Search Documents

By B Banerjee, H Masoumi, X Shen, S Raval, D Tannant

Structural mapping of pit walls can be performed using digital images and photogrammetry software, but the performance is limited by weather and environmental conditions including dust, rain and light. On the other hand, active sensors such as terrestrial laser scanners (TLS) and total stations (TS) suffer from vertical orientation bias and occlusions when persistent discontinuities dip at the same angle as the scanner line-ofsight. The recent development of the compact light detection and ranging (LiDAR) systems has made it possible to mount these sensors on unmanned aerial vehicles (UAVs) or drones which offer the potential to overcome limitations that are inherent in existing mapping systems. This study details the research involving integration and application of an advanced UAV-LiDAR system for structural mapping of a highwall. A state-of-the art laser scanner with an inertial measurement unit (IMU) and real-time kinematic global positioning system (GPS) was integrated on to a UAV. The system was first tested in a laboratory condition. Then the UAV-LiDAR system was employed to map a highwall of a coal mine. The planned flight trajectories tested the system at variable distances from the highwall face and at various speeds. The raw data collected from individual sensors were fused, filtered to remove noise, and segmented to produce a surface scan model. Finally, the point density and surface coverage were measured using the surface scan model of the highwall. The parameters were compared with equivalent measurements computed from a reference TLS data. The study demonstrates the capabilities of a UAV-LiDAR system to generate accurate and occlusion free data for mapping highwall geological structure with very quick and efficient flights in the field. CITATION:Raval, S, Banerjee, B, Shen, X, Masoumi, H and Tannant, D, 2018. Evaluation of a UAV-LiDAR system for mapping geological structures in an open pit highwall, in Proceedings The Fourth Australasian Ground Control in Mining Conference (AusRock), pp 496–503 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 30, 2018

By S Karosiya, A Sharma, M Jain, N N. Viswanathan, M M. Pande, D Kumar, S Kumar

Desulfurisation of steel during ladle refining is governed by both thermodynamics and kinetics. For effective desulfurisation, thermodynamically, a low partial pressure of oxygen at the steel-slag interface and highly basic slag which possess a large sulfide capacity are desired. Kinetically, the mass transfer coefficient of sulfur in the liquid steel and in the slag determines the rate of desulfurisation. A fast desulfurisation rate is achieved by maintaining sufficiently strong argon stirring of the melt. In the present work, sulfur mass balance for steel and slag was performed after the desulfurisation treatment for several industrial heats. The decrease in the sulfur quantity of the liquid steel was more than the increase in the sulfur quantity of the slag. The discrepancy in the sulfur mass balance suggests that the sulfur could be transferred to: (a) the gas (via slag) phase; or to (b) the refractory (crucible) phase. The preliminary investigation of the refractory samples taken at slag-refractory and steel-refractory interface showed no interaction of sulfur with the refractory. Therefore, the possibility of sulfur transfer to the gas phase was verified by carrying out melting experiments of sulfur containing slag in an argon/air atmosphere. Sulfur containing slag was initially melted in an MgO-C crucible under an argon atmosphere followed by creating the air atmosphere just above the melt. Careful sampling and analysis from the cold spots of the crucible, much above the melt surface, revealed formation of a fibrous structure. Scanning electron microscopy energy dispersive X-ray spectroscopy (SEM-EDS) analysis of these fibrous deposits confirmed the presence of oxides and sulfides. Oxidation of sulfur containing slag under air atmosphere was also performed using a thermogravimetric analysis (TGA) set-up. It showed a constant sulfur loss in the range of 1300– 1500°C. Thermodynamic calculations carried out using FactSage™ ver 8.3 for these experimental conditions are in good agreement with the observed results.

Aug 21, 2024

By K Gottliebsen

Many hydrometallurgical and chemical processes produce large amounts of acid waste. This is illustrated by the copper S/X-E/W process used at the Mount Gordon mine in North Queensland, which produces a tank house bleed in the form of a concentrated sulphuric acid stream. The bleed stream is necessary to remove impurities such as iron that decrease the efficiency of the electrowinning process. However, this bleed stream comes at a high financial cost due to large quantities of make up sulphuric acid required as well as the need to neutralise the bleed stream prior to disposal. The present work describes the approach taken to develop a solvent extraction process for the selective recovery of sulphuric acid from copper tank house bleed liquor. The proposed extraction system was investigated using a branched long chain aliphatic tertiary amine tris(2-ethylhexyl)amine (TEHA) as the extractant, Shellsol 2046 as the diluent and octanol as a modifier. Computer simulations were used to determine the optimum operating conditions for the recovery process. It was found that the process was able to selectively recover up to 90 per cent of the sulphuric acid from the copper electrolyte. This is recovered as a pure aqueous acid stream at a concentration of up to 130 g/L that can be recycled back into the tank house circuit or other areas of the process. The raffinate acid concentration was reduced from 180 g/L to as low as 18 g/L, significantly reducing waste disposal and the environmental impact of the copper process. The equilibrium data and simulation results were also compared with an alternative extractant, CYANEXR 923. Finally the efficiency of the TEHA extraction system was investigated on a pilot-scale in a pulsed perforated plate column. This information was used in order to scale the process for an industrial application. The same methodology applied in this case study could be used to provide innovative and cost-effective solutions to waste streams encountered in other hydrometallurgical or chemical processes.

Jan 1, 2000

By P Louden, C Rothnie, G Showers

Tiwest employs several methods to assess the quality of heavy mineral concentrates in ore and process samples. Mineralogy is determined using a method called MA98, developed in conjunction with JKMRC over the last three years (Zhang and Whiten, 2001). A range of other techniques are also used to characterise ore, heavy mineral concentrates and mineral products. MA98 is the culmination of efforts since 1989 to determine mineralogy from chemical analysis without recourse to heavy liquid fractionation, which has traditionally been used to discriminate between light-heavy , zircon, rutile and leucoxene. The major advance with MA98 is the use of statistical mass balancing for all chemical species, as opposed to reliance on key chemical species for each mineral. Three magnetic fractions are analysed by X-ray fluorescence spectrometry, with a minerals balance performed for each. Heavy mineral concentrates processed by this method include drill samples, process samples from the wet concentrators and Dry Mill, and mineral products. TBE can be avoided for higher heavy mineral grade samples since quartz is determined from SiO2 balance. In this sense the method is sufficiently universal and robust to cope with a wide range of sample types and compositions. The MA98 algorithm provides abundant information in addition to mineralogy, including TiO2 and Fe2O3 grades of ilmenite and leucoxene, and concentrations of weakly magnetic zircon and kyanite. Information such as this is invaluable in tracking different minerals through the processing plants. Other ore assessment procedures used by Tiwest provide for modelling of orebodies by mineral sizings, Fe in zircon, and FeO and U+Th in ilmenite. Microscopy is used to provide important qualitative information such as grain shape, surface staining and degree of cementing. These quality measurements are included with mineralogy in geological ore models and are available for mine scheduling. In using the above methods to characterise heavy mineral concentrates, Tiwest is better placed to predict and monitor plant performance and product quality from any ore zone.

Jan 1, 2001

By L Ding, B Xu, C Wang

In this paper, we introduce the term ‘LJC’ to refer to the LJC Automatic Magnetic Flotation Separator, which is an advanced technology developed by Longi Magnet, integrating various techniques such as hydro separation, magnetic flocculation, and magnetic columns. This technology combines gravity, hydro separation, and magnetic separation to achieve efficient and reliable separation processes. With its low maintenance requirements and high reliability, the LJC technology has proven to be effective in magnetite processing. The LJC technology offers two primary benefits when compared to traditional magnetic drum separators. Firstly, it can enhance the quality of the targeted or improved concentrate at a coarser product size by minimising the carryover of gangue minerals into the concentrate. Secondly, it can significantly improve the concentrate quality (eg achieving >67 per cent Fe) while maintaining similar liberation size and mass yield. In China, this technology has been widely adopted in magnetite processing, replacing traditional magnetic drum separators and fines flotation in the final stage of the process. Through collaboration with a magnetite producer in Western Australia, Longi Magnet successfully implemented the next-generation LJC Automatic Magnetic Flotation Separator to replace the original stage 3 magnetic drum separators. The application of the LJC technology resulted in an increase in product P80 from 32 μm to 43.1 μm, while maintaining a final concentrate grade of 65 per cent Fe. Additionally, the power consumption, measured in kWh per tonne of concentrate, was reduced by 10 per cent. By eliminating the bottleneck caused by the requirement of a coarser liberation size to achieve the desired concentrate grade, the plant’s throughput was increased by significantly. The LJC technology has demonstrated its ability to reduce the carbon footprint, improve concentrate grade and enhance mass recovery, offering an alternative solution for magnetite processing. The high-grade magnetite produced by the LJC technology is particularly suitable as a raw material for Directed Reduction Iron and green steel production. This paper introduces the principles of the LJC Automatic Magnetic Flotation Separator and provides details of its application in a magnetite operation in Western Australia.

Sep 18, 2023

By G Simpson, S Dressler, A E. Levett

Tailings storage facilities often represent a mining operation’s most significant liability, posing serious environmental, social and safety risks. Almost all mining operations dispose of wet tailings (Valenta et al, 2023), which represents a risk of failure due to the potential for a rapid strength reduction of the unconsolidated materials leading to static liquefaction and subsequent dam wall failure. As a waste stream, tailings disposal, decommissioning and relinquishment aim to be inexpensive processes, ruling out many highly engineered solutions. Advantageously, tailings consolidation does not need to be immediate, opening the door for relatively passive, inexpensive consolidation methods that aim to gradually increase the strength of tailings over extended periods (ie years). In this paper, we present the prospect of novel in situ tailings stabilisation, learning from studies that have investigated the most erosion-resistant landforms on Earth.

Aug 2, 2023

By Q Zhou, H Nordberg, W Wang-Geissler

Efficiently controlling foam/froth within mineral processing continues to pose a challenge to the mining sector. The foaming characteristics of aqueous solutions for two-phase systems of air/liquid are well-studied with theories and mechanisms proposed to describe and predict foam formation and stability. The types and structures of reagents that either promote or prevent foaming/froth formation and stability are well-defined in these studies and practiced across various applications. Three-phase systems of air/liquid/solid, such as froth from mineral slurries, however, pose a challenge with the presence of a large quantity of relatively fine mineral particles. Theories and mechanisms that rationalise the effects of chemical additives as a defoamer or foaming agent in aqueous can be applied as a general rule, but do not provide the most effective solution for mineral slurry systems. Silicone-based defoamers, particularly their O/W emulsions, have been widely and successfully used at various stages of mineral processing to efficiently control the mineral slurry foaming properties. However, their foaming control ability could be significantly impacted by different processing aids used during the upstream process. In a zinc-rich mineral system, a silicone-based defoamer starts losing the properties necessary to effectively control foaming in the leaching circuit when throughput is increased. In this study, the synergistic defoaming/anti-foaming effects from surfactants and silicone-based defoamers are discussed to effectively control foaming/froth in the zinc leaching circuit, even with lower total defoamer dosage. Improvements during mineral processing can also lead to a cleaner mineral grade by reducing waste.

Aug 24, 2022

By P B. Schwann

The commonly accepted genetic theories of Pilbara iron ores and Woodie Woodie manganese ores have often presented them as quite unique. This apparent uniqueness is not confined to just iron and manganese, but is also seen in gold and copper deposits in Western Australia. The published material on iron and manganese ores would seem to have either a quite complicated genesis or none at all. An alternate theory for the origin of these deposits is presented which involves a protore with simple oxidation and pH controls with hydrothermal fluid sources from the diagenesis and dewatering of the underlying strata. This theory explains the distribution, thinning, cold dolerites and very high concentrations of deleterious minerals observed in these deposits. This genesis system is also related to the systems that deposit hydrothermal gold and copper in sediments in the region.This paper presents the author’s observations, sampling and mapping after several decades studying and exploring for the minerals in Australia and locations overseas. All of these theories were developed with (or in spite of!) the guidance of Mal Kneeshaw, but would never have seen the light of day without him and the others presenting here. It is not what I would call scientifically polished, and possibly deserves more detailed studies; it is, however, presented as a discussion paper.CITATION:Schwann, P B, 2015. Related genesis for iron, manganese and gold-copper ores in Western Australia, in Proceedings Iron Ore 2015, pp 327–336 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

By J Maxlow, M J. Woods, M P. Sandy

The Newcrest Mining Limited Telfer operation comprises both open pit and underground operations producing gold and copper. The underground operation is made up of three production areas, the sublevel cave (SLC), M Reefs narrow vein open stoping and Western longhole open stoping areas. With stoping situated on the abutments of a mature and active sublevel cave, the interaction between mining areas is often complex. This is particularly evident in the M Reefs orebodies with high levels of extraction in all four reefs, and reliance on pillars to maintain local and global stability. A key concern was the potential for a cascading pillar failure to develop and rapidly progress through the M Reefs stoping area. The monitoring plan needed to capture any change in overall stability and identify if deformation was caused by pillar failure within the M Reefs and hanging wall closure, or shear on the reefs caused by SLC influence.

Nov 29, 2022

By S Grimsey, E Janetzki, J Emery

Floor failure on the longwall face is a complex problem due to the dynamic interaction between the surrounding strata and powered roof supports involving multiple variables. It can also be highly problematic and costly when not well understood as there are significantly less remedies available post event. This was the early experience at the case study mine where significant lost time was incurred due to unplanned delays in the first two panels. To detect and prevent such occurrences is clearly the best approach, hence a tool to predict both floor failure occurrence and magnitude prior to mining was developed. Several parameters were determined as the key drivers for the failure events that had been experienced at this site. These parameters were, in list of influence from highest to lowest, material strength, retreat rate and the presence of water. The parameters were evaluated using a semi quantitative risk rating system ‘Heave Risk’ and given a weighting per their apparent influence. This ‘expert system’ methodology was selected as the use of risk rating systems in underground coal mining is well established. The heave risk model was first applied to previously mined panels. It accurately identified all areas of known major floor heave, with clearly defined areas of low and high risk apparent. The heave risk model was then used prior to mining and evaluated post mining based on observed conditions. It was found to also be highly accurate for prediction. The variability of each parameter and its influence on the overall risk rating is illustrated and discussed.

Nov 29, 2022

By C Linklater, J Chapman, A Watson

Closure options under consideration at some sites include backfilling mined-out pits with waste rock. Backfill may include mineralised and non-mineralised waste rock. Following groundwater rebound, flow-through conditions may develop in the pit post-closure. The backfill located in the saturated zone below the water table may release solutes under such conditions. It is therefore important to understand the potential impacts that backfilled pits could have on postclosure groundwater quality.Geochemical characterisation programs are the foundation for assessing the potential chemistry of water that has contacted mined wastes. Such programs must be designed to obtain data relevant to the closure options under consideration. To complement standard testing techniques, SRK utilises saturated column testing designed to generate data on leaching rates under anoxic conditions that could be encountered within submerged backfill.This paper presents the findings of saturated column test work carried out on waste rock samples from an iron ore mine in the Pilbara.CITATION:Watson, A, Linklater, C and Chapman, J, 2016. Backfilled pits – laboratory-scale tests for assessing impacts on groundwater quality, in Proceedings Life-of-Mine 2016 Conference , pp 110–114 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jun 28, 2016

By G Chitumbura

Raise boring is a critical aspect of mining at Xstrata Copper’s Mount Isa Copper Operations (MICO). MICO’s internal raise boring department regularly develops ventilation rises, orepasses and stope cut-off rises and reams approximately 2500 m per annum. Developed, trialled and implemented as standard practice over the past two years, procedural changes in constructing the raise bore machine’s foundations have significantly reduced operator exposure to raise boring’s inherent risks of working around open holes and manual handling. An additional cost benefit of this newly-adopted procedure is derived from reducing the likelihood of damaging the machine while de-rigging.When conforming to standard industry raise boring practices, exposure to an open hole begins when the reamer breaks through the concrete pad and ends when it is removed from the hole – a process which, depending on the size of the hole and the raise boring machine, can take up to three days to complete. Although wearing fall restraint equipment, operators working on and around the raise bore machine during de-rigging are continually exposed to the risk of falling from heights. In contrast, MICO’s newly-developed and successfully-implemented presink raise boring system reduces this exposure to a maximum of four hours, regardless of hole size. Exposure to manual handling hazards is also substantially reduced as the presink procedure eliminates manual placement of a 100 kg drill bit under the machine to commence pilot-hole drilling. Outcomes of implementing the presink System at MICO have been so beneficial that it is now standard procedure for all reaming in excess of 1 m diameters.

Mar 21, 2011

By J J. Van Wijk, A R. Penney

Successful management of geotechnical risk at a mining operation is more than just having a good ground control management plan or using advanced numerical modelling and the latest monitoring technologies. The fundamental requirements for effective geotechnical risk management include identification of potential failure modes, identifying and implementing appropriate controls, and demonstrating the effectiveness of those controls. Effective geotechnical risk management requires an integrated approach by confirming that appropriate risk management systems have been identified and implemented (management plans, procedures etc), and that these systems are executed consistently in the field across all working areas. Development of a thorough integrated auditing process executed by an experienced team of technical subject matter experts with substantial operational knowledge, provides a more complete picture of catastrophic hazard management. Following consistent evaluation criteria allows benchmarking of systems and implementation compliance between the sites being audited, and the results can then be ranked against other operations in an industry database.

Nov 29, 2022

By L MacDonald, D Molver, D Pepper

Increasing contamination/impurity levels (including arsenic, antimony, mercury etc.) of concentrates is an issue of global commercial and health / environmental significance. With increasing environmental pressures at smelters, penalties for contaminants in concentrates continue to rise, accompanied by lower reject limits. There is a strong incentive for miners to investigate alternative means to remove contaminants in order to increase the value of complex ores and concentrates. This paper discusses the global problem of contamination in complex ores and concentrates, how the Toowong Process technology is a potential solution to this problem, and the opportunities this technology brings to the business of dealing with deleterious elements. CITATION: MacDonald, L, Molver, D and Pepper, D, 2018. The Toowong process for treatment of complex ores, in Proceedings Complex Orebodies Conference 2018, pp 119–121 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 21, 2018

By S Pradhan, A Kuras, R Mahajan

This paper describes the design of the precast concrete segmental lining for the 13.1 m internal diameter and 450 mm thick, 2.4 km long mainline tunnels for the Waterview Connection project in Auckland for the New Zealand Transport Agency.The design and detailing of this segmental lining presented some noteworthy challenges, including an alignment that has sections of low cover in soft ground. Key points of interest are that this precast segmental lining is the largest to ever include steel fibres as the primary method of reinforcement and the lining includes cams on circumferential joints to control ring deformation.The paper describes some of the key design decisions that were made in a collaborative manner with the construction team, tunnel boring machine manufacturer, segment manufacturer and the designers.CITATION:Mahajan, R, Kuras, A and Pradhan, S, 2014. Design of segmental lining for Waterview Project, Auckland, New?Zealand, in Proceedings 15th Australasian Tunnelling Conference 2014 , pp 289–294 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 17, 2014

By B D. Saffron

In 1983, open cut coal mining operations were suspended at the Tent Mountain coalmine, located in Alberta, Canada in an area called Crowsnest Pass. Montem Resources (‘Montem’), an Australian mining company, purchased the asset in 2016. They conducted several drilling campaigns and undertook environmental monitoring with the intent to restart operations. In 2020, Montem completed a Definitive Feasibility Study, which indicated a mine life of more than 14 years.

Aug 2, 2023

By R Carstens, L Munsamy, L Prinsloo, C Huang, C Zhang, R Liang, I Canbulat

With recent advances in machine learning, data-based automated decision-making has been proven successful with promising outcomes in many industries. Its application in the mining sector can be ground-breaking; particularly the data-driven analytics that can support decision-making in the mine and consequently enhance mine safety, efficiency and sustainability. However, the current data science applications in the mining industry are mostly noncomprehensive, especially inadequate in evaluations, thus often requiring further study to be potentially beneficial to operations. Furthermore, it was found that existing literature paid limited attention to understanding the role of such techniques. Hence, in this paper we aim to build an end-to-end machine learning powered data-driven framework for intelligent geo-hazard analytics to support decision-making for underground mining data management, where multiple types of data are managed in an integrated database to support the unified machine-learning model. Here we present the framework as data-driven workflow processes, including data gathering, data preparation, data processing and data presentation. In addition, we present an application scenario of the proposed framework, where falls of ground (FoG) is managed with the historical FoG investigation reports, related panel hazard ratings, compliance data and rock mass characteristics. A demonstration can be dynamic forecasting of high-risk areas for FoG based on both spatial and temporal factors, including a 3D data visualisation. Such a scenario shows the potential of the proposed framework to establish connections among various data fields across a diverse category of data. Furthermore, the results offer important insights for ground instability management and can potentially optimise the underground operation flow.

Nov 29, 2022

By P J. Bangerter, J Pan

Optimising for Net Present Value (NPV) with a strategic optimiser such as COMET, Prober-E, Blaser or Minemax has hitherto lacked a dynamic method for analysing the so-called third-order outcomes (such as Carbon emissions) of optimisation within life-of-mine planning. Optimisation, per se, has natural effects on carbon emissions in a life-of-mine plan. Contemporary strategic planning employs a mathematical optimiser to make sense of non-linear data (ie a block model) and produces a best-NPV optimised mining schedule, within a set of constraints. The very act of optimisation influences emissions, and in a dynamic way.

Aug 2, 2023

By E Hernandez, I Agustian, W Kusumohastuti

PT Freeport Indonesia is completing the first underground gyratory crusher excavation at their Deep Mill Level Zone (DMLZ) mine located in the mountains of Jayawijaya, District of West Papua, Indonesia. DMLZ is an underground block cave mine with an expected output of 80 000?t/d and a scheduled production start in 2015.In order to deliver crushed ore to the mill through the existing conveyor belt, the DMLZ block cave mine will construct two 1000?kW 1.6?×?2.3?m gyratory crushers with their own respective ore flow conveying systems underground. Each crusher is composed of top, middle, and bottom chambers with an ore bin. This system includes a series of high capacity conveyors approximately 5 km in length including transfer stations and support facilities.The development methodology required a combination of lateral development by jumbo drilling machines and vertical development by mechanised raise climbers (MRC) due to the complexity of the chamber design.This paper will discuss the project scope, design and development methodology, ground conditions, innovative survey controls, and the challenges faced due to the remote location.CITATION:Hernandez, E, Kusumohastuti, W and Agustian, I, 2014. Excavating the first underground Gyratory Crusher at the Deep Mill Level Zone mine, PT Freeport Indonesia, in Proceedings 12th AusIMM Underground Operators’ Conference 2014 , pp 43–50 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Mar 24, 2014

By H von Blottnitz, A C. Keith

The influence of the life of a mine extends beyond its immediate vicinity both in geographic and temporal terms. Decisions around mine approvals are generally made based on economics, for the mine owner and immediate environmental and social impacts by governments and communities. The value from life-of-mine planning can also be viewed in a holistic frame across the entire value chain from mine to product user. This research examines the Carmichael Coal Mine in light of the holistic benefits and impacts along its value chain from the mine to relieving the lot of energy poor in India.CITATION:Keith, A C and von Blottnitz, H, 2016. Can Australian coal alleviate energy poverty in India – a case study, in Proceedings Life-of-Mine 2016 Conference , pp 52–56 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jun 28, 2016