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By A. S. Macfarlane

The introduction of new technology into mining operations is seen as a strategic necessity by many mining companies, in order to improve safety and to improve operational effectiveness. Many attempts have been made in recent years to introduce new technologies into mining operations in southern Africa. Amongst these are noteworthy successes, as well as some disappointing failures. Often, the reason for failure does not lie with the technology itself, but with the work system into which the technology is introduced. Such failures may come with a significant opportunity cost, and have a detrimental effect on future development, simply because the system has not been adequately engineered, and the risks have not been adequately assessed and managed. This paper examines the reasons for such failures, and proposes a methodology to be followed to ensure successful and sustainable implementation of new technologies, such as to reduce technical and financial risk to the company, and to energize the workforce into ensuring the initial objectives of the project are met. The paper also focuses on the application of appropriate technology, and the development of technological applications which are commensurate with the level of development of the work environment into which it is introduced. The paper therefore focuses on the application of risk management, change management, systems engineering and feasibility analysis as being key elements of a successful and holistic technology implementation programme.

Jan 1, 2001

By I P. Hodkinson

SMC Resources Limited is implementing a selective mining approach at the Hadleigh Castle mine, formerly operated by Aurora Gold Limited. The main ore zone has a length of 250 metres and dips at 40 - 45¦ to the south. Gold mineralisation occurs in a variety of quartz-sulphide lodes in sericitised granodiorite. Shallow dips, alteration intensity and mineralisation style combine to make mining relatively difficult. Previously unworked, high-grade, shallow dipping (30 - 45¦), narrow quartz-sulphide lodes within the hanging-wall of the deposit are also being selectively exploited. Annual production of 35 000 oz Au is forecast from 185 000 tpa ore grading 6.5 g/t Au over a currently envisaged mine life of six years. Operations completed to-date include deepening the decline and access development of the first two levels beneath the previous workings. Longhole stoping operations have commenced in the main ore zone with air leg stoping also underway in the hanging wall lodes.

Jan 1, 1998

By Jack G. Hazan

The Critical Path Method is the modern scientific answer for solving the planning and scheduling problems inherent in today's complex projects. With this method, nothing is left to chance. All resources are controlled and kept to the minimum. The various phases are properly planned and strategically determined. Optimum conditions are evaluated for the most economical and fastest way to complete a definite project. The method must be fully understood and implemented with positive data and continuous feedback to obtain the best results. This paper covers the various aspects of the Critical Path Method and mentions some of its applications in the mining and metallurgical fields. T 0 progress to a higher state of human welfare necessarily involves sacrifices. The greatest sacrifice is to relinquish social freedom in favour of economic freedom. In the old days, for example, a cobbler was free to work at whatever time of the day he chose; today, he can't. He is now forced to adapt himself to environment and to work at stand-

Jan 1, 1965

By K B. Holm

This paper deals with the advances made at Syferfontein Colliery in the calculation and control of dragline methodology. The high capital outlay and operating cost of a dragline necessitates strict control of all aspects of the dragline operation. Before purchasing a dragline, a complete evaluation of all the parameters that can affect the viability, now and in the future, of the dragline operation needs to be completed. Such parameters as thickness of burden, material properties (swell), “castability”, pit width and pit length, etc. need to be considered.

Jan 1, 1994

By G. B. Quaye

The deep level gold mining environment is characterized by high stresses that give rise to intense mining induced fracturing of the rock mass surrounding the stopes. In a geologically disturbed region where the intensity of mining induced stress fracturing is high, the degree of faulting and/or the frequency of other geological features such as joints may pose serious strata control problems. Unfavourable intersection of these discontinuities namely, faults, joints and mining induced stress fractures tend to divide the immediate hangingwall into unstable keyblocks which, if not supported, may result in extensive falls of ground. Effective support strategies therefore demand detailed investigation of the predominant inclinations and orientations of these discontinuities. The orientations and inclinations of these discontinuities surrounding a deep level stope have been measured. The results are projected onto the lower hemisphere of a stereographic net to determine the factors that contribute to the falls of ground in the stope. The analyses reveal that unfavourable intersection of these discontinuities divides the immediate hangingwall into unstable wedges that may become dislodged between support units.

Jan 1, 1998

By T. Lindstad, V. Myrvågnes

In the production of high silicon alloys, carbonaceous materials like coal, coke, charcoal and woodchips are utilized as reducing agents. Primarily based on historical prices of charcoal compared to fossil reduction materials, the Norwegian Ferroalloy Industry has mostly been using coal and coke (char) as carbon source. The most important role of the carbonaceous material is to react with the SiO gas to produce SiC. The ability of the reduction materials to bind SiO gas can be measured and the value is recognised as the reactivity of the carbon source. This reactivity is one of the most important parameters in the smelting process in order to obtain a high yield of metal. The reactivity of the carbon materials is directly correlated to the material properties. It is known that the rank of the coal influences the SiO reactivity where low rank is beneficial. Coals of the same rank have however proven to have varying reactivity. In order to investigate how the micro-constituents of coal influence the reactivity towards SiO gas, three single seam unwashed coals of different origin which fulfil the requirements of the Norwegian Ferroalloy producers have been chosen. As the structure in the carbonized product is a function of petrographic constitution and carbonization parameters, the coals have been separated into different density fractions. The various density fractions of the same coals proved to have significantly different petrographic composition. The coals were carbonized according to a procedure simulating the conditions the coals experience when charged to an industrial furnace. Chemical-, physical- and petrographical properties of both the coals and the resultant chars have been thoroughly examined and correlated towards the SiO reactivity.

Jan 1, 2007

By Fernando Romero Lage

The purpose of this paper is to analyze detailed crushing and screening configurations and the interrelationship as they relate to mass flow balance, operating efficiency, plant availability and final production. The entropy of ore bodies limits the standardization of crushing and screening plants, however, consideration for a continuous and sensible assessment of the mass flow balance of the circuit will yield the best achievable results. Since energy costs have continuously risen in the last few years, it is imperative that these circuits offer low power requirements and low operating expenses. The paper will detail how the efficient implementation of continuous mass flow balance in the application of crushing and screening plants will generate quality improvement and process improvement, which will translate into bigger production and energy savings.

May 1, 2010

By K. Fleck

Energy West Mining Company (EWMC) has implemented a geologic program for improving stability and support requirements along deep two-entry longwall gateroads at its Deer Creek Mine operations located near Huntington, Utah. Together with geotechnical monitoring and concurrent review of mine seismicity in cooperation with MTI staff, it has become possible to improve longwall layout designs for two seam extraction of the Hiawatha and Blind Canyon seams. The geologic program consists of surface and in-mine exploration drilling, surface and in-mine geologic mapping, rock mechanics testing and detailed measurements of changes in depositional and structural conditions during development of every longwall gateroad. The geotechnical program consists of underground measurements at seven locations in two neighboring mining districts located in the Hiawatha and Blind Canyon coal seams under moderate to deep cover. Within the last five years, additional measurements, including data on seismicity and face conditions, have been incorporated into the data collection program for verifying the insitu coal strength and load transfer mechanisms for improving two-seam designs and support systems. Geologic mapping results are also used to predict local stability of headgate and tailgate entries, combining mine roof mapping, stratigraphic profiles of the coal and roof, and depth-of-cover information and dual-seam mine overlays, for use by operations personnel in planning roof and rib support for the retreating longwall sections.

Jan 1, 2012

By A J. Scogings, W J. Shaw

The successful development of industrial minerals projects requires an integrated, holistic understanding of the metallurgical and product performance test work in the context of the geological setting of the deposit and applied to mining, processing and marketing of saleable products. The product specifications provide the essential starting point for geometallurgical studies. A sound understanding of the desired product is needed to design and interpret a program of test work. Examples are provided from recent studies on bentonite and graphite deposits.For bentonite projects, the naïve testing of only the cation exchange capacity (CEC) as a measure of purity can lead to unexpected outcomes when the deposit is mined. The CEC attribute may remain the same, while other important properties such as pH and swelling index change markedly with depth, due to weathering and oxidation, leading to disappointing production outcomes.For graphite projects it is not enough to report only total graphitic carbon content (TGC). Knowledge is required of the in situ flake size and textures in addition to purity and flake size distribution of extracted graphite, which may all vary from one domain to another across the deposit. Such geometallurgical attributes of the ore will impact on the ‘basket price’ used to estimate the value of marketable parcels of expected product.Disclosure of such information must be considered part of fully informing the market. As with all new project developments, consideration of the JORC (2012) and VALMIN (2015) Codes requires disclosure of all material information. This includes the geometallurgical characterisation, ie those aspects of the mineralogy that impact on resource evaluation, ore reserve definition and project valuation.CITATION:Shaw, W J and Scogings, A J, 2017. The importance of geometallurgical test work for industrial minerals projects, in Proceedings Tenth International Mining Geology Conference 2017, pp 83–92 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 20, 2017

For establishing sustainable material cycle process in human system, a brand new concept should be created, which could recycle the waste materials, which are land-filled and discarded under present economical situation. The concept of 'RtoS' (Reserve (of waste) to Stock) to create 'artificial deposit' of the materials concentrate is one of the best ideas to be applied. From this viewpoint, separation technology, in especial, solid phase separation such as mineral processing technology contributes much to the concentration, making 'artificial deposit' with less energy consumption compared with melting and/or dissolving technologies. Results of rare metals concentration in the e-waste are also introduced as an example with combining novel comminution and parts/powder separation.

Sep 13, 2010

By D. Vogt, T. Hattingh

"This paper argues that the technology change to mechanization is also going to require a change in people. It presents a model for technological progress and adapts it to the mining industry. It then goes on to motivate the need for mines to become learning organizations in order to achieve maximum value from their people as they become less labour-intensive. In an important sense, mechanization is as much about knowledge as it is about technology.The change when a mine introduces mechanization or a level of automation is not simply one of technology but also a stage in the development of mining from ‘art’ to ‘science’. ‘Art’ describes a state of technology characterized by tacit knowledge, an understanding that comes only from experience, and has no formal procedures and little structure. In contrast, ‘science’ represents a state of technology where all the component processes are understood in detail, all knowledge is explicit, and processes and structures are formal.Studies of other industries, including metal part manufacture and aviation, show that each stage in the progression from art to science changes the nature of the organization and requires a different mix of skills from the workforce. Perhaps the most important change is the increase in knowledge and decision-making required as the technology gets closer to science.There is anecdotal evidence that South African underground hard-rock mines are not learning organizations. Mines by their nature are capitalintensive with long lead times from investment to returns, so there is reluctance to change from the original plans or to encourage staff to think independently. Particularly as mines move from art to science, this reluctance must be overcome.The important lesson for engineers involved in introducing mechanization is to understand that success or failure will be determined by the people involved, and not solely by the technology. The process will almost certainly require a culture change on the mine. We recommend that the mechanization team includes an expert in human and organizational behaviour to ensure that a receptive workforce and management are in place to accept the new technology when it arrives."

Jan 1, 2016

By R J. Holmes

An accurate knowledge of the chemical, mineralogical and physical characteristics of ores and mineral products that are mined, processed and traded is crucial to effective resource utilisation, plant design, process optimisation and finally quality control to ensure that contract specifications are met. However, all too often the responsibility for sampling is entrusted to managers and personnel who do not fully appreciate the significance and importance of collecting representative samples for analysis, and everyone seems satisfied as long as some material is collected and returned to the laboratory for analysis. Furthermore, sample stations incorporated into the design of new plants are often the first casualties when cost cutting exercises commence. This needs to change, because there is little point in accurately analysing samples if they are not representative in the first place. The resultant analyses can be next to meaningless and the effort taken to analyse such samples is to a large extent a waste of time and resources.Ultimately, a poor knowledge of the characteristics of ores and mineral products limits the ability of mining companies to optimise the life of ore resources and plant performance, and failure to meet final product specifications can have disastrous consequences, including price penalties and more seriously loss of sales contracts. It is high time that sampling is given the attention it deserves as the first critical step in the quality measurement chain.CITATION:Holmes, R J, 2013. The importance of sampling in the mineral industry, in Proceedings MetPlant 2013 , pp 34-49 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 15, 2013

Blasts should be designed so as to maximise the percentage of charges which shoot to a free face (Le, to a pronounced rock/air interface).Free faces should be rough, parallel and reasonably near to blastholes and, very importantly, concavely·biplanar relative to the charges (see Fig. 6b). The presence of biplanar free faces requires that each charge fragments and detaches its quota of the burden rock before the detonation of:1. later-firing adjacent charges in single-row blasts, and2. dependent charges in multi-row blasts.In multi-row blasts, biplanar faces are best achieved:1. by drilling blastholes on equilateral triangular grids,2. by selecting a VI, V2 or V3 initiation sequence, and3. by using down-the-hole delays.Biplanar faces start to be created only when the conventional value of effective blasthole spacing/effective burden distance (Se/Be) increases beyond about 2.4. Values of Se/Be less than about 2.4 result in planar free faces. Where biplanar faces are created, conventional values of Se/Be are invalid and appreciably greater than real values of Se/Be.

Jan 1, 1986

By James M. Barker

Industrial minerals are critical to most aspects of modern society. They are pervasive in both industry and in everyone's lives (McVey, 1989; Barsotti, 1993). They are also the dominant class of minerals produced in the United States but this fact is little known outside the industry. For example, in 1993 (U.S. Bureau of Mines, 1995, table 1) industrial mineral dollar value was double that of metals ($20.86 billion vs. $10.88 billion) and employment levels were nearly so (74,000 vs. 40,000). A further difference is that transportation tends to dominate production costs (FOB end user) whereas they are much less significant in other mining ventures or other industries. Finally, metal mines are more concentrated west of the Mississippi; industrial mineral operations are more prevalent to the east (U.S. Bureau of Mines, 1995, p. 16-17). The significance of transport cost is discussed in Part 2, which is essentially Barker and Austin, 1995. Part 1 will update and expand portions of Barker and Austin (1995) and provide a more detailed discussion of import/export relationships using a China/United States reference point because of China's dramatic influence on some industrial mineral markets since the mid-1980s (barite, etc.).

Jan 1, 1996

By Robert E. McIvor

"The Functional Performance Equation for ball milling circuits allows us to isolate the circuit classification system efficiency (CSE) from the mill’s grinding performance. The factors which affect circuit CSE are reviewed, with emphasis on water usage at the classifiers. It is shown that manipulation of such water usage can be carried out to improve plant grinding circuit efficiency, at times by more than 30 percent.THE FUNCTIONAL PERFORMANCE EQUATIONObservation of the feed and product size distributions going into and discharging from the mill in grinding circuits with low versus high circulating load ratios initially led to the definition of “circuit classification system efficiency” (or CSE, McIvor, 1988a), and ultimately the discovery of the Functional Performance Equation (McIvor, 1988b, and McIvor et al, 1992). The CSE is the percentage of “coarse” (typically with reference to the plus P80) size material occupying the mill (versus “fines” or product size material, finer than the circuit P80), and can be calculated by taking the average of the percentage of coarse material in the mill feed and mill discharge. As this also represents the percentage of the mill energy expended on targeted, coarse size material, it is directly proportional to overall grinding circuit efficiency and production rate. This is all clearly expressed in the Functional Performance Equation for ball milling circuits, which is derived as follows.We define “fines” as any product size material, and “coarse” as that targeted to be further ground, the two typically differentiated by the circuit target P80. For any grinding circuit, the production rate of new, product size material (fines) must equal the specific grinding rate of the coarse material (i.e. fine product generated per unit of energy applied to the coarse material) times the power applied to the coarse material."

Jan 1, 2009

Essential features of the role of the fill material in mechanized cut and fill mining are discussed, with particular emphasis on its dewatering and strength development after emplacement. The fill material is regarded as a chemically-reactive porous medium, the most important property of which is permeability. Methods are described for measurement of permeability and other fill properties and results of such measurements applied to develop an orderly approach to the operation.

Jan 1, 1966

Multiple regression analysis was used to predict elemental concentrations of copper and nickel in soils from consideration of the concentration of these elements in vegetation in an ultrabasic complex in New Zealand. Regression equations were computed from sixteen independent variables involving concentrations of ten elements in plant ash, and various physical factors such as slope and altitude of the site, and height of the tree. One elemental and one physical variable were significant for nickel at the 90 per cent level of probability and five elemental and two physical variables were significant for copper at the same level. Use of the regression equations explained 32·5 per cent and 26·5 per cent of the variance in the respective relative accumulations (amount in plant divided by amount in soil) of copper and nickel.Predicted concentrations of copper and nickel in soils agreed more closely with the observed values in the soils than did the levels of these elements in plant ash.Although the results may specifically apply only to the test area, the principles should have universal application.

Jan 1, 1972

By A. More, J. M. Míguez, J. Bullón

In 2000 Ferroatlantica started a project with the aim to develop a new casting machine for silicon and other ferroalloys. Until now, it has been cast more than 25.000 tons of silicon for the chemical and metallurgical market. This system has improved the process yield, productivity and product quality which place?s Ferroatlantica at the top of technology development in this field. After the first presentation of the Ferroatlantica?s casting machine at Infacon X, we would like to show the improvements in the control which have permitted us to increase the lifetime of the copper and to obtain, at the end of the machine, the right product size for the customer avoiding the current necessity of crushing and sizing the lumpy metal. Furthermore, we have improved the system in relation to the obtaining of smaller granulometries at the end of casting machine. Not only is this kind of machine cost competitive for special silicon applications but also for other normal ferroalloys with different specifications of size and thickness.

Jan 1, 2007

By A Hoyle, P Walker, D Bennett

The Phu Kham copper-gold operation located in Laos People’s Democratic Republic (PDR) is owned and operated by Phu Bia Mining Limited. PanAust Limited, based in Brisbane Australia, holds a 90 per cent interest in Phu Bia Mining Limited, with the remaining 10 per cent held by the Government of Laos PDR.The 12Mt/y copper-gold concentrator at Phu Kham commenced production in April 2008. Flotation copper and gold recovery from commissioning was consistently poor, due to the high levels of pyrite and problematic secondary and oxide copper species and non-sulfide gangue.The low recoveries of copper and gold from Phu Kham were recognised during the feasibility study design phase. A bulk sulfide flotation regime in roughing produced high recoveries, however a large capacity cleaning circuit was required and there was risk of not meeting saleable concentrate grade specifications. The installed design offered a capital efficient compromise to ensure that a concentrate grade of 24% copper could be achieved at acceptable recoveries.Incremental improvements in copper recovery were achieved by 2011 through conversion of conditioning cells to flotation cells in both roughing and first cleaning and increased cleaner capacity through the installation of a Jameson cell. In 2012 the Phu Kham Upgrade Project was commissioned to increase mill throughput, along with additional rougher and cleaner capacity to increase residence times at the nominal 16 Mt/y throughput. The marginal reduction in primary grind size due to the additional ball milling power also provided a small recovery improvement.This paper presents the development, design, implementation, and performance of the Increased Recovery Project commissioned in April 2013 which targeted the major causes of copper loss from the circuit. Based on fundamental and detailed test work and mineralogical analysis of concentrator streams, an optimised design was developed which has increased copper and gold recoveries by over 5% and 10% respectively. The Increased Recovery Project has positioned the concentrator to process high pyrite ores that were previously considered untreatable, and opened further opportunities for maximising flotation recovery by de-bottlenecking plant regrind and cleaning capacity.CITATION:Hoyle, A, Bennett, D and Walker, P, 2015. The increased recovery project at the Phu Kham copper-gold operation, Laos PDR, in Proceedings MetPlant 2015, pp 246–265 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 7, 2015

Direct reduced iron (DRI), produced by the reaction between iron ore and reducing gasses, is used as a source of low-residual iron, in addition to ferrous scrap and pig iron, in the production of steel mainly through the electric arc furnace (EAF) route of steelmaking. The main DRI technologies in use are those of Midrex and Hyl, but in recent years a myriad of newer processes emerged based on variations in feedstock, reducing agent and fuel sources. Since the beginning of the nineties, DRI has increasingly emerged as a cheaper, low-residual iron feedstock for EAFs, which have traditionally relied almost entirely on ferrous scrap feed. The main stimulus behind the interest in DRI has been the increasing popularity of the EAF and the ?mini-mill? set-up as the favoured steelmaking option compared to the traditional and much less flexible blast furnace/ basic oxygen converter. This, however, has been creating a problem with regard to availability of low-residual scrap, resulting in upward pressure on high quality scrap prices and leaving DRI, traditionally the ?expensive alternative?, as a much more competitive consideration. The second main determinant has been the increasing production efficiency of existing steel plants which, in the light of improvements such as continuous casting and near net shape casting, has been constraining the supply of low-residual domestic scrap, traditionally the prime source of EAF feed. The explosion of current and proposed DRI projects has been accentuating the mounting interest of global role-players in assuring the availability of reliable sources of low-residual iron units for the future, especially in cases where definitive competitive advantages exist with regard to proximity to primary sources of iron ore and fuel (gas or coal).

Jan 1, 1999