Search Documents

By D van der Spuy, T Kewe, K Keet, N Moffatt, A P. Paine

The Blue Cube Mineral Quantifier Inline (MQi) instrument uses reflective light spectroscopy and advanced chemometrics to measure mineral or elemental grade in a slurry line. The instrument takes scans continuously and sends data to the DCS or PLC control system.Controlling the concentrate grades on a flotation circuit using low-frequency measurements can be difficult or impossible, especially on a circuit that has fast process dynamics. The ability to rapidly measure changes in grade makes it possible to continuously manipulate the flotation circuit operating parameters such as level, airflow and reagent addition set points to optimise plant performance throughout changing conditions.At Barrick’s Porgera mine in Papua New Guinea the flotation circuit feeds sulfide concentrate slurry to a pressure oxidation circuit. In order to maximise gold recovery in the flotation plant and increase performance in the pressure oxidation process, there is a stringent requirement to maintain a stable and optimum sulfur grade. The gold recovery is directly affected by the sulfur grade as most of the gold at Porgera is submicroscopic and associated with the sulfides (disseminated?pyrite).Porgera considered various points in the flotation circuit for installing Blue Cube analysers. This was part of a plant upgrade to improve process control. Due to budget constraints it was decided to initially only install one Blue Cube analyser on the final concentrate stream of the flotation circuit measuring sulfur, sulfides, gold and particle size. The accuracy of the calibration results were very good for all these properties. The sulfur measurement was used in an advanced control system to optimise and stabilise the grade. The paper presents comparisons between mineral grades determined using analytical laboratory analyses and the online Blue Cube data measurements, as well as benefits achieved by measuring grade online. An analysis of the plant data before and after installation of the Blue Cube and the advanced process control upgrade indicate that the flotation recovery increased by 1.98 per cent.CITATION:Kewe, T, Moffatt, N, Strobos, P, van der Spuy, D, Paine, A P and Keet, K, 2014. Evaluation of the Blue Cube MQi slurry analyser for application in an advanced control system for the optimisation of a gold sulfide flotation circuit, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 357–362 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

Thermo Fisher Scientific is the worldÆs leading supplier of analysers for laboratories and process industries. The companyÆs X-ray fluorescence (XRF)-based slurry immersion probes were originally developed by the acquired Amdel Instrumentation. These analysers have found limited application within wet beneficiation plants for measurement of iron. The recent trend of renewed efforts to maximise recovery from existing resources and lower costs has increased industry interest in online analysis. In the mid-1990s the company developed online analysers (the light element slurry analyser û LESA) for slurry applications using the prompt gamma neutron activation analysis (PGNAA) method. The company has successfully installed LESA for the direct measurement of lighter impurity elements in Brazilian plants using flotation for rejection of silica. A case study is presented. The PGNAA technique has the unique ability to provide elemental analysis of bulk materials on a conveyor belt. The company released its eighth generation cross belt Omni analyser using PGNAA in 2007. Results from a recent project with sinter are presented. The Niton range of hand-held XRF analysers is also supplied by Thermo Fisher Scientific. These handy devices are finding widespread use in the mining industry to provide quick and easy analyses in exploration settings. In contrast to PGNAA this is a surface technique. A prototype for light element analysis is being tested for iron ore.

Jan 1, 2007

Development of a global failure criterion for rocks has been a desired goal in rock mechanics. Due to variations in factors affecting rock specifications and their mechanical properties, proposing a single failure criterion suitable for all rock types has proven to be unachievable. The theoretical failure criteria do not fit the real data correctly. Amongst empirical criteria, the Bieniawski criterion has demonstrated an acceptable agreement with laboratory generated data. It has been experienced that the ability to estimate rock strength via the modified form of this criterion is significantly improved. Based on the modified Bieniawski criterion and using VB.net, an associated Microsoft Windows program named 'RAMOCE' has been developed. The inputs of RAMOCE can be triaxial compressive strength data, Bieniawski parameters of a specific rock or the type of given rock. Based on input data, potential outputs of the program are Bieniawski's rock parameters, sensitivity analysis of the effective parameters, rock failure prediction and defining the type of given rock.

Nov 25, 2010

By K Seddon

Segregation of tailings on deposition can occur as a result of a) sub-aqueous deposition, and b) sub-aerial deposition at lower solids concentrations (i.e. when the solids concentration is less than the segregation threshold). The effects are likely to be more pronounced in the case of subaqueous deposition.This paper presents the results of an investigation of a sub-aqueous tailings facility.Data from the investigation show extreme variations in particle size and density compared to test results for non-segregated ‘all-in” tailings. The results indicate that on segregation both the fine and coarse splits tend towards a well sorted (poorly graded) mix, and both have significantly lower consolidated density than the all in tailings. This result is reasonably well known for the case of the segregated fines (“slimes ponds”) but less appreciated for the coarse fraction. The results suggest that if the effects of segregation are not allowed for, the overall density of the deposit can be seriously over-estimated at the design stage. Also the quantity of water retained in the tailings can significantly influence water recovery and water balance results.CITATION:Seddon, K, 2018. Segregating tailings – effects on density and water retention, in Proceedings Mine Waste and Tailings Stewardship Conference 2018, pp 299–308 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 23, 2018

By G D. Richmond, J C. Chomley

Copper has been mined intermittently at Gunpowder, north of Mount Isa, since 1927. Most ventures have had some initial success but fluctuating copper prices, the small-scale of the operations and the remoteness of the site led to closures or sale. Processing routes have included direct sale of high grade ore, flotation of oxide and sulphide concentrate, and copper cement production from mine solutions. Copper cathode has been produced by heap and in-place leaching coupled with solvent extraction and electrowinning (SX/EW). Aberfoyle Limited recently purchased the Gunpowder operation and is expanding operations. An innovative high recovery tank leaching process, including a low temperature, low pressure autoclave, has been adopted. Copper cathode will be produced from an expanded solvent extraction/electrowinning plant at approximately 45 000 tonnes per year. The combination of expanded throughput and high metal recoveries will make Gunpowder a cost competitive producer.

Jan 1, 1998

By A D. Campbell, G R. Power

The increasing availability of marker data in sublevel caving operations is changing the way draw can be managed to achieve positive recovery outcomes in these mines. This paper describes how marker data has been incorporated into flow simulations to help calibrate full mine ore recovery simulations for the forecasting and optimisation of recovery.Some flow modelling techniques do not use marker data, relying instead on the outcomes of physical and numerical experiments to guide assumptions about an idealised recovery flow shape. Other mines have access to marker trial data, but find it difficult to specifically link this marker trial information to their recovery models. This can make it difficult to create a link between the marker trial information and recovery forecasting and limits the potential value of the marker trials at the mine.In the simulations shown here, the marker rings are fully incorporated into the flow model, and can be tracked in the model. The model is compared against the real underground marker recovery information to give the user an indication of how accurately the flow settings in the model are reflecting the conditions in the experimental marker rings. An example of use of this system at an operational mine is included.CITATION:Power, G R and Campbell, A D, 2016. Modelling of real-time marker data to improve operational recovery in sublevel caving mines, in Proceedings Seventh International Conference and Exhibition on Mass Mining (MassMin 2016), pp 105–110 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2016

By M S. Powell, M P. Bueno

The commonly used SAB, SABC and run-of-mine (ROM) ball mill circuits can achieve high throughputs with good operating stability. However, these circuits consume a substantial amount of grinding media, which can have a substantial impact on the OPEX and the æcarbon footprintÆ, specifically when viewed as an æembodiedÆ energy input. On the other hand, fully autogenous (AG) circuits can operate at much lower operating costs, but with limited throughput. The control of AG mills, fed by ores with hard and soft components, can also be challenging, due to the sensitivity of the mill to the ratio of hard to soft components.In this paper, a multi-component modelling approach was used to demonstrate that the harder component should be used as grinding media, and its use should be kept to a minimum to avoid reduction in the mill throughput. There is an optimal blend of hard to soft, and any optimal blending condition is both ore-dependent and mill-specific. Establishing this blend is challenging, and consequently discourages the use of autogenous mills. The new modelling approach addresses this challenge by providing a quantitative prediction of the influence of blending soft and hard components in a mill. This prediction can then be used to establish the required blend for maintaining a stable and efficient operation in autogenous grinding mode.CITATION:Bueno, M P and Powell, M S, 2012. How to use hard ore components as grinding media, in Proceedings 11th AusIMM Mill OperatorsÆ Conference, pp 31-36 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Oct 29, 2012

By V Yadi

Geostatistics has been widely used for more than four decades as a powerful tool in ore resource/reserve estimates and grade control. This method has gradually replaced the conventional method such as polygon and cross-section for grade estimation by more mathematical techniques such as kriging. The advances in geostatistical understanding and the availability of appropriate software packages have given much more contribution in speed and high accuracy during production. However, in many cases, these techniques are sometime applied without support with a good thorough understanding of the geological controls on metal distribution. To produce the result close to actual, the geological control in interpretation and appropriate geostatistical task is a must. Geological logging was described in the core must be consistent with the level plan produced by commercial modelling software used as a guide for grade control during production. Experience gained through evaluation of the Central I deposit resulted that the most effective systems continue to be based on geostatistical methods of resource estimation. Computer applications modelling software packages are necessarily as the core of an efficient in undertaking these assignments. They contribute to make a valued to data management and are becoming increasingly effective during processing. The latter role is particularly important to check the actual versus estimated values where will significantly to improve personnel to have a confident with their knowledge combined with experience and complete their jobs satisfy.

Aug 22, 2011

By P Knights

This paper examines the process and specialised skills required to extract insight from data routinely collected by mine operations, maintenance, engineering and environmental departments. Typical insights include: enhanced understanding of root causes; recommendations for next best actions; and simulation of likely scenarios. The skills required for advanced analytics are not currently the domain of mining engineers. The professions required by tomorrow’s mines are likely to be diverse and multi-disciplinary, and will include control engineers, software engineers, mathematicians and statisticians. A case study is presented that correlates mobile equipment production delays with rainfall events across three mines on the east coast of Australia. One mine is shown to have significantly more rain related downtime than the other mines, providing compelling evidence to improve productive performance.

Nov 22, 2011

By M T Roche

The Cannington deposit is one of the largest accumulations of silver-lead known. Located 135 km southeast of Cloncurry in North West Queensland (Figure 1), Australia, the deposit is currently in the feasibility stage of its development. The deposit is named after the nearby Cannington Pastoral Property which runs some 25 000 sheep on 'downs' country. The investigations of the Cannington deposit are carried out under the authority of Mineral Development Licences 139 and 144 and Exploration Permit for Minerals 6788, Answer Downs. Exploration for Broken Hill Type (BHT) silver-lead-zinc deposits in the Mt Isa region has been undertaken by The Broken Hill Proprietary Company Limited's Minerals Division (BHPM) since the early 1980s following in-house research which showed that the Eastern Succession of the Mt Isa Block exhibits characteristics which were favourable for hosting BHT

Jan 1, 1994

By T Belligoi

Diamond cores and drill chips provide the only direct physical evidence for ore containing rocks. Early characterisation of cores and drill chips is important as it provides critical information for downstream processing. Traditional characterisation techniques include visual logging by a geologist or analytic and spectroscopic methods but they are time consuming and can miss some important textural or geomechanical features.The goal of this work is to evaluate the application of image analysis to iron ore cores and drill chips and to suggest improvements to existing core-scanning and chip monitoring systems. Two samples of massive ore differing by their mineralogy and texture, as well as two different batches of drill chips, have been imaged and analysed. Results are compared in function of the imaging system and the classification algorithms.As a conclusion, despite the necessity for more testing and improvements in calibration and lighting, it is obvious that image analysis technologies can bring a lot of useful information in the perspective of a geometallurgical mapping of the deposit.

Jul 11, 2011

By M Medina, J Alexander, R J. Longey

Capricorn Copper Pty Ltd (CCPL) are operating the Capricorn Copper Mine located at Gunpowder, Queensland. As current holder of the environmental authority for the site, CCPL have obligations to rehabilitate areas of the mine that are no longer operational and have the potential to cause/contribute to environmental harm. CCPL sought a voluntary Transitional Environmental Program (TEP) to provide an agreed program of works to cap and rehabilitate the former Mammoth Tailings Storage Facility. The voluntary TEP contained conditions that were required to be met, to reduce the potential for environmental harm from the facility. The former Mammoth Tailings Storage Facility commenced use in the early 1970’s, and is an unlined valley in-fill structure, contemporary in design compared with other such approved structures of the era. The decommissioned Mammoth Tailings Storage Facility, now known as the Old Tailings Storage Facility (Old TSF), has been a legacy source of contamination due to the existing capping not meeting modern cover criterion, and allowing oxidisation and infiltration to the underlying acid forming tailings resulting in Acid and Metalliferous Drainage (AMD) from the facility. A cover design for the Old TSF, and other mine waste storages onsite that required clay capping, had been proposed by previous operators. Under the TEP cover design phase, it was identified that a key constraint was the lack of significant quantities of low permeability clay onsite. The lack of available clay prompted the consideration of alternate lining materials for the Old TSF, with a Bituminous Geomembrane Liner (BGM) being adopted as the preferred alternative. The BGM compared favourably with clay-based materials on seepage analysis, and led to other benefits by eliminating the need for borrowing clay off site, reducing the site’s environmental footprint, and reducing construction time. The BGM cover system on the Old TSF is being monitored with the intent to use this as a case study to confirm expected performance, enabling the cover design to potentially be adopted on the remainder of the site’s mine waste storages that require capping.

Jul 1, 2021

By C Nyoni, T Nguyen, C R. W Seymour, G D. Dempers

Unplanned dilution directly adds cost to production from mining, milling, tailings disposal and administration. Additionally, unplanned dilution decreases the productivity, profitability and may affect the planned life of mine. Identifying and quantifying the potential for unplanned dilution allows optimisation of the mining plan and mining practices to minimise the adverse impact on productivity and the cost of production. The Dilution Rating System (DRS) has been developed to more accurately predict dilution thickness and the variable potential for dilution, from individual stopes to life of mine planning. The DRS utilises the methodology developed for the Mining Rock Mass Model (Seymour et al 2007, Jenkins et al 2009) to generate a three-dimensional dilution rating model, which is then calibrated against stoping performance. Dilution can be predicted more accurately and the parameters affecting dilution can be determined and minimised through improved mining techniques, for example blasting and ground support design. Potential high dilution areas can be identified in the planning stages of the mine and systems put in place to mitigate the risk of excessive dilution. This paper presents the methodology used to develop the DRS and then successfully predict dilution for both the hangingwall and footwall of stopes at the Gara Gold Mine. This has enabled the expected dilution to be more accurately predicted and mitigated where possible thus reducing unplanned dilution.

Mar 15, 2021

By J Rola

This paper outlines a laboratory-based design method, founded in critical state soil mechanics, for identification of an appropriate compaction specification to ensure dilative conditions prevail across the design TSF stress range. The method makes use of the critical state line (CSL) and consolidation tests prepared at varying compactive efforts. The CSL and consolidation curves are plotted together in e-log p’ space, with the compaction curves transformed from vertical effective stress to mean effective stress using the coefficient of earth pressure at rest (K0). Consideration is given to the sensitivity of K0 as it is generally not available during the design phase. An example of the design method is illustrated with laboratory data.

Jul 1, 2021

By Y K. Leong

Occasionally additives are used in the wet processing of iron ore tailings and slurries, for examples, in the thickening of tailings with flocculant to recover process water, and in the smooth pumping of concentrated slurries. They can mitigate slurry behavioural issues that could significantly affect the plant operation and production. The nature of iron ore business requiring the plant to have a high throughput to be economical, large amounts of slurries are therefore processed every day. The quantity of additives needed will correspondingly be large and so are the associated costs. This could have a significant impact on the plant profitability. If additives are used they must be very costeffective. NaOH is among the lowest cost chemicals available, at ~US$400 per ton. In this paper we will look at use of composite additives involving phosphate compounds with NaOH added to reduce the cost, for the control of iron ore slurries rheology. The NaOH worked synergistically with the phosphate compounds. The effectiveness of these composite additives in viscosity reduction can be neutralised by another cheap additive such as lime or a Ca(II)-based salt turning the slurries back to being a paste. Tailings paste is an ideal material for safe storage in the dam. These composite additives can also be used to facilitate the recovery of iron ore at commercial grade from tailings (Leong, 2020a, 2021a).

Sep 18, 2023

By T Honeyands, L Jelenich

We are currently witnessing large fluctuations in the relative price of ironmaking raw materials brought on by changes in the dynamics of supply and demand, market conditions, environmental regulations and technical factors affecting the iron and steelmaking process. From a customer perspective, it is the behaviour of iron ores in downstream processing that give them their value; their impact on the sintering or pelletising process and subsequently blast furnace ironmaking. It is therefore important to consider this value when developing projects, making mine planning/cut-off grade decisions and in setting price differentials for differing quality.This paper describes the use of the Marx value-in-use model to quantify the downstream value of lump iron ores. The Marx model consists of heat and mass balance modules for sintering and pelletising and a rigorous two-stage heat and mass balance model of blast furnace ironmaking. Mass balance and cost models are applied for steelmaking, casting and rolling. The use of a heat and mass balance allows accurate comparison of the impact of raw material properties on blast furnace operation. The impact of minor elements, such as alumina, silica and phosphorus, and metallurgical properties on ironmaking is described, and examples are given for the calculation of a lump premium.CITATION:Honeyands, T and Jelenich, L, 2015. Lump ore properties and their impact on value-in-use in ironmaking, in Proceedings Iron Ore 2015, pp 359–362 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

By P Brown, M Nagarajan, A Green, P Dare-Bryan

Coal loss is an important issue at many coalmines, with losses of five per cent being common. The type of loss varies from mine to mine but is dependent on mine strata, the drilling and blasting processes applied and the mining method used. Typical coal loss mechanisms from the drill and blast process are coal roof damage and edge loss. Usually a reduction in coal loss is in direct competition with the need to provide material that is well-fragmented and a muck pile that has the required cast percentage. These competing issues were addressed over a two-year period at a mine in the New South Wales Coalfields by implementing a five-step approach. This was centred around building an understanding of the coal loss mechanisms utilising proprietary heave- modelling software, measuring coal losses by comparing survey to drill and/or gamma logs and implementing appropriate coal loss reduction processes. The end result exceeded expectations with a 95 per cent reduction in coal loss. Mine excavation productivity was maintained and coal loss minimised to less than one per cent of the in situ coal block.CITATION:Nagarajan, M, Green, A, Brown, P and Dare-Bryan, P, 2015. Managing coal loss using blast models and field measurement, in Proceedings 11th International Symposium on Rock Fragmentation by Blasting, pp 429–436 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 24, 2015

By G Forbes, D J. Bradshaw, G S. Heinrich, D

Traditionally, operators on mineral flotation plants have relied on visual inspection of the froth surface when making adjustments to process set-points. Machine vision systems are being developed to relate froth surface descriptors, which can be consistently measured in real time, to flotation performance. By investigating the impact of various selected operating variables on both froth surface characteristics and metallurgical performance it is possible to develop a management strategy for the control and optimisation of the process. This paper presents the results of testwork conducted at Kennecott copper mine which investigates the relationship between the froth colour and the concentrate grade and discusses the factors which affect the froth colour. This work shows that the main factors that influence the froth colour in this system are molybdenum, copper and iron concentrate grade, pulp and concentrate per cent solids and pulp iron grade.It goes on to develop models to predict the concentrate grade based on colour information and velocity and stability information. It also shows that the most accurate prediction is made with combined colour and stability information.

Jan 1, 2005

By P Craig, A Crosky, H Ramandi, S Saydam, H Chen

Frequency of reports on premature failure of rock bolts and cable bolts have increased in past two decades. Such a failure threatens both the safety of underground mine workers and the economic viability of the operations. Herein, we report on analysis of rock bolts and cable bolts failed recently in three underground mines in Australia. Magnetic particle inspection (MPI) and scanning electron microscope (SEM) techniques were used to study the failed bolts. MPI showed a number of subcritical cracks on the surface of the bolts. The majority of the cracks in both cable bolts and rock bolts were initiated from the base of ribs (indentation) where the stress concentration was high. SEM examinations showed tearing topography surface (TTS) in all failed rock bolts and cable bolts. These indicated that the failure occurred through hydrogen assisted stress corrosion cracking (HISCC). The results of this study enhanced the understanding about the failure of rock bolts and cable bolts in underground mines. CITATION:Chen, H, Ramandi, H, Craig, P, Crosky, A and Saydam, S, 2018. Analysis of premature failure of rock bolts and cable bolts failed in underground coal mines, in Proceedings The Fourth Australasian Ground Control in Mining Conference (AusRock), pp 407–413 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 30, 2018

By B W. Atkinson

Full-stream mechanised sampling apparatus, that collect a full cross-sectional increment from the complete screen discharge, will always be the preferred option for sampling screen overflows. However, the reality is that provisions for automated sampling are rarely, if ever, provided at the discharges of individual screens within beneficiation plants.Sampling from the discharge of high capacity vibrating screens, especially multi-slope screens, is subject to sampling bias, due to the stratification of the ore that occurs on the vibrating screen deck. The stratification in the vibrating bed translates to a stratified falling stream at the discharge end of the screen, typically with smaller particles at the back of the falling stream and large particles at the front of the falling stream (Figure 1).The chemical and physical characteristics of heterogeneous ore (mineral or coal) particles vary significantly with particle size. If samples do not correctly reflect the source material size distribution, they will be biased and the resulting analytical/assay data will not reflect the actual physical nor chemical characteristics of the source material.Prior published data for coal preparation research (Australian Coal Association Research Program) has demonstrated that a bias appears to exist for samples collected from high capacity multi-slope screens.A new form of sampling scoop has been developed with the aim of overcoming this issue.Bias was evaluated at a coal preparation plant by comparing the desliming screen overflow size distribution to that for æreferenceÆ coal preparation plant feed samples collected using the recognised stopped-belt technique. The study procured 20 sets of comparison samples in order to ensure statistical relevance.Two forms of sampling device were employed for the multislope screen discharge.A conventional square aperture scoop was demonstrated to exhibit a significant coarse bias, in that the resulting samples exhibited a significantly coarser size distribution compared to the reference samples. In other words it was evident that the conventional scoop æfavouredÆ material from the front of the falling stream.A new æcollapsibleÆ sample scoop was evaluated in parallel, and its samples were found to exhibit no relevant bias.CITATION:Atkinson, B W and Swanson, A R, 2012. A new method for sampling from high capacity screens, in Proceedings Sampling 2012 , pp 89-94 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 21, 2012