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By G Pattenden, R Hargreaves, P Pettit

"Even with the cyclic nature of mining, when it comes down to it, the bottom line is that whatever direction the commodity market is going there is always a desire to improve the economics of an operation in order to deliver a greater return to investors. Adapting to market pressures by introduction of an operational process change can often have a downstream impact. What may be less obvious is that reconciliation can play an important part in measuring the effectiveness of many operational changes. Through the adoption of best practice reconciliation and related comparisons, it is possible to measure the impact of changes across the mine value chain and identify variability that may have been introduced. Using analytical business improvement tools, examining and monitoring planned changes can be crucial in understanding whether the introduced changes have been effective and whether they have provided the expected result. Using several case studies, the authors will highlight the benefits provided by modern business intelligence tools, which can provide data validation and accurately report data trends related to both planned and unplanned change events.Citation:Hargreaves, R, Pattenden, G and Pettit, P, 2016. Measuring the Effectiveness of Change through Best Practice Reconciliation, in Proceedings Ninth AusIMM Open Pit Operators' Conference 2016, pp 71–83 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Nov 15, 2016

By Y Peng, D Wannas

In the fine particle flotation technologies being developed today the fine hydrophilic (gangue) particles are usually well dispersed. These highly dispersed fine particles can be recovered into the flotation froth product by mechanical entrainment. Flocculation of hydrophilic particles caused by polymer depressants could potentially reduce the mechanical entrainment of these particles. This paper reports testwork completed on fine particles of several solids, iron oxide, hydroxylapatite, galena and sphalerite, as well as on a relatively coarse quartz sample (-75+38 ¦m). Dodecylamine was used as a collector for the quartz, and several dispersants and polymer depressants, including sodium silicate, sodium metaphosphate, zinc sulfate, potassium dichromate, corn starch, corn dextrin and carboxymethyl celluloses (with molecular weights of both 700 000 and 80 000) were used as flotation modifiers. The major part of the testwork involved flotation tests in a 200 ml flotation column. Both water and solid recoveries were recorded. The degree of flocculation and dispersion was determined by settling tests in 250 ml graduated cylinders. It was observed that flocculation of the fine hydrophilic particles significantly reduced their mechanical entrainment, while dispersion severely aggravated it. Thus, in the flotation separation of artificial mixtures of the -75+38 ¦m quartz and fine iron oxide or hydroxylapatite, polymer depressants that caused flocculation were found to perform better than the ones that did not cause flocculation.

Jan 1, 2005

Minerals and Metals Group (MMG) Century mine (Century) is a large open-cut mine in northwest Queensland approximately 2.5 km long, 1.5 km wide and 240 m deep, with an ultimate pit depth of 320 m. In 2009, the mine experienced three failures which began as small failures, and progressively developed into significant multi-batter failures. The incidents were managed by a combination of analysis, redesign and practical management to achieve positive outcomes for the mine. On the south wall of the mine, a series of batter-scale wedge failures occurred in December 2007. Analysis of structure orientations and design changes aimed to minimise the risk of failure extending over multiple batters, while accepting a risk of further small-scale failures. Design changes were constrained by a culturally sensitive area (CSA) located south of the wall. As mining progressed, shallow wedge failures developed over multiple batters and cracks were observed 60m back from the pit crest, indicating that a large-scale wedge failure was developing. Movement increased in January 2009 as a result of significant rainfall. After considering several design options, the area was stabilised by a cut-back of the wall. Two multi-batter failures also occurred on the north wall as mining progressed through a structurally complex area. Both north wall failures began as small failures that progressively developed, and required a redesign of the wall below as well as practical management of safety aspects. The complex structural geology was difficult to predict ahead of mining, and required geotechnical input into design changes as mining progressed. All three failures potentially had significant impact for ore recovery, and were managed by a combination of analysis, redesign and operational management have resulted to achieve positive outcomes in a challenging mining environment.

May 1, 2010

For more than 15 years after the Northparkes orebodies were first discovered in 1976, the project was delayed by the need to find an economic way of mining the low-grade E26 deposit. The decision to use a low-cost block caving method to mine the orebody was made in the early-1990s; but the project's future did not solidify until 1993 when a radical new approach was adopted which sought to integrate business imperatives with technology and organisation strategies. The approach led to the establishment of a strategic vision which tied together all the components that could have a major impact on the project, to provide a framework for guiding strategic choices. The strategic vision strived to break away from the old rules of how mines are organised and operated; and involved finding imaginative new ways to radically redesign mining processes to achieve quantum leaps in performance.

Jan 1, 1997

Exploring long-term future possibilities for your business and methods for achieving them are critical functions of leadership. More than ever, strategic initiatives today have to be planned and delivered in an environment of disruptive change û driven by shifting business or regulatory imperatives, new technologies and global economic change, and diverse stakeholder interests. The notion of The Future as a single inevitable outcome is obsolete. There are many possible futures. This paper explains an innovative process û known as scenario planning û to help executives in the construction and testing of longer-term strategies to deal with uncertainty.

Jan 1, 2006

By L Smith, R Beckie

Controls on environmental loading from acid rock drainage (ARD) are not well understood in waste rock material. In particular, relationships between subsurface flow and the timing, duration, and intensity of leaching of metals and acidity from waste rock dumps remain ill defined. This study investigates field-scale relationships between subsurface flow processes and geochemical processes in unsaturated waste rock. A 12-metre tall, unsaturated waste rock pile, constructed in 1994, was deconstructed and sampled at Key Lake, Saskatchewan, Canada, during the summer of 2000. A detailed sampling methodology was developed to characterise physical and chemical properties of waste rock material within the waste rock pile. Physical properties were characterised by measuring soil-water suction, volumetric water content, and grain-size distribution at 60 random locations within the pile and grain-size distribution at 20 grid locations within the pile. Attempts to develop a field-based soil water characteristic curve from physical field-data failed due to spatial variability and hysteresis of waste rock properties. As a result, grain-size distribution was used as a relative measure of subsurface flow. Paste pH, pore-water geochemistry, mineralogy, and water-soluble extraction results were used to characterise geochemical processes and sulfide oxidation at each of the 20 grid locations. Geochemical characterisation results demonstrated the preferential weathering of marcasite relative to pyrite and chalcopyrite. Dolomite was the main buffering carbonate mineral. Gyspum, jarosite and iron oxyhydroxides were the main secondary minerals. Pore-waters contained up to 800, 11.7, and 6 mMolar (78 000, 690, 1400 mg/L, respectively) of sulfate, nickel, and uranium, respectively, suggesting significant weathering has occurred. Measures of weathering indicators show no discernable correlation with grain-size distribution nor do they show any spatial relationship within the sampled grid. Reasons for this may include limited duration of waste rock exposure to weathering and development of fluid flow-paths, and limitations of characterisation methods used. Indeed, six years may not be long enough for weathering patterns to develop due to fluid flow-paths in this unsaturated waste rock pile.

Jan 1, 2003

By T Niitti, J Turunen, P B, A Rinne

In todayÆs marketplace, with high metals prices, many operations are faced with the challenge of improving recovery in the particle size ranges which are normally difficult to recover. This presentation focuses on the various methods used to alter the flow dynamics in a mechanical flotation cell, thereby improving metallurgical results. Modern computational fluid dynamics (CFD) tools have been used in the design phase, with subsequent validation at the plant. Some of the validated variables include mixing profile, power draw and local air hold-up. This presentation underlines how modern CFD analysis can be used to screen and select different approaches before commencing costly trial-and-error experiments at plant scale. Two methods of affecting flow dynamics are discussed û firstly, by altering the geometry of the rotor-stator area and, secondly, by fitting additional features in the tank. The rotor-stator area can be modified to provide more concentrated turbulent kinetic energy or, respectively, to provide more pumping efficiency with less attrition. The tank can be fitted with various additional features, aimed to create different particle suspension profiles. The benefit of both methods is that they can be applied not only to newly installed flotation technology, but also to existing plant cells, thus enabling potential improvement in the mixing profiles, solids suspension, tank sanding and metallurgical performance. Results of several sitesÆ tests are discussed in terms of flow variables measurement as well as metallurgy. This paper demonstrates the effects of different flow dynamics on the mixing profiles and metallurgical results of existing mechanical flotation cells.

Jan 1, 2006

By C A. Chaves

During most of its history, the metallurgical industry has been seen as a source of pollution for the environment. However, during the second half of the 20th century, as the world environmental legislation became more protective and the global environmental conscience consolidated, this landscape began to change. Metallurgical activities have become increasingly related to the social and environmental impacts caused by human activities. With the adoption of environmental management in steel plants, there has been a significant change in steel-related activities which have begun to introduce modern plants, managed with environmental, social and productive efficiency. More and more, steel companies search for a decrease in negative impacts of their industrial operations on the environment, fitting them to the current environmental legislation and even increasing productivity and profitability. The steel industry has started to become a clean and more efficient industry. This work presents a case study of a sustainable steel plant project, located in an environmental preservation area. The project includes treatment and reuse of industrial liquid effluents, air emissions control, noise control, recycling, recovery and adequate waste management. It also incorporates production processes using clean technologies, capable of coproducing energy resources which may be used in the plant showing how is it possible to produce steel with environmental and social responsibility and even increase the enterpriseÆs profitability.

Jan 1, 2009

Beach sands on the Morobe coast of New Guinea contain significant amounts of chromite. This chromite, together with the more abundant associated minerals such as olivine, enstatite, tremolite, antigorite and feldspar has been de- rived from rocks of the Papuan Ultramafic Belt and transported to the beaches by three rivers, the Paiawa, the Saia and the Sesimbai. Of the hundreds of samples taken, 26 have been analysed mineralogically and chemically in some detail. On this basis, five groups of samples, four on- shore and one offshore, representing character- istic mineral assemblages, have been recognized. The chromite grains themselves have been exam- ined to determine variations in amount and in the Cr/Fe ratio, since this is of economic importance. Much of the chromite fails to reach a high Cr/Fe ratio as a result of magnetite rims around chromite grains. The precious metal content of the sands is negligible.

Jan 1, 1973

By M C. Evans

"Mine decommissioning is the final phase in a mining project. Planning for decommissioning must commence for a proposed mine even before the government approves it. Queensland mining approvals require proponents to commit to completion (or closure) criteria defining successful rehabilitation. Queensland mining project statutory environmental authorities must also specify how progressive rehabilitation is to occur throughout the mining project. Final landforms with graded banks together with creek and run-off diversions are often required and constructed early in the life of a mining project. At closure, mining projects must demonstrate that future medium-term risks are not significant, or failing this, a residual risk financial payment must be made to the state. CSIRO climate change projections indicate that Queensland is likely to become warmer this century with less rainfall in parts and with extreme rainfall events likely to occur more frequently. This project was undertaken to?determine: if current rehabilitation planning tools assist in determining the environmental risks from mining closure not adequately addressing climate change if these risks are addressed by current rehabilitation outcomes.The north-west Queensland mining region and the central Queensland coalfields were represented in this project by five study sites. Local data sets for temperature, rainfall and rainfall intensity were produced using conservative greenhouse gas emission scenarios representing likely future atmospheres, and using the SimCLIM climate model, Evaporation data sets were also derived from available climate parameters. These projected climate variables supported equations and models used in Queensland to determine mining project rehabilitation completion criteria. Storm intensities and return intervals were directly applied to assess the likelihood of failure of engineered structures such as stormwater diversions and banks. Plant cover change determined by an existing growth model together with rainfall intensity and changes in the R and C factors of the universal soil loss equation (USLE) erosion model enabled estimates of long-term erosion rates. Flood estimates were undertaken using regional rated catchments.The study found that stormwater diversions and banks on recontoured rehabilitated landforms, if constructed to currently accepted completion criteria, would likely fail within 30 years and with the likelihood of failure steadily increasing thereafter. The change in likelihood of failure was able to be estimated and could be applied to the determination of residual environmental risk for approval of a surrender application involving rehabilitation. The USLE model showed that long-term erosion rates increased as a consequence of climate change from north to south across the Queensland mining precincts. Because the growth model did not consider carbon dioxide fertilisation affects, results would likely be worse-case.Likely climate change outcomes have consequential residual environmental risks of mining project rehabilitation failure. This increased risk may result in increased payments to the state from mining projects where high consequences exist. The liability to the state and risk to the environment can be avoided if today’s completion criteria address tomorrow’s climate change impacts.CITATION:Evans, M C, 2014. Queensland mines should consider climate change impacts for decommissioning, in Proceedings Life-of-Mine 2014, pp 535–562 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Jul 16, 2014

By Jagger ND

Pressure filters were found to be necessary to produce Elura silver/lead and zinc concentrates at sufficiently low moisture contents for bulk cargo shipment by sea to smelters.The difficulty in obtaining low moistures was due to the fine primary grind, 80% passing 45 microns, and resultant fine concentrates, 97% passing 45 microns.The filtration system was designed to filter up to 90,000 tonnes/year silver/lead concentrates and up to 130,000 tonnes/year zinc concentrates.This paper details the preliminary test work to select Larox automatic pressure filters, and the commissioning and operation of these filters to achieve design criteria for both concentrates. The design criteria for both concentrates have been bettered due to the concentrates being coarser than the design sizing.

Jan 1, 1985

By M Schaffer, T Kewe, N Moffatt

Porgera mine is 95 per cent owned by Barrick Gold Corporation. It is located at an altitude of 2200–2700 m above sea level in the Enga province of Papua New Guinea and produces approximately 460 000 oz per annum with a proven and probable reserve of 6.2 Moz. The refractory ore is ground in a conventional semi-autogenous grinding and ball mill circuit. After the gravity gold is recovered, the slurry is floated, oxidised in the autoclaves and then leached. This paper will focus on the flotation circuit and the recent upgrade of the control system. The five interdependent flotation circuits were challenging for operations to control as they dealt with variable grade, throughput and circulating loads, as well as the physical limitations of the equipment. With the installation of 18 Portage Froth Characterization® (PFC) cameras, the plant’s operation has been converted from a level-control based strategy that was focused on individual cells to one that targets grade and recovery control across the entire circuit. Variability in feed and the corresponding launder issues were addressed with a unique site initiative of deflector plates to indicate filling level. Non-linear closed loop control was implemented directly in the DeltaV Distributed Control System (DCS) using Portage Advantage Regulatory Control (PARC) algorithms and optimised with AwaRE advanced controllers. The most noticeable benefits achieved with the upgrade include improved flotation gold recovery, consistent flotation sulfur grade and autoclave performance. Correspondingly, there was a significant drop in boiler diesel fuel usage and launder overflow conditions.CITATION:Kewe, T, Moffatt, N and Schaffer, M, 2014. Porgera flotation circuit upgrade and expert system installation, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 345–356 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

Central to any business is its Asset Management Plan which encapsulates the business context and key organisational objectives such as profitability, safety and environmental standards. Life Cycle Planning (LCP) is a key component of an overall Asset Management Plan. A comprehensive approach to Life Cycle Planning forecasts the financial expenditure required to support the performance of the asset over the business life. It incorporates capital, maintenance and operational expenditure along with an estimation of economic life. Within its body the LCP provides the detail of the maintenance plan and method of its execution. Once optimised the LCP becomes the overarching plan executed through the application of several elements of the Asset Management Plan to ensure the return on investment from the assets is optimal. Each of the elements of the LCP is bound by a set of loops that provide information based on the analysis of outcomes. These loops drive the continuous improvement of performance and cost over the life of the asset. In this way we ensure that the LCP is a dynamic plan responsive to the changing business environment. The paper being presented today will describe the process undertaken and the outcomes derived when this approach was applied to a $600 M+ coal handling and preparation plant in QueenslandÆs Bowen Basin. It will also delve into the difficulties encountered from both technical and cultural aspects; the latter proving to be the most difficult to manage. It will describe the hurdles and barriers that hampered progress including the human influences and the natural desire to revert to what has been done in the past when things became a bit difficult. In the end the results are there to show that the upfront expenditure and investment in time was time and money well spent and the outcome has the operation well placed to manage the assets in a manner designed to deliver the optimal business outcome.

Jan 1, 2007

By V Novoselov, R Sabirov

Flotation processing technology of water-soluble minerals has made it possible to realise, since the 1960s, the wide scale industrial processing of potash and potassium-magnesium ores (about 200 million tonnes per year) as well as to create the multi-tonnage worldwide production of sylvite (KCl) for industrial and agricultural application. In this paper the particularities of the effect of reagents (blinders, collectors and frothers) during cation flotation in saturated saline solutions are outlined. New reagent modes for activating the effects of alkylamines during the flotation of KCl and the perfecting of technological flow sheets for processing potassium ore have been developed. The results of research on the reverse flotation of carnallite ore, with the help of alkylmorpholine û a new developing technology for benefication carnallite as raw material for the production of metal magnesium and fertilisers are listed. Examples are given of the industrial applications of processed reagent modes at potash flotation factories in Russia.

Jan 1, 2005

By D M. Verster, P L. Gillot, A Kone

Randgold ResourcesÆ MorilaÆs gold leach plant is subjected to uncommon æoxygen stressesÆ. Feed ores exhibit very high oxygen demands, primarily caused by iron sulfides. In addition, ore oxygen demand varies significantly over time, as well as between different feed ore sources. The inability of the Morila gold leach plantÆs oxygenation system to cope with these high and fluctuating oxygen stresses manifested itself in variable gold residue grades, and cyanide consumption rates.Management launched a Morila oxygen system review project during September 2009, with the objective of auditing the performance of the then current oxygenation system, against required performance parameters as calculated from oxygen demands of the various feed ore types and targeted dissolved oxygen levels in the leach train.This paper describes the systematic changes made since 2009 to the Morila oxygen system in four main areas: O2-supply plant, O2-volumes, O2-controls and oxygenation equipment. Data are provided on corresponding improvements in leach plant performance. Theoretical, as well as practical aspects of gold leach oxygenation systems are covered.CITATION:Verster, D M, Gillot, P L and Kone, A, 2013. Oxygenation system upgrades and leach plant performance improvements at Morila Gold Mine - 2009 to 2012, in Proceedings World Gold 2013 , pp 215-224 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 26, 2013

By C J. Greet

Oil can enter a flotation circuit from a number of sources (for example, from mining equipment, oil leaks from the grinding equipment and coatings on the grinding media, but to name a few). Folklore generally states that any oil that contaminates the ore entering the flotation circuit is considered to have a negative impact on flotation. That is, a loss in concentrate grade and recovery.This represents a dilemma for some grinding media suppliers, who use a variety of quenching medium (air, polymer, oil or water) to achieve the desired physical properties of the ball. In the case of high chrome grinding media it is necessary, in some instances, to quench in oil to give the ball the right degree of toughness, which invariably leads to these balls having a thin film of oil on their surface. Once the grinding media arrives on site and site personnel recognise that the balls are “covered” in oil, they generally insist that the oil will have a deleterious impact on flotation performance.Obviously, any supplier “worth their salt” would take remedial action at the point of manufacture to minimise this problem. However, does quenching oil actually present a significant “threat” to the flotation process? This paper provides both laboratory and plant data describing the effect quenching oil has on the flotation of copper sulphide ore, with surprising results!

Aug 8, 2011

By F K. R Klose

Malmberget is a sublevel caving mine owned and operated by Luossavaara-Kiirunavaara Aktiebolag (LKAB), a Swedish state-owned iron ore mining company, in northern Sweden. The mine has an annual iron ore production of approximately 15 Mtpa. The current strategy foresees an expansion which will increase the mine’s depth considerably. Ventilation and air conditioning modelling for the planned expansion is ongoing. One of the most influential parameters for ventilation planning anddesign for a deep mine is geothermal gradient, which is crucial for the design of the refrigeration system. It is determined through virgin rock temperature (VRT) measurements carried out at various depth below the surface. This paper details these measurements and the determination of geothermal gradient for Malmberget Mine for the expansion study, which were necessitated by thelack of information for the focus depth and area.

Oct 12, 2022

By N Maistry, C Carelse, A Singh

Banded Iron Formations or more commonly known as BIF are sedimentary rock formations with alternating silica-rich layers and iron-rich layers that are mainly composed of iron oxides (hematite and magnetite), iron-rich carbonates, and/or iron-rich silicates. Considering the depletion of highgrade iron ore reserves in South Africa, there is a need to maximise resource utilisation through the exploitation of low-grade/uneconomic resources particularly BIF material, which makes up more than 65 per cent of current reserves. Previous test work conducted by alternative BIF sources globally indicates the need for fines processing in order to produce a concentrate. South African BIF however is amenable to coarse and fines processing producing an on-grade product or blended feedstock. C-Type material within South Africa’s Northern Cape Province grading at approximately 33 per cent Fe was supplied for research purposes. Top size optimisation via gravity Heavy Liquid Separation (HLS) tests was conducted. The laboratory results being perfect separation (Ep=0) were modelled to predict pilot performance, the results of which were tested on a pilot scale for the finest size fraction (-1 mm). It was observed that a top size of -2 mm provided optimum results in terms of upgrade and recovery, with crushing finer not necessarily producing superior results. At a target grade of 60 per cent Fe, recoveries of 65.6 per cent were achieved on the laboratory scale, whilst recoveries of approximately 58 per cent were achieved on the pilot scale. Targeting higher upgrades of 63 per cent would inevitably result in lower recoveries of 57.2 per cent on a laboratory scale and approximately 54 per cent on a pilot scale. This is in line with grades and recoveries achieved globally for BIF material albeit at finer grind sizes.

Sep 18, 2023

By Davis RA, Wasp EJ, Cowper NT

The transportation of solids by pipeline is not new. In 1891 a United States patent broadly covering a method of pumping coal with water was granted to W. C. Andrews. His pilot plant was constructed on what is now the site of the New- York Public Library in Manhattan. His process was applied to pumping coal mine waste back into the worked out portion of coal mines. On October 26, 1967, the world's first long distance iron ore slurry line was put into service by Savage River Mines. The commissioning of this 5.0 million dollar installation climaxed three years of development, testing, and construction and proved the Company's faith in pioneering' this unique transportation method for iron ore. This paper will discuss some of the more pertinent items in connection with that three-year period. Also to be discussed will be the operation of this line during the past eleven months.

Jan 1, 1969

By A Singh, C Da Corte

Banded Iron Formations or more commonly known as BIF are sedimentary rock formations with alternating silica-rich layers and iron-rich layers that are typically composed of iron oxides (hematite and magnetite), iron-rich carbonates, and/or iron-rich silicates. Considering the depletion of highgrade iron ore reserves in South Africa, there is a need to maximise resource utilisation through the exploitation of sterile resources in particular BIF material which makes up greater than 65 per cent of current reserves. BIF, like most resources, is non-renewable and the deposition of BIF is thought to have come about by the reaction of Fe2+ ions in the ocean water with dissolved oxygen billions of years ago. BIF ore derived from the Limpopo region in South Africa (SA) located in the Penge Iron Formation is according to Cairncross, Kramers and Villa (2018) equivalent to that contained within the Asbestos Hills Iron Formation of the Transvaal Supergroup in the Northern Cape, SA. Considering that these are one of the largest iron ore deposits in SA, the case study involved mineralogical characterisation followed by beneficiation of BIF from these two regions to ascertain the comparability. Coarse and fines gravity separation comprising of Heavy Liquid Separation/Dense Media Separation on the +1.18 mm size fraction and shaking table on the -1.18 mm size fraction was conducted to ascertain whether an on-grade product or blended feedstock could be produced. The Limpopo mixed and Northern Cape conglomerate BIF samples achieved similar overall responses due to the conglomerate sample containing 15.3 per cent additional -1.18 mm fines. A combined coarse and fines product grading at 60 per cent Fe could be achieved at a yield and recovery of 43.9– 53.0 per cent and 62.2–63.8 per cent respectively. Increasing the grade to 63 per cent Fe reduces the overall recovery by 13.3 per cent. At the higher target grade, the contaminant specifications could be achieved for both samples. The Northern Cape laminated BIF sample is the most promising of the three samples studied. At the two iron target grades overall yields and iron recoveries of 72.9–65.4 per cent and 85.2– 80.2 per cent was achieved. In both instances the silica grade exceeded the product specification, however if the silica content is the driver the target iron grade should increase to 63.32 per cent. This will result in a minimal decrease in recovery of 0.4 per cent. The promising results of this study indicate that coarse beneficiation of BIF material is possible. These ore types could be blended with superior grade products to improve overall yields and recoveries or sold directly at a 63 per cent Fe product grade whilst sacrificing 0.4–13.3 per cent recovery.

Nov 8, 2021