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By E Villaescusa, A Kusui, R Talebi, R Hassell, C Arcaro

Northern Star Resources (NSR) operates several seismically active mines as part of its Kalgoorlie Operations. In order to successfully continue mining at depth in increasing stress conditions, strategies need to be developed to reduce, control and manage the impact of seismicity causing damage to the rock mass. Consequently, a research partnership was developed with the WA School of Mines (WASM) through Mining3. The main aim of the project was to develop appropriate ground support standards that could withstand the expected dynamic response with minimal to no rehabilitation required for the life of that excavation. The project utilised a design methodology for determining the required energy demand based on detailed geotechnical mapping, probabilistic analysis of wedge formation and an estimate of rock ejection velocity based on uniaxial compressive strength of the intact rock (Villaescusa et al. 2016). The ground support scheme consists of high tensile chain link mesh, resin encapsulated de-coupled posimix bolts and plain strand cable bolts, in one, or multiple passes together with plain shotcrete. Implementation of the design posed several challenges including how to install the chain link mesh, maintaining the required productivity, ensuring quality control, and understanding the interaction of the several ground support components within the scheme. The implementation of the system within a trial area was successful from development mining to open stope extraction. The most significant field verification of the system occurred with near field M+1.9 seismic occurring in proximity to an operating long-hole drill. Despite large displacements exceeding 0.5m in places, there was no significant ejection of rock or failure of the ground support system. Following the successful trial, the ground support design methodology and standards have been implemented across several NSR sites. The system forms the basis for the successful extraction of resources in future high seismic risk areas.

Mar 15, 2021

By Budiselic C, Hefter G

The uptake of gold by activated carbon from acid chloride solutions involves the reduction of gold(IIl) to metallic gold. Deposition occurs only on the surface of the carbon at localized active sites at first, and subsequently at less active areas. The rate of uptake depends on the surface area of activated carbon, which confirms results from a recently published study (de Siegel and Soto, 1984). Increased rates of uptake were observed at higher temperatures and lower chloride concentrations due to the decreased stability of AuCI4-, the major gold(IIl) species present. Recoveries of gold approached 100 per cent for a contact time of 60 minutes at 20°C in a well stirred solution initially 5 ppm in gold(III) and containing 0.5 per cent w/v coconut-shell carbon. The presence of 0.25 Mnitric acid or 100 ppm iron(IIl) had no detectable effect on either rate or efficiency of gold uptake.

Jan 1, 1985

By E Villaescusa, C Drover

The stability of access tunnels is one of the main engineering challenges in deep underground mine construction. Many underground hard rock mining operations are now reaching depths where the induced stresses are such that sudden and violent failure of the excavations can occur very soon after construction. The loading conditions on the installed ground support schemes are often underestimated by conventional engineering design methods. Therefore, the actual loading conditions often exceed the installed ground support capacity. This can result in failure of the excavations and, in extreme cases, potentially closure of mining operations amounting to hundreds of millions of dollars in lost production. More frequently, violent excavation instability at great depth causes operational delays, costly and unplanned rehabilitation, as well as risks to worker safety. In order to address this challenge, this paper briefly summarises a modern, innovative approach to the design and construction of mine development at great depth. The process follows seven main steps. The first step is to characterise the rock mass strength, structure and stress. The second step is a stability assessment, which identifies the plausible modes of excavation failure, based on the rock mass characterisation. The third step is the definition of an excavation geometry which is harmonic to the high stress conditions. The fourth step is to prepare a site-specific face destressing drill and blast design which will reduce the potential for rock mass instability during the development construction cycle. The fifth step is to accurately quantify the expected loading conditions on the installed ground support. The method of doing so is uniquely analytical and probabilistic. It is based on the natural mechanical relationships between rock strength, structure, induced stress and the physical characteristics of the instability, including its mass and ejection velocity. The sixth step of the design process is to specify a ground support scheme arrangement with sufficient strength and displacement capacity to exceed the rock mass demand by a safe margin. The final stage is to install the complete ground support scheme using mechanised technologies which minimise the exposure of the equipment operators to unsupported ground at the tunnel face.

Nov 29, 2022

The case study has identified and characterised additional subsidence arising from longwall mining above or under existing longwall goaf. It suggests that the magnitude, mechanisms and prediction methods for such additional subsidence are different between the two mining configurations. This paper presents a proposed method to predict maximum vertical subsidence due to longwall mining under existing longwall goaf. It suggests that, unless different results from further new cases become available, the findings presented in this article, including the aforementioned prediction method, be applicable to the majority of sites in New South Wales, where multi-seam longwall mining is to take place. This article also presents an important concept of 'overburden modification' due to multi-seam mining. A causal relationship between the above-mentioned additional subsidence and 'overburden modification' has been identified as a result of the case studies. Further investigations into the physical processes that cause such overburden modification will be fundamental to the understanding and management of multi-seam subsidence.

Nov 25, 2010

The history and milestones in the evolution of support systems utilised in the mass-mined chrysotile mines of Shabanie and King are discussed in detail. The use of block caving, false footwall or sublevel caving mining methods brings with it some major support problems, which are exacerbated, in our low rock strength mining environments. The paper discusses the various support elements and systems that have been used successfully or otherwise in these operations. Some predictions for the future of rock reinforcing in our ground conditions are highlighted, in relation to geomechanics, levels of mechanisation and production risk analysis.

Jan 1, 2000

By T G. Vizcarra, T J. Napier-Munn, A T. Karbowiak, M G. Hart

Squeezing extra performance from existing equipment (‘sweating the assets’) is key to continuous improvement initiatives, particularly during times of cost cutting where the option of spending additional capital to facilitate circuit upgrades can be severely constrained. A common challenge, however, is identifying the best combination of settings for different process variables, as their effects can be camouflaged by interactions with other process variables and, of course, noise in historical data.This paper describes a recent investigation at Boyne Smelters Limited to identify strategies to coarsen the product of its dry, fixed-speed, open-circuit AG mill, without the need for installing pre-screens prior to the mill. The product is used as insulation material for the reduction of alumina to aluminium, and an excessively fine product was inhibiting the ability of the cover material to dissipate heat from the underlying anodes. The approach was to undertake a series of experiments, designed according to statistical criteria, to elucidate the effect of key process variables (feed blend and power draw) upon the product sizing. The results provided clarity about what strategies would encourage the production of a more desirable mill product (with some surprises). The study is a good example of how properly designed experiments can identify hidden potential in processing circuits, thereby mitigating the need for capital-intensive upgrades.CITATION:Vizcarra, T G, Hart, M G, Karbowiak, A T and Napier-Munn, T J, 2018. Getting the most from existing processes: using cleverly designed experiments to optimise the line 3 AG mill at Boyne Smelters Limited, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 207–216 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

By J Knoblauch, D, P J. J Strobos, C Foggo

The Sally Malay Project is located 120 km north of Halls Creek in the eastern Kimberley region. Since commissioning, ongoing improvements on the plant have resulted in recoveries now greatly exceeding the initial design targets. The continual optimisation endeavours of the Sally Malay metallurgy department included an automation project that was done in close collaboration with Mintek. In this team effort, several problem areas were addressed and the FloatStar advance control system was successfully commissioned to stabilise and optimise the flotation circuit. The remote location of the Kimberley Nickel Mines operation, fly-in, fly-out roster and the current mining boom makes the acquisition of experienced flotation staff difficult. The implementation of an automated flotation control system reduces this burden and contributes to the training of inexperienced staff. This paper illustrates not only the process control improvements achieved as a result of the installation of the FloatStarÖ advanced control system, but also how it has assisted operational personnel with their understanding of the process.

Jan 1, 2006

It is difficult to evaluate exploration properties in a manner that is transparent, repeatable and easily re-calculated to cater for different geological interpretations, but the risk-based assessment methodology, the Geological Risk Method, developed and described by Lord et al (2001) attempts to satisfy all these criteria. This paper examines a case study example based on valuations of exploration projects conducted by SRK Consulting using this methodology, and describes some of the advantages and limitations of the method.

Jan 1, 2007

By H Park, V Sahajwalla

"Due to the increasing amount of gangues in iron ores, a beneficiation process is required more as a preliminary step for ironmaking process. However, mechanical grinding and washing of iron ore needs tremendous effort that increases operating cost. Therefore, there is a necessity of a novel approach to ironmaking which can tolerate considerable amounts of silica or alumina. In the present study, a high alumina-carbon composite pellet was examined for an ironmaking process. The effect of compositional changes in the CaO-FexOy-Al2O3-SiO2 oxide system on the reduction of carbon composite pellets was investigated in a purpose built thermo-gravimetric analyser (TGA) at 1473K (1200¦C). As a result, alumina increased the reaction rate of carbon composite pellets by increasing surface area, while silica decreased the reaction rate by lowering surface area of samples. Infrared gas analysis assisted with the reaction kinetics of carbon composite pellets through measurement of CO and CO2 in off-gases. This study will assist with establishing the new pelletising method which differs from the conventional fluxed pellets.CITATION:Park, H and Sahajwalla, V, 2013. Effect of CaO-FexOy-Al2O3-SiO2 oxide system on the reduction of carbon composite pellets, in Proceedings Iron Ore 2013, pp 467-472 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Aug 12, 2013

By C Slaughter, J C. Tien

Commonly held ideas about effective training have long emphasised the importance of realism. Realistic training builds better experience among the trainees and a better perspective on the training material, making training more effective. While great strides have been made in this realm for mine safety and mine rescue training there are still areas that can be improved. One possible area is the expanded use of a mine fire simulation program where the migration of gases and smoke can be realistically displayed in an emergency, and outcomes varied as different conditions are being simulated. The use of mine fire simulation software potentially allows for the creation of more realistic scenarios in that smoke advance rates can be measured and recreated in evacuation scenarios, or that gas readings in mine rescue training can be dynamically and realistically changed to show the effect that time has on the fire scenario.CITATION:Slaughter, C and Tien, J C, 2015. The potential use of mine fire simulation software as an enhancement for mine safety and mine rescue training, in Proceedings The Australian Mine Ventilation Conference, pp 285–290 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 31, 2015

The Kunwarara magnesite deposit is the largest known magnesite (MgCO3) deposit in Australia. It is located under black soil plains to the north of Rockhampton in Queensland. The deposit consists of magnesite nodules set in a fine-grained sandstone, siltstone and mudstone matrix. The magnesite is derived from weathering of serpentinite in adjacent hills and transport of magnesium in solution to a Tertiary/Quaternary river system. The magnesium has come out of solution in the active river system, and combined with atmospheric and biogenic CO2 to form magnesite nodules. The magnesite can be very pure with certain varieties up to 98 per cent MgO (LOI free). The deposit has been mined since 1991 and processed into magnesia (MgO) which is sold into refractory, agricultural and other markets. The geologist is an integral part of the small mine technical team. The role of the geologist includes characterisation of the ore through drilling and bulk sampling, supervision of geological aspects of mining and assistance in the optimisation of ore processing.

Jan 1, 2000

By J Mauk, J Rowland

The Karangahake epithermal Au-Ag mine consists of two main lodes, the Maria and the Welcome/Crown hosted in Miocene andesites. Mineralisation is strongly constrained to major structures and is genetically linked to dynamic tectonic processes. Two main periods of faulting are represented in the deposit: 1. NE striking right-lateral/normal oblique linked spatially and temporally with the mineralising system, and 2. ESE striking right-lateral/normal oblique post-mineral faulting that displaces the lodes. Paleostress analyses performed on a limited kinematic data set indicate NW-SE extension during the formation of the vein system. Veins and lodes strike NNNE and accordingly contain a strike-slip component. The kinematics of vein formation at Karangahake is broadly consistent with that of other deposits within a NNE-trending belt of deposits. Oblique shear on deflecting structures will create zones of compression and dilation. Dilatant zones created on steep structures create fluid pathways potentially focussing large volumes of fluid from deep parts of the system into dynamic structures.

Jan 1, 2003

By P Myers, T Elkington, S Wonday

Sierra Rutile LimitedÆs (SRL) heavy mineral sand mining operation in Sierra Leone, West Africa, is embarking on a new phase of its life. After confronting many challenges during the 1990s and 2000s, SRL is embarking on a strategy of growth to recover maximum value from the mine over the rest of its life. Sophisticated linear programming techniques have been used to develop an optimum strategy for extracting SRLÆs many known deposits of economic grade, while considering options for expansion and for a variety of mining and processing methods and combinations. CITATION:Myers, P, Elkington, T and Wonday, S, 2012. Strategic optimisation at Sierra Rutile - A case study in maximising project value, in Proceedings Project Evaluation 2012 , pp 59-66 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 24, 2012

By D K, S Freij, A Rossiter, X Han, B Feng

In mining operations, the removal of overburden to expose the ores is achieved by rock blasting using ammonium nitrate based explosives, eg ammonium nitrate-fuel oil mixtures, commonly known as ANFO. However, ammonium nitrate can react with pyritic shales that are often found in many mines, leading to premature detonation or spontaneous explosion. In order to minimise the occurrence of spontaneous explosion, the reactivity of the shale in a mine must be assessed. This will provide a better understanding of blasting risks and thus will improve the safety and the cost efficiency of blasting through the selection of appropriate explosives. In this study, shale samples were collected from different locations in Western AustraliaÆs Mt Whaleback iron ore mine and geochemically characterised. The reactivity of the shale samples towards ammonium nitrate and ANFO was investigated using a combination of large-scale firing range tests and laboratory isothermal reactor tests. Results of the firing range tests show that the reactive ingredients of the shale are the limiting factor for the reactions between shale and ANFO. Based on the firing range test results, further isothermal reactor tests were conducted to investigate the reactivity of shale samples towards ammonium nitrate under controlled conditions. Analysis of the results from the firing range tests and the isothermal reactor tests shows that there are correlations between the reactivity of shale samples and several geochemical characteristics such as sulfate, sulfur, ferrous and zinc content.

Jan 1, 2005

By K Williams, G M. Evans, S M. Iveson, K P. Galvin, C E. Loo

The Australian Research Council (ARC) has recently established an Industrial Transformation Research Hub in the area of iron ore, focused on iron ore characterisation, beneficiation, materials handling and end-use functionality. The research hubs are part of a new initiative aimed at building stronger relationships between industry and universities, while addressing issues of national significance. The ARC Research Hub for Advanced Technologies for Australian Iron Ore will focus its attention on developing innovative approaches for creating enhanced value across the full value chain through the characterisation of different ore types, beneficiation and materials handling and transport. This hub brings together five industrial organisations and a research team formed from well-established research groups based at the Newcastle Institute for Energy and Resources. These groups have a record of working closely with industry to create opportunities. Examples include new beneficiation technologies such as the Reflux Classifier for achieving gravity separation, the expertise of TUNRA Bulk Solids in materials handling and the Iron Making Centre at Newcastle, which is a capability maintained by BHP Billiton following the closure of its Technology Centre in 2009. The purpose of this paper is to provide an outline of the research hub and its objectives, some background on the research groups that now form the hub and an insight into the strategy adopted for developing and implementing new technologies. The paper also describes a range of novel technologies that have the potential to be developed and applied to iron ore beneficiation.CITATION:Galvin, K P, Roberts, A, Loo, C E, Evans, G M, Williams, K and Iveson, S M, 2015. Australian Research Council research hub for advanced technologies for Australian iron ore – an introduction, in Proceedings Iron Ore 2015, pp 7–12 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

By E Asakpo, S Chaffer, A Heath

Newmont has had continuous production at their Ahafo operations, Ghana, since 2006. In 2013, Ahafo initiated an efficiency programme to improve mill performance and reduce energy consumption. Following this assessment, a Turbo Pulp Lifter (TPLTM) was installed in the Ahafo SAG mill in April 2015 to replace the existing radial pulp lifters. Plant operational data showed delivery of a power saving of 10 per cent, an improvement in throughput of 3.3 per cent, with no loss of grind size. Pulp lifter life was also doubled from 11 to 22 months.However, during subsequent relines when the grates were removed it was found that one in four of the outer pulp lifters were wearing at a faster rate than the remainder. This was investigated by Discrete Element Method (DEM) modelling, which predicted some overtopping and internal recycle within the pulp lifter. Significantly, the model predicted that the recycled material would pass back down every fourth outer pulp lifter, matching the field observations. Subsequently, the DEM investigation was continued and became an R&D project to improve the TPL design. The results are summarised here, leading to the development of the next generation Spiral TPLTM.CITATION:Heath, A, Chaffer, S and Asakpo, E, 2018. The development of optimised pulp lifter design for the Ahafo SAG mill using discrete element method modelling, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 585–594 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

By J J. Cilliers, K Hadler

Air is fundamental to flotation; not only is it required to collect the valuable particles, but it also controls the froth stability and consequently the separation performance for a given feed. Froth stability can be described and quantified in numerous ways, which are subtly different. Air recovery is one such measure of froth stability which accounts for both the stability of the bubbles and the mobility of the froth. The benefit of using air recovery as a measure of froth stability is that it exhibits a peak as air flow rate is increased, and this corresponds to the air rate at which the optimal separation performance is obtained. As such, it provides a single target value for optimising air flowrate for a given set of feed conditions. Use of air recovery, however, has one potential drawback: accurate measurement of the inlet air flow rate to a flotation cell is required. This can be problematic for operations, particularly where calibration of air flow rate is carried out infrequently or where there is no air flow rate measurement, such as for many self-aerated flotation cells. To this end, we present an alternative method for determining the peak in air recovery (PAR) air rate.We introduce a simplified method for determining the PAR air rate using trends in froth velocity and overflowing froth height, both of which are readily measured using existing froth image analysis systems. We will show, using industrial data, the application of this simple technique to find the optimal air flowrate for flotation cells. We will also discuss other alternative techniques for air rate optimisation that have the potential to improve separation performance using existing technology.CITATION:Hadler, K and Cilliers, J J, 2018. How to find the optimum air rate for flotation cells, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 377–384 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

By K Nesbitt

Draw control at Premier Mine is considered important to avoid conditions of isolated draw, which results in early waste ingress, compaction of the kimberlite ore and loss of ore reserves. The Premier Mine kimberlite pipe is unique in that the pipe is cut at a depth of 400 metres below surface by a 75 metre thick gabbro sill. All cave mining at Premier is below the sill and failure to exercise good draw control could cause early ingress of gabbro waste. Gabbro causes problems in the diamond recovery plant and the amount of gabbro sent to the plant needs to be closely monitored. Fortunately coarse gabbro fragments are easy to recognise in drawpoints. It was anticipated that only 85 per cent of available ore would be drawn from the blocks immediately overlain by the gabbro sill before excessive gabbro waste forced the closure of drawpoints. Data on tons drawn per drawpoint and loaded per LHD as well as the tons tipped per pass is gathered by the vehicle monitoring and control (VMAC) system and information recorded by the load-haul-dump (LHD) drivers. Draw control staff monitor drawpoints on a shift basis and record the occurrence, type and height of hang-ups. Information pertaining to the status of the drawpoint in terms of support, waste and availability is also recorded. A database has been compiled that has been used to analyse the overall pattern of draw control, the frequency of occurrence of different types of hang-ups, secondary blasting efficiencies and drawpoint and LHD productivity. The gabbro sill has provided a unique marker horizon that has allowed the arrival of rock from a level 100 metres above the production level to be recognised. Data shows that ore migrates extensively towards groups of drawpoints that are heavily drawn with many drawpoints more than 100 per cent drawn before gabbro waste was recognised. This indicates that an accurate mixing algorithm is essential for good draw control. Data on tons drawn, drawpoint availability, productivity and the occurrence of various types of hang-ups has allowed better control of the mining operation and provided data for planning future caves. In the BA5 mining block a drawpoint spacing of 22 metres, horizontally across the major apex, has still allowed drawpoints to be pulled to waste with no loss of ore. In the BB1E mining block the drawpoint spacing has been increased to 23 metres and no problems have been experienced to-date. Future initiatives centre on improving the data gathering integrity of the vehicle monitoring and control system and a linear programme that will optimise draw control and productivity.

Jan 1, 2000

By G R. Ballantyne, B Putland, I Lovatt, M Di Trento

The Tropicana Gold Mine, owned by AngloGold Ashanti Australia Ltd (70% owned and managed) and Independence Group NL (30%) is located 330 kilometres east-northeast of Kalgoorlie, Australia, in the newly developed Albany-Fraser Orogen. Following extensive feasibility studies, a high pressure grinding roll (HPGR)-ball milling circuit was selected based on the reduced power requirements and thus reduced operating expenses. The HPGR-ball mill circuit was estimated to require 75% of the energy of a standard semi-autogenous grinding (SAG) mill circuit. Even with an anticipated greater capital cost, the HPGR-ball mill circuit was found to give significantly better financial returns in all cases investigated in the feasibility study. A comparison between the specific energy requirements of the HPGR, crush and SAG based circuits (SABC) from the feasibility work was conducted and the HPGR circuit was found to be considerably more energy efficient. A survey was conducted and the efficiency of the HPGR was similar to both the overall circuit design and the HPGR laboratory results, reflecting the accuracy that is possible for design and operation of HPGR circuits.Between 2015 to 2016, the Tropicana circuit has achieved a 20% increase in throughput from 780 to 930 t/h, and this increase has been maintained in 2017. This improvement can largely be attributed to upgrades to material handling processes, increased HPGR speed and smaller HPGR screen apertures. The result of these changes has been to increase the ball mill capacity by increasing the breakage conducted by the HPGR.CITATION:Ballantyne, G R, Di Trento, M, Lovatt, I and Putland, B, 2017. Recent improvements in the milling circuit at Tropicana mine, in Proceedings MetPlant 2017, pp 73–83 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 11, 2017

By R A. Medower

This paper provides a glimpse into the future of minerals processing with emphasis on æAutomation InnovationsÆ for the new millennium, particularly those involving advanced process control and innovative new applications of process control technology in 2007.

Jan 1, 2000