible outcomes based on acquired data. Traditional multivariate statistical methods are often confused by variable relationships that are non-linear, data distributions that are non-normal, and by the data themselves that may contain missing values, text and both continuous and discontinuous numeric values. Modern data mining methods are available to understand the relationships within and between diverse data sets, and identify relationships or trends associated with processes, measurements and mine design parameters in mines. The self-organizing map (SOM) is a data mining approach with the advantage that all input data samples are represented as vectors in a data-space defined by the observations (variables). The SOM procedure is an exploratory analysis tool that highlights patterns and relationships. Results are internally derived, in an unsupervised fashion based on measures of vector similarity. Our SOM outputs are highly visual, which assists in understanding and illustrating the dataÆs structure and internal relationships. Two studies are presented. The first uses SOM to investigate the relationships between a range of measured and derived rock property parameters and their observed behaviours during mining. Our aim was to determine whether a SOM analysis would allow a better understanding of observed and predicted rock behaviours from their rock properties. The SOM analysis showed that there were indeed relationships between æbrittleÆ, æsugaryÆ, æslabbyÆ and æsqueezingÆ rock behaviours and a number of the input parameters. The computed SOM æstructureÆ was then used to assess the likely behaviour of unknown samples by assigning them into behavioural fields based on their measured and derived geotechnical responses. The second study was aimed at assessing whether a SOM analysis of microseismic data at the Kalgoorlie Consolidated Gold MineÆs (KCGM) Mt Charlotte mine can contribute towards understanding and potentially forecasting/minimising seismicity at the mine-design stage. The database comprised 40 sample æclustersÆ of microseismic parameters from the MS-RAP software package, which were derived from 2500 individual seismic events. The SOM analysis showed that some of the initial mining conditions are related to the seismic parameters. In each of the studies, the SOM procedures assisted in understanding the data and provided new insights. Because of its æordered vector quantisationÆ foundation, the SOM procedure is a substantial improvement over traditional statistical methods in three main areas:its ability to analyse data from disparate sources, including different data types; its ability to analyse sparse data sets with missing values; and its ability to analyse and visualise non-linear relationships within a data set.

Jan 1, 2006

As has been the case since the early Phoenician traders, the minerals used by modern man come from deposits scattered around the globe. The price received is more and more being set by worldwide supply and demand. Thus the price component in the profit equation:Profits = Material sold (units)x(Price/unit û Cost/unit) is largely determined by others. The recent price history for two of the major metals, copper and iron, are given in Figures 1 and 2, respectively. As can be seen there has been a steady decline in the prices (when expressed in constant dollars) over the 20 years which have lapsed since the first of the International Conferences on Mass Mining, æDesign and Operation of Caving and Sublevel Stoping MinesÆ was held. If one would look back over the entire 20th century this would also be the trend. Cost containment/reduction through efficient, safe and environmentally responsive mining practices is serious business today and will be even more important in the future with increasing mining depths and more stringent regulations. A failure to keep up is expressed very simply as: Profit This, needless to say, is unfavourable for all concerned (the employees, the company, and the country or nation). The mining companies have had to look at ways of reducing the expense part of the profit equation while maintaining safe, environmentally conscious operations. Table 1 summarises the rules for working in todayÆs economy.

Jan 1, 2000

By E Corpuz, J Weissman, S Winter, R Evans

The surface-to-inseam (SIS) directional drilling technique has been utilised at Oaky Creek Coal for more than a decade to predrain both the Oaky No 1 and Oaky North mining areas. The cumulative drilling program constitutes a total of 140 lateral and 200 vertical holes, and 405 km of lateral drilling.The use of SIS gas drainage has been successful with the following site-specific benefits being recognised:ability to drain German Creek seam gas contents to residual gas levels of new mining areas within an 18-month period from commencement of well productionstructural geological verification of the mine design well in advance of development mining occurring in an areaability to conduct successful predrainage of the overlying Aquila seam to reduce subsequent goaf emissions.Appropriate and up-to-date geological knowledge during the design and drilling process is a significant influence to achieving success. Vertical production wells need to be located in a position that is most effective to remove water from hole. The lateral hole should not include intersections with significant geological structure.SIS drilling provides continuous seam roof/floor data to help define seam geometry and locate geological hazards with high accuracy. In faulted ground and with variable seam gradients, SIS data can resolve geological ambiguities from seismic sections and enhance seam correlation that would otherwise be available only from discrete and closely-spaced infill vertical exploration drilling.Here, we review some examples of SIS configurations and practice to highlight key learnings in drilling long inseam holes (up to 1900 m per arm) ahead of development and mining. Aspects on prerequisites, evolution of network design, tolerances and drainage outcomes in a variety of geological situations are discussed as technical basis towards a viable and effective SIS drilling program.CITATION:Corpuz, E, Evans, R, Weissman, J and Winter, S, 2015. Surface-to-inseam (SIS) drilling at Oaky Creek coal mine – SIS design aspects and drilling environment, in Proceedings The Australian Mine Ventilation Conference, pp 93–104 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 31, 2015

By J Centofanti, D Conti, R Riske, C Morley, A Cook

Why is it so difficult? Why are there differences throughout the resources industry in how reconciliation factors are reported and calculated? Why is there no standard formula to use? These are common questions asked when mining companies try to compare reconciliation results across operations or attempt to undertake internal or corporate governance reporting processes. For many mining companies the calculation of reconciliation factors is often a very time and resource intensive part of mandatory reconciliation reporting. Some major mining companies, that move millions of tonnes of material per annum, dedicate full time resources to the calculation of reconciliation factors. The willingness of these companies to set aside resources demonstrates the value that operations place on good reconciliation reporting. Reconciliation is about measuring the variance between two like measures at different points along the mining sequence. It can be undertaken between predictive models, forecast plans and actual measured performance. Calculations are used to derive a variance between two sections within the mining sequence, with the result being commonly known in the resources industry as a æfactorÆ. Mining companies use the calculation of reconciliation factors as key performance indices (KPIs) to provide a æhealth checkÆ of their operation, with variances often pointing to issues either with the accuracy of the original estimate or the quality of the measurement being used in the comparison. There are many reconciliation factors that can be calculated and reported. This paper will set out, clarify and provide a recommended standard means of calculating each specific factor that, where adopted by a company, will ensure compliance with the international reporting codes, such as JORC. Using case studies from Rio Tinto Group (Rio Tinto) and BHP Billiton Mitsubishi Alliance (æBMAÆ), and the authors experience across a wide range of mine sites, the outline of a generic solution for tracking a parcel of material from the pit through to the port along with appropriate reconciliation factors is provided. The intention of proposing standardised reconciliation factor terminology and methodology is to provide the foundations of a system to enable communication and comparison across different commodities, companies and mines sites.

Jan 1, 2009

By C Yeung, N Swa, D Gribble, R Reupana

BlastLiteÖ is a low density explosive developed by Dyno Nobel and has been in use at BHP Billiton Iron OreÆs Mt Whaleback Operation since March 2004. The Mt Whaleback Operation utilises BlastLite because it offers an attractive alternative to ANFO in soft to medium strength rock types. Its use also reduces the amount of liquid fuel oil consumed and is well aligned with BHP BillitonÆs corporate Energy Excellence initiatives to reduce greenhouse gas emissions. This paper presents the:results of characterisation work completed on-site as a fourth year mining engineering thesis, and application and benefits of the product at Mt Whaleback. One of the key features of low density products is that the detonation is non-ideal. That is, the explosive does not react fully in the detonation driving zone. This manifests itself in that the product is highly dependent on charge diameter and confinement conditions. Dyno Nobel has access to the Vixen suite of detonation codes for characterising the ideal and non-ideal behaviour of explosives. The objectives of this work were to use the Vixen_i code to characterise the detonation performance of BlastLite, in order to understand the role of the bulking agent and to allow modelling of the explosive. The detonation performance was established by detonating a series of unconfined charges at various diameters and measuring the velocity of detonation (VoD). The work program consisted of sourcing and preparing cardboard tubes of various diameters (80 mm to 305 mm). The tubes were loaded with explosive at the BHP Billiton Iron Ore Mt Whaleback test range and detonated one at a time. Over the past three years BlastLite has been used in various applications across the site. Initial findings illustrate that shovel productivity from BlastLite shots was comparable to the baseline ANFO blasts. The study results were also backed with visual inspection and feedback from shovel operators. A work program is currently in place to develop different blends of BlastLite and TITAN« BlastLite to tailor the explosives to various blasting applications. The trials at Mt Whaleback are leading to future opportunities of BHP BillitonÆs satellite orebodies.

Jan 1, 2007

By M Yahyaei, M S. Powell

Mineral processing plants have become large and complex, generally through progressive expansions. Addition of a pre-crushing stage to conventional Semi-Autogenous-Grinding (SAG) and ball mill - crushing (SABC) circuits has introduced a complex materials handling system coping with +200 mm particles. Application of High Pressure Grinding Rolls (HPGRs) and implementing hybrid comminution circuits (ie, HPGR-SAG mill) requires proactive control of the feed size distribution to each unit. Application of Vertical Tower Mills (VTMs) and other fine grinding equipment to achieve a finer grind size, while maintaining the throughput, requires splitting the feed evenly between parallel units. Many of the conventional comminution circuits (ie, staged crushing and screening followed by staged ball milling) must deal with the transition from open pit ore, which is generally altered and soft, to underground ore, which is intact and hard, requiring existing crushers to produce a finer product to unload the ball mills.This paper presents common process improvement opportunities which have been identified during a number plant process reviews conducted by the authors in Australian and international operations. The operation of comminution circuits to known and accepted standards, which is explained in this paper, could improve the performance of circuits by between 5 and 10 per cent, generally at no capital cost and often at a lower operating cost. The performance improvement can be realised as throughput increase, a finer product size, or reduced operating costs (ie, energy saving, low maintenance, less consumables).Process optimisation opportunities presented in this paper include: enhancing materials handling and storage to avoid segregation; standard operation of screens to reduce misplaced materials; proper feeding arrangement and control of crushers to increase their utilisation; preparing proper feed for SAG mills to reduce grind size; splitting the feed evenly between parallel equipment to improve utilisation, and controlling operation of classification units to improve energy utilisation.CITATION:Yahyaei, M and Powell, M S, 2018. Production improvement opportunities in comminution circuits, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 233–248 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018