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By P Cooper

Continuous improvement using six sigma methodologies commonly follows the DMAIC methodology of define, measure, analyse, improve and control. A key requirement in the use of this approach is to ensure that data is trusted, validated and contextual. In today’s production environments it is common to find disparate technology comprising the system architecture and highly customised interfaces between the various technology layers. This complexity often leads to inaccurate data presented at the operations management layer or worse, data that is not trusted. Identifying defects and making corrective actions cannot be efficiently carried out unless trusteddata can be easily obtained with a production context. It is also common to find that disparate systems of this nature present information in multiple ways and through multiple presentation systems. This paper discusses how the use of web-based technologies in an integrated technology stack can aid the accessibility, accuracy and trust of data used in decision-making and also how a unified visualisation environment can lead to greater operator efficiency.

Jul 11, 2011

By Dredge K, Becker G

The successful dissolution of the valuable metal components of a solid phase is often a basic requirement for a successful hydrometallurgical treatment process. Sulphide concentrates are often an intermediate product in the production of refined metals. These concentrates need to be further processed to realise the contained metal values in a useful form. Pyrometallurgical techniques have tended to dominate, at least the initial treatment of metal sulphide concentrates. The technology described, Activox«, has been developed specifically for the hydrometallurgical treatment of these sulphide mineral concentrates, in particular those containing copper, nickel or gold. The Activox« dissolution technology coupled with the use of existing, or newly developed, downstream processing techniques, offers alternative processing options for the recovery of full value, saleable metal products. The technology is suitable for application down to relatively small scales opening up the opportunity for on-site production of metals even at modest scale mining Operations.

Jan 1, 1995

By Stuart M. S, Allen P. B

The Childe Harold deposit was mined by the Granny Smith Joint Venture (GSJV) from late-March through to early-December 1993. This was a fast-tracked mining project whose history began with an offer to purchase agreement being signed at the end of October 1992. A feasibility study was completed by the end of December 1992 after completion of a reverse circulation (RC) and diamond drilling program. Subsequent additional definition drilling culminated in a remodelling of the reserve by March 1993, by which time all necessary governmental and company approvals had been granted. The crucial aspect of mining Childe Harold quickly was to maintain oxide ore supply to the Granny Smith mill at the maximum possible rate for blending with existing fresh ore stocks. As a result, high production rates had to be balanced with

Jan 1, 1994

By B R. Castley

Consumable materials used in mines are often transported to the working areas down shallow angle decline shafts, typically at anywhere between 10¦ and 30¦ to the horizontal. The winding equipment is usually a relatively small single-drum winder and the material is transported in one or more cars, running on rails in the decline. The winding rope is attached directly to the cars, which are mechanically coupled together. For small rock hoisting declines, the cars are replaced with hoppers or skips. The winder is normally of basic design, fitted with only the minimum required safety devices and very elementary brake control. Since these winders are not ælicensedÆ and are usually located in remote areas, the standard of maintenance on the installations is often poor, leading to frequent accidents, resulting in runaways, derailments and broken ropes. These problems can be overcome easily with the application of the rope haulage principle. When large volumes of ore have to be transported to surface, belt conveyors are used on shallow angle inclines, or high-capacity friction winders are used in vertical shafts. Conveyors are limited to inclines no steeper than 14¦ and vertical shafts with large friction or drum type winders are extremely capital-intensive. Rope haulage systems can be used on decline shafts where the inclination is too steep for belt conveyors and too shallow for conventional drum winders. Rope haulage systems also offer a variety of safety, technical and cost advantages over other winding and transport systems. This paper describes the adaptation of the rope haulage principle to modern requirements and, combined with 21st century electronic technology, explains how the principle can be used as an efficient, safe and practical solution to some problems associated with the transport of materials, personnel and ore in mines. The authors describe the designs, methods of operation, safety aspects, automated control, loading and unloading facilities of modern rope haulage systems used for transporting personnel, material and ore. This paper considers a variety of systems already designed for different applications, from small material-only installations to multi-purpose and large rock-hoisting systems with payloads as much as 180 t. It also describes in more detail, a material transporting system recently commissioned in South Africa.

Jan 1, 2005

By B J. Hutchison, S Gannon, J Chambers, D Oko-oboh

The Kanmantoo copper mine is located in the Adelaide Hills area of South Australia and is owned and operated by Hillgrove Resources (HGO). The mine is a drill and blast, truck and shovel operation mining sulfide (chalcopyrite) ore located in chloritised andalusite biotite schist. The initial Kanmantoo open pit operation occurred in the 1970s, before falling copper prices closed the mine. In 2010 the mine was reopened by HGO and the Kavanagh cutback of the Kanmantoo pit was undertaken. The Spitfire, Nugent and Emily Star satellite pits were also mined through to 2015 before the latest steep wall Giant pit design was developed to take mining out to 2019.There are no major fault structures and only two significant shear zone structures exposed in the open pit walls. The main Garnet Andalusite Biotite Schist (GABS) unit is quite competent so the pit designs have therefore mainly been controlled by four distinct joint sets. This paper is a case study on the influence of the joint regime on the wall stability of the main GABS unit and how a better understanding of the joint regime and the use of rock reinforcement has allowed the steep wall design to be adopted.The paper also describes the remote geotechnical mapping and slope monitoring techniques used to manage the rockfall risks associated with the steep walled slope design.CITATION:Hutchison, B J, Chambers, J, Gannon, S and Oko-oboh, D, 2017. Case study of joint structure and the design and performance of open pit walls at the Kanmantoo copper mine, in Proceedings Tenth International Mining Geology Conference 2017, pp 355–364 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 20, 2017

Comminution Kinetics equations are developed to take into account difference of grindability of mineral components. The equations describing both batch and closed circuit grinding or crushing processes are given. These equations are applied to industrial data to derive comminution kinetic and classification characteristics of the component minerals in a multi-mineral ore. Control strategy based on these concepts is presented.

Jan 1, 1985

By G Pasin, F Wirfiyata, G Khomaeni, W Valery, A Maclean, A Jankovic

The grinding circuit at PT Newmont Nusa Tenggara (PTNNT) – Batu Hijau mine consists of two SABC (semi-autogenous milling, ball milling, pebble crushing) trains, including four 20'?×?33'6? ball mills that have been lined with steel liners since the commissioning of the plant in 1999. During 2011 and 2012 an industrial trial was conducted to evaluate Poly-Met liners (a combination of rubber and steel liners). These new liners were installed in two of the ball mills (ball mills 1 and 2) and operated in parallel with ball mills 3 and 4 with steel liners.The objective of the trial was to compare the plant performance with the Poly-Met and steel ball?mill liners with regards to wear life, mill throughput, grind size and total unit costs. The trial was conducted over the entire life of the liners. The evaluation methodology implemented consisted of frequent spot sampling around the ball mill circuits, complete surveys/audits in both ball mills, and detailed analysis of process data. This paper presents the results of the industrial trial and main conclusions.CITATION:Maclean, A, Wirfiyata, F, Khomaeni, G, Jankovic, A, Pasin, G and Valery, W, 2014. Ball mill Poly-Met liner evaluation at PT Newmont Nusa Tenggara – Batu Hijau mine, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 255–262 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

By G Kennewell

At 11 am Monday 8 September 1997, the successful detonation of the 5/9 Mass Blast at Pasminco - Elura was signified by the subsiding of æMt KevinÆ (a 15 m high earth fill mound). The blast was in response to earlier mine subsidence, which holed through to the surface affecting future stability of underground workings. The blast was a first for Elura which fires small tonnages regularly to avoid rapid oxidation of the ore. This paper discusses the strategy and the considerable planning that went into EluraÆs first blast of this magnitude in order to succeed first time round.

Jan 1, 1999

By Freeman N

A microcomputer based control system has been developed and implemented at ZC Mines (now Pasminco Mining). The control system maximises throughput at a product size set point while maintaining a "safe" cyclone underflow and mill operating pulp density.To characterise mill and cyclone operation over a range of ore types, 60 circuit surveys were carried out by ZC Mines personnel over a period of four months. The data for each test were model fitted to check for data consistency and to accurately estimate circulating loads.The model fitted results were combined with instrument readings (including in-stream analysis probe assays) and the data checked for ability to predict key variables such as product size and underflow density from measurable inputs.In the resulting control scheme, panicle size and underflow density are not monitored directly, but are predicted by regression equation models based on directly measured variables. The tonnage control loop uses a dynamic model to maximise responsiveness.The system provides a data log output to an mM compatible personal computer at programmable intervals. Comparative data logging over a period demonstrates substantially smoothed circuit performance.The grinding control system was originally implemented using Fischer and Porter micro-DCI controllers. The program has also been implemented on a distributed control system using a sequence oriented programming language.

Jan 1, 1990

By J Hartnett, B Tarrant, A Rayner, D O’Toole, P Davies

Since 2009, the Northern Territory and Australian governments have been working under a national partnership arrangement to inform a rehabilitation plan for the former Rum Jungle uranium mine. Part of the rehabilitation strategy is to backfill a flooded former pit (Pit), which extends down to 100m below the current pit lake surface and was historically partially backfilled with uranium tailings. It is proposed to utilise the remaining pit volume below water level to sub-aqueously store Potentially Acid Forming (PAF-I) waste rock which currently occupies large stockpiles across the site. The rehabilitation design and planning process undertaken to develop a strategy commensurate to project objectives and construction constraints involved the establishment of key constraints derived from the analysis of historic data sources and preliminary design efforts. Tabled strategies were balanced against dependent project tasks and project objectives, especially surrounding minimising disturbance of highly contaminated materials within the Pit. Ideas were developed in conjunction with industry input and review of case histories to develop a remediation solution that is constructible within the project timeframe and constraints.

Jul 1, 2021

By P Duuring

Late-Archean banded iron formation (BIF)-hosted deposits in the Yilgarn Craton of Western Australia are less well understood compared to the larger Paleoproterozoic, Superior-type BIFhosted deposits of the Hamersley Province. The Weld Range greenstone belt, in the Murchison Domain of the Yilgarn Craton, hosts two Archean, high-grade deposits, Madoonga (68 Mt resource at 57.7 wt per cent Fe) and Beebyn (62 Mt resource at 59.6 wt per cent Fe, ASX announcement 2008). Five main types of high-grade (>55 wt per cent Fe) iron mineralisation at Weld Range each display characteristic grades, tonnage, and contaminant levels, which affect exploration strategies and beneficiation methods:1. ‘Residual’ ore formed as a result of two generations of hypogene alteration of BIF. The first alteration phase replaced silica-rich bands with siderite and/or Fe-rich dolomite; the second phase involved the removal of carbonate gangue minerals and the concentration of residual Fe oxide-rich bands in the BIF via volume reduction. The product is a high-grade, high-tonnage Fe orebody, with minor contaminants.2. Magnetite-bearing shear and fault zones cut BIF along lithological contacts. These zones of secondary magnetite formed as a result of the addition of hypogene magnetite via the circulation of Fe-rich, hypogene hydrothermal fluids through BIF. This type of mineralisation produces narrow (low-tonnage), high-grade magnetite-rich ore zones with high levels of contaminants (eg SiO2, Al2O3) due to the difficulty in mining these zones.3. Specular haematite ± quartz-bearing shear and fault zones cut residual orebodies and magnetite bearing structures. They share similar characteristics to magnetite-bearing structures.4. Goethite-haematite supergene ore zones are controlled by brittle faults that cut BIF. These faults promoted the flow of supergene fluids through BIF and resulted in large ore zones with variable Fe grades and contaminants.5. Detrital deposits comprise transported BIF fragments and are intensely goethite-haematite supergene-altered. These orebodies are locally extensive, with moderate Fe grades.

Jul 11, 2011

The need for formalised geotechnical reporting has not been fully explored at many operations. With the continuing need to provide safer and more efficient workplaces, the requirement for good geotechnical reporting systems (as with other reporting systems) has become of greater importance.Historically, the risk from rockfalls has been the largest cause of fatal injuries in the underground mining industry. The response of the ground to mining is generally poorly documented at many mines. At Olympic Dam, it was found that the existing corporate hazard and incident reporting (HIR) procedure did not record enough specifics about geotechnical issues. A separate and more specific geotechnical reporting process was set up to address this problem.This paper examines the role that geotechnical reporting plays at the WMC Resources Olympic Dam Mine; from reporting and rectifying day-to-day geotechnical issues that affect the operation to documenting and analysing longer term trends.

Jan 1, 2004

By R Valenta, I Fahey, M Klawitter, N Spanswick

Zinc-Lead-Silver (Zn-Pb-Ag) mineralisation at the George Fisher Mine occurs in multiple structurally-disrupted stratiform orebodies hosted within a mid-Proterozoic sequence of calcareous siltstones and variably pyritic shales (e.g. Valenta, 1994; Chapman, 2004). The geological model for the mine has been constructed based on a large number of stratigraphic domains which have been defined using recognised patterns of the constituent rocktypes, aided by recognition and mapping of K-rich tuff marker beds (TMBs). The continuity of these domains has been affected by the presence of several sets of faults which are extensional in the plane of stratigraphy, leading to the common occurrence of fault-related stratigraphic gaps in drillholes. Recent improvements to the detail of the geological model have led to significant improvements in the head grade of ore at George Fisher, with relatively small loss of metal. Recognition and accurate logging of these domains requires a high level of knowledge and expertise amongst mine geologists. In order to aid this process, the George Fisher mine installed a Minalyzer CS (core scanner) on site, with the aim of using high resolution X-ray fluorescence (XRF) geochemical data and core photography to increase the speed, accuracy and consistency of the site geological logging system. This contribution describes some preliminary results from a research project aimed at using the Minalyzer CS XRF data to perform high-resolution rocktype identification and domain boundary mapping in drillcore at George Fisher. CITATION: Spanswick, N, Klawitter, M, Valenta, R and Fahey, I, 2018. Rocktype classification and domaining of complex stratiform Zn-Pb-Ag mineralisation at the George Fisher Mine using high resolution XRF Core scanning, in Proceedings Complex Orebodies Conference 2018, pp 58–59 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 21, 2018

In general the iron ore industry has been slow to adopt the Whittle Pit optimising software in the evaluation of iron ore deposits. The reasons for this are two-fold:the iron ore industry has developed techniques, usually bespoke software residing in the corporate offices of the respective iron ore companies, to establish their final pit limits; and the fact that the Whittle software doesnÆt easily lend itself to estimating a sales product of constant quality without maximising grade (metal content). The Whittle software is based on the work done by Lerch and Grossman (in the early 1970s), which proposed that graph theory be used to establish an optimal surface that maximises the revenue from a deposit. The maximised surface created in the pit optimiser is translated into a proposed optimal final pit shape that can be used by the mine design engineers as a target outline to lay out the final practical pit. By treating a geological and ore resources model that was created for an iron ore deposit as a subset of the recoverable resources estimation (RRE) type of geological models, the evaluation of an iron ore deposit and establishing the final pit is greatly simplified in the Whittle 4-X optimiser. Instead of trying to optimise the iron content of the deposit, the emphasis swings to maximising the extraction of a finished and saleable iron ore product. This is achieved by treating the finished saleable iron ore as an element in the multi-element Whittle optimiser. The quality of the finished sales product is represented, and the material that cannot be used in the blended product is also shown. Proposals for enhancing the functionality in the Whittle 4-X optimiser to make the evaluation of iron (and coal) deposits easier includes the creation of a new reporting function that will allow the user to specify which field(s) can be used as the divisor(s) for the reporting of the element grades in the model.

Jan 1, 2007

By J Lyons, M Hasan, D Pepper, C Vadeikis

Processing of large volumes of ultrafine ores has long challenged mineral processing operators because of lower recoveries and increased tailings. This has led to many deposits, or parts of existing deposits, being viewed as uneconomic. As the mining industry can no longer afford to overlook resources that require finer sizes to achieve liberation or result in high tailings losses, the need for technologies to address these issues has increased. Mineral Technologies (MT) worked with a prominent Australian iron ore producer over five years to implement an innovative gravity separation technology for the beneficiation of ultrafine magnetite. The magnetite mineralisation requires a liberation size of <40 μm and selective rejection of ultrafine silica prior to magnetic separation. Through collaboration with the client, MT applied their Lyons Feed Control Unit (LFCU) technology for the beneficiation of finely grained magnetite. LFCUs are widely used in the mineral sands and iron ore gravity plants, and in tailings applications, to recover water and provide constant high density process streams. This project was an extension of knowledge gained from these applications. Test work was conducted on-site, using 1 t/h pilot and 300 kg/hr laboratory scale units. This test work showed that the LFCUs could reject 20 per cent of feed mass to tails whilst recovering >94 per cent of Fe to product. This upgraded the feed from 53.7 per cent Fe and 19.7 per cent SiO2 to 63.8 per cent Fe and 8.8 per cent SiO2. Recovery by size data showed a minimum 88 per cent Fe recovery to product for <8 μm material and up to 98 per cent Fe recovery for the -38+25 μm fraction. The LFCU rejected 70 per cent of <25 μm SiO2. The information obtained from the test work was utilised in the design of the full-scale units which are due for installation at the project site in 2021. This paper outlines the results of this laboratory and pilot scale test work and how the data obtained was used to design the full-sized units.

Nov 8, 2021

By W A. Peck

Raise boring is the preferred option for constructing ventilation shafts in Australia. The trend has been towards larger diameters and longer single-pass shafts, and if at all possible, reaming through to the surface. The risk of raise failures, due to missed, unforseen or latent ground conditions has therefore been increasing, along with the need for better, more confident stability assessments.While the stability of specific weak zones and structures must be assessed individually, empirical rock mass classification schemes have been successfully used for about the last 20 years to assess general raise stability; eg the McCracken and Stacey method (M&S).Unfortunately M&S, as originally documented in McCracken and Stacey (1989), did not include a database of raise diameter and rock mass conditions versus actual performance. Nor was there a procedure for assessing the risk of failure due to adverse ground conditions. Peck and Lee (2008) published an Australian database of raise bore performance. Raise diameter and ground conditions, in terms of a lower bound Qr value, were presented for 50 cases versus raise performance. This paper updates the 2008 raise performance plot with more and SRF-corrected data. McCracken and Stacey (1989) had previously recommended that additional geotechnical data should be acquired and analysed when the proposed raise plotted on the unstable side of raisebore stability ratio (RSR) = 1.3, but the Australian data used in this study also suggests that all sites with Qr Contributions and sensitivities of various rock mass parameters (RQD, Jn, Ja, Jr, Jw, SRF, time-dependent weathering/deterioration) to raise stability and risk of failure are discussed. Numerous case studies are used to illustrate issues with stability assessments.As raises can now be remotely supported using sprayed fibrecrete, questions of time-dependency are also discussed. In recent times, contiguous piles, ‘mini-piles’ and grouting have also been successfully used to presupport or otherwise improve the stability of near-surface sections of weathered, or poor quality rock masses.

Mar 21, 2011

Hydraulic transport of coal has been used for many years on the West Coast of New Zealand to extract small blocks of steeply dipping coal. Recent development at Strongman 2 Mine has seen the use of high pressure monitors to cut coal and a corresponding increase in the scale of production.This paper provides a brief introduction to hydraulic mining, describes the present system used at Strongman 2 and discusses future potential development.

Jan 1, 1998

By Denholm W. T, Rankin W. J

The reduction of zinc from lead blast furnace slags using hydrogen was studied at 1300¦C as part of a laboratory investigation of zinc fuming. To perform the experiments, 300 g "spent slag" was melted in a crucible. Hydrogen was then injected into the slag through a lance and fresh blast furnace slag was added regularly in small quantities over a period of 40 minutes. Zinc added in the fresh slag was reduced and the zinc level of the bulk slag attained a steady state value of between 1 and 9% after about 10 minutes, depending on the gas injection rate. Because of the high reactivity of hydrogen, bulk supply of hydrogen to the slag was the rate limiting step at the flow rates used and it is believed that the gas-slag reactions in the system were at equilibrium. A partially/stabilized zirconia cell with a Ni/NiO reference electrode was immersed in the slags during the experiments and the steady/state oxygen potentials of the slags were measured. By using the experimental oxygen potential values and calculated values of the steady state concentrations of zinc in the offgas, the activity of ZnO in the slags was calculated from the Gibbs&apos;s free energy change for the reaction:

Jan 1, 1989

By Taylor R. N

Flow simulations have been performed on the flash-smelting burners currently used at KNS. This paper presents studies of the heat transfer between gas and particles at the burner exit. Gas and particle temperatures, velocity and concentration profiles of the two-phase flow are calculated by the mathematical model. The predicted gas temperatures have been favourably compared against values measured by thermocouples placed near the burners in the flash furnace. The predicted particle temperatures are also reasonable when compared with the measured temperatures.

Jan 1, 1992

By G Corder

Even though most major operating companies in the minerals industry have Board-level endorsed sustainability principles and objectives, design engineers typically have no mechanism that allows them to implement those objectives in their work. In addition, the existing project management systems do not readily deliver the innovative solutions needed to address key sustainability issues, such as those related to significantly reduced carbon emissions, minimal environmental impacts, and maintaining the societal ‘licence to operate’. SUSOP® (SUStainable OPerations) is an approach for the integration of sustainable development principles into the design of mineral processes, which has been developed through the Co-operative Research Centre for Sustainable Resource Processing (CSRP). Somewhat analogous to the well entrenched HAZOP (Hazard and Operability) studies, SUSOP® is a holistic, systematic and rigorous mechanism for identifying and assessing sustainability opportunities and risks at each stage of project development - from corporate planning, through design and operation, to decommissioning and rehabilitation – without compromising financial rigour. SUSOP® was developed, tested and enhanced through its application to real case studies in the minerals industry. This development path provided significant insights into the process of identifying and evaluating opportunities for improving an operation’s contribution to sustainability and its long-term business case.This paper will discuss the need for a methodical approach for integrating sustainability principles into mineral processing plant design, present the key elements of SUSOP®, and outline its development path through real case studies. In addition, the reasons why such an approach will have growing importance into the future will be raised.

Aug 8, 2011