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By Flann R. C

A small modification to current industrial practice should lead to better nickel powders for use in alloying, electroplating, and powder metallurgy. Nickel powder compacts sold for alloying are not always suitable for electroplating applications, since some presently used commercial powders will expand on sintering. Further, such nickel powders are unsuitable for use in the production of powder metal parts, because of expansion during heating of the near-net-shape preforms. Research in these laboratories has enabled the elimination of expansion, and led to techniques for the production of compacts suitable, in particular, for commercial use in both alloying and electroplating. The techniques include: powder pretreatment, cold pressing and sintering, hot pressing, and hot pressing and sintering. In this way compacts are readily prepared with densities of at least 93 per cent of solid nickel, and these, when used as anodes in Watts general purpose and bright baths, give both cathode current and plating efficiencies of 90-98 per cent.

Jan 1, 1979

By D Yan, D Connelly

Beneficiation of magnetite is an integral part of the future of iron ore processing. Historically, the focus of Western Australian producers has been on exporting direct shipping ore (DSO) namely haematite. The future for new DSO resources is limited so companies are changing their emphasis into processing the very large, undeveloped magnetite ores in Western Australia (WA), using beneficiation to produce shippable magnetite concentrates. These magnetite resources require higher cost processing techniques such as fine grinding and beneficiation to produce saleable concentrates. This distinct difference, from the DSO ores, has led to the development of a number of new technologies. This paper reviews: the different techniques used for magnetite beneficiation and provides some case studies in the WA industry; the use of mineral liberation analysis (MLA) to describe the nature, grain size, occurrence and associations of the mineralisation;the consideration of coarse cobbing as a critical upgrading; the application of high pressure grinding rolls (HPGR) to save energy; how the field of magnetic separation has resulted in new machines with higher field strength (SLon Separators); ultra fine grinding requirements of magnetite concentrates; andthe application of reverse flotation to reduce silica in the concentrates.

Jan 1, 2009

By O Ishiyama, L Lu

Sintering is the most economic and widely used agglomeration process to prepare iron ore fines for blast furnace use. Due to the depleting reserves of traditional high-grade iron ore, there have been considerable changes in iron ore resources available throughout the world, especially in steel mills in East Asia. Corresponding to the changes in the availability of iron ore resources, the amount of impurities in iron ore has been slowly increasing. Some of these impurities have been found to have deleterious impacts on sinter quality and sintering performance. In the meantime, an increasing number of large blast furnaces with inner volumes of more than 5000 m3 have been built that require more sinter and are often more demanding in terms of the quality requirements of the ferrous materials. Finally, sinter plants are facing increasing pressure due to more stringent regulations regarding their environmental impact. This paper gives an overall review of a variety of technologies developed worldwide to tackle the changing raw material characteristics and mitigate emissions from sintering operations.CITATION:Lu, L and Ishiyama, O, 2015. Recent advances in iron ore sintering, in Proceedings Iron Ore 2015, pp 61–68 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

By A Tawadrous, D S. Preece

Cave mining is of interest to the mining community as it offers a chance to extract large, deep orebodies with low operating costs and high production rates. It allows for extracting large low-grade orebodies, which may not have previously been considered for mining. Cave mining is done either top down (ie sublevel caving) or bottom up (ie block/panel caving). Both approaches rely on gravity, stresses and weakness of the rock to fracture and achieve a controlled collapse.Block caving starts at the base of the orebody. It progresses upward and across through continuous collapse of the roof. To achieve this, a critical hydraulic radius must be exceeded. This is accomplished by blasting drawbells, through which the caved ore passes to the production level. An entire level above the drawbells (undercut level) is excavated to help initiate the cave. The undercut level ensures the connection between drawbells and achievement of the required hydraulic radius.Conventionally, drawbells are generated by drilling and blasting several times from the production level as well as the undercut level. Mucking between each shot is required to generate enough void space for the rock to swell. The need for several blasts necessitates some downtime between each blast. Also, the cost of developing and maintaining the undercut level can constitute up to 35 per cent of the cost of mining the panel.A new blasting technique was developed to create the drawbells in a single blast from the production level. The technique ensures the connection of the drawbell to the neighbouring ones, thus, the critical hydraulic radius is reached and propagation of the cave achieved without the need for the undercut level. The technique has the potential to reduce the capital cost of a block caving operation, increase its feasibility and reduce time to reach the ore and consequently the payback period. This paper presents the modelling of a traditional drawbell excavation process, the philosophy of the developed technique, the modelling of that new design and its implementation.CITATION:Tawadrous, A and Preece, D S, 2015. A novel blasting technique to create drawbells and eliminate the undercut level in block cave mining, in Proceedings 11th International Symposium on Rock Fragmentation by Blasting, pp 617–624 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 24, 2015

By Griffin PT, Espinosa-Gomez R, Jameson GJ

Two major issues are to be addressed in the Copper Concentrator of Mount Isa Mines Limited. The first of these is the need to increase concentrator flotation capacity to increase copper recovery, while the second is the need to reduce the iron sulphide dilution to meet future smelting requirements. Extra capacity in the cleaner and retreatment sections of the concentrator have been identified as key target areas, with additional copper recovery of at least one per cent identified from plant trials. Extensive pilot plant tests have been undertaken to evaluate the performance of the Jameson cell compared to conventional mechanical cell and column circuits. This work has shown that Jameson cells present an opportunity to achieve the desired grade and capacity specifications at lower capital cost than available alternatives. This paper outlines metallurgical results of work undertaken in the Copper Concentrator, together with a summary of pertinent Jameson cell operating parameters investigated during the period.

Jan 1, 1993

By A Innis, A Bye, B McCarthy, S Glover

Technology adoption in the mining industry has been steadily increasing over the past decade, driven by the need to improve operational efficiency, safety, sustainability, and profitability. As mining companies wish to implement solutions to improve mining safety and productivity, various technologies are being integrated into mining operations to enhance processes, reduce risks, and optimise resource utilisation. Adoption of new technologies such as autonomous trucks requires a strong focus on foundational operational technology (OT) and a systems-thinking approach. OT support is critical however, OT is traditionally not considered or integrated into standard maintenance activities. Consequently, sourcing and applying service support to OT systems in real-time has posed significant challenges to date. Neglecting the monitoring and upkeep of these operational technologies and equipment can lead to a host of adverse consequences. Operating instability becomes more prevalent, necessitating reactive measures, and the vulnerability to cybersecurity threats increases significantly. To address OT monitoring and maintenance challenges, a systems wide mindset and remote support discipline must be utilised. Remote operations support refers to real-time, 24/7 monitoring, control and support of site OT: network, production systems, maintenance systems, enterprise systems and mobile and fixed plant through a single interface remote from site. The presence of a disciplined team, grounded in a systems-oriented approach, is of the utmost importance to remote monitoring, given the intricate interdependencies of OT systems. The ability to understand the relationships among multiple systems, coupled with the capacity to distinguish between symptoms and root causes, assumes a pivotal role in operations. Through diligent monitoring and the astute understanding of system thresholds, remote operations support can actively identify and alleviate constraints, in turn, serving as the enabler for transformative advancements in technology output.

Sep 1, 2024

By Rashleigh C

The selection and application of an effect- ive firing system first require a clear under- standing of the initiating abilities of the com- ponents in such systems. The conditions under which charges can be prematurely initiated by a detonating cord downline must be appreciated. This is a principal consideration in the design of a successful downline/'Anodet'/primer assembly. The advantages and limitations of an electric and several non-electric initiating systems are explained. The factors which in- fluenced selection of the two most suitable systems for use at Isa Mine (viz. downline/ 'Anodet'/primer assemblies and the reinforced long-lead 'Anodet'-type delay system) are dis- cussed. Blasts are detailed in which each of these has been applied. The initiating design for a hypothetical 2 x 106 tonne blast using electric short delay detonators and multi-channel exploders is presented. In this design, charges in remote blastholes are activated after the detonation of earlier firing charges by protecting the firing lines with sandbags.

Jan 1, 1978

By J E. Everett

Maximising ore tonnage at a selected target grade requires that appropriate ore identification criteria be established. Iron ore mining block models may consist of many millions of estimated blocks, each block corresponding to the selective mining unit (SMU), with grade interpolated from drill hole data. Each block can be considered as a potential ore candidate. Analysis of such a huge database can require large computational resources, especially for sensitivity analysis requiring multiple computations. However, an alternative streamlined approach is possible, where the data are compressed to an appropriately smaller and representative subset. The consequent data reduction not only makes it feasible to consider the simultaneous analysis of multiple pits but also considerably speeds up computation, enabling sensitivity analysis of the potential ore tonnage as a function of the required grade. Ore identification criteria can be successfully established using appropriately chosen reduced data comprising less than one per cent of the blocks. The ore identified is virtually indistinguishable in tonnage and grade from the ore that would be selected using the entire block model.Two methods of data reduction are tested: sampling (using a proportion of unaltered blocks) and binning (consolidating groups of blocks to a single average grade). The source blocks are first sorted (such as by location, analyte grade, principal component score, random order or value) before sampling or binning. In this study, the sorting options considered were by location and Fe grade. The effectiveness of each method was evaluated using the block model subsets to select the maximum tonnage of ore at a specified target grade. Block model data from an anonymous Pilbara iron ore project with about one million blocks averaging 1.132 kt were used. The blocks are from multiple resource models, to be blended to a single product. Sampling is shown to be superior to binning because sampling preserves the full variability while binning, although matching the mean block grades reduces their variability.It was found that the appropriately sampled data sets (sorted by location) gave results virtually identical to the results for the full data set, even when the samples comprised less than one per cent of the original blocks. The reduction in computer time to identify maximum tonnage at a specified grade was approximately proportional to the sample percentage. The increase in computation speed greatly facilitated sensitivity analysis. A sampled data set of one-eighth the total block model was used to investigate the effects of changing each of the component grades around the original grade specification. The results of this sensitivity analysis are discussed, and illustrate the potential benefit of carrying out sensitivity analysis in determining feasible and marketable product grades.CITATION:Everett, J E, 2015. Block model data reduction and sensitivity analysis, in Proceedings Iron Ore 2015, pp 263–270 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

By M Fritz, B Ziegelaar

"For moisture samples, the International Standard for iron ore sampling states the following: Moisture samples shall be processed as soon as possible and test portions weighed immediately. If this is not possible, samples shall be stored in non-absorbent airtight containers with a minimum of free air space to minimise any change in moisture content, but should be prepared without delay. ISO 3082 (2009)Prescribing what to do is of course easy. Putting it in practice is, however, a little more problematic.The iron ore industry has seen quite some changes in the last ten to 15 years, such as: a large increase in the volume of seaborne trade new ore types and blends coming onto the market new mines, processing plants and port facilities producing more and loading faster an increase in wet processed ore products a dramatic rise and then equally dramatic fall in the iron ore price followed by a recent recovery.All of the above have had an effect on sampling facilities. The large increase in volume coupled with ambitions such as labour efficiency, safer operations and higher precision has driven the installation and retrofitting of automated sampling and robotic sampling preparation plants in order to keep up with increased quality control.Designers of sampling facilities are invariably instructed to build plants that comply with ISO 3082. In general this means that the plants are compliant in respect of the number of primary increments, gross sample masses and sample division rules. The clause at the beginning of this abstract is mostly overlooked as it only appears in a section (4.1) describing the basic requirements of a sampling system.An error of 0.1 per cent in moisture changes the value of 1 Mt of iron ore at US$50/t by US$50 000. At 700 Mt/a of Australian iron ore exports, this is US$35 M. Frequently, errors from 0.5 to 1 per cent in moisture measurements are encountered.In comparison an error of 0.1 per cent Fe is US$0.081 (US$50/t and 62 per cent Fe base) per tonne, that is US$81 000 per Mt or about US$51 M for the same Australian annual iron ore exports.It is somewhat mystifying that we in the ISO Technical committees spend extraordinary energy (= money and time) on improving measurement techniques, whilst the big costs are in sampling errors. This is particularly true for moisture measurement. Our paper quantifies some of the sources of moisture measurements errors and suggests mitigating actions.CITATION:Ziegelaar, B and Fritz, M, 2017. Sampling for the percentage moisture in the iron ore industry, in Proceedings Eighth World Conference on Sampling and Blending, pp 271–274 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

May 9, 2017

By J Miedecke

A metalliferous mine has operated at Storys Creek from the 1890s to 1979. Storys Creek drains from a pristine catchment and National Park and remains as the most degraded stream from historic mining in north-eastern Tasmania. It has been the subject of public concern since the closure, particularly at times of high rainfall such as existed in 1985 and 1986. The mine is located on the banks of the creek, which flows into a major river, the South Esk River, which is one of TasmaniaÆs largest rivers and important for recreational fishing and water supplies. For much of the life of the of the operations tailings were directly discharged into the creek, and in latter years stockpiled or very close to it. Little rehabilitation was carried out at mine closure. The result was erosion and subsequent deposition on the banks of the creek downstream. Direct emissions of adit water and the consequential emission of contaminated ground water to the creek continue to affect water quality. Contaminant loads discharging from the mine and tailings comprise 70% of the metal load in the catchment and are by far the largest single source. Acidity data suggested that the introduction of systems to introduce alkalinity could be effective in ameliorating the residual acid drainage impacts in the Storys Creek catchment. After a period of investigations and trials which proved their effectiveness, treatments adopted have included the following: relocation of tailings to a constructed and clay capped disposal area and rehabilitation of tailings area; crushed limestone addition to stream flows; crushed limestone addition to creek banks and exposed tailings; sealing of a drainage Adit; and construction of an anoxic drain to generate alkalinity to surface waters draining to old mine workings. These innovative treatments have resulted in a marked improvement in water quality draining from the area. The anoxic drain is believed to be one of the few, if any, which has been constructed to have generated high levels of alkalinity from clean waters and offers a solution to the clogging problems experienced in such drains in the past. Similarly, the use of crushed limestone in an active stream has proved effective in buffering acid drainage and removing metals from solution.

Jan 1, 2003

By D Finn, D Kentwell

Experience has shown that the E-Type multiple indicator kriging (MIK) estimation technique often works well for resource estimation in stockwork mineralisation that contains a mixture of high and low-grade mineralisation types that are difficult or impossible to separate spatially. E-Type MIK, like ordinary kriging (OK) is a smoothing estimator and where data is sparse can result in estimates of grade tonnage curves that do not reflect the true block variability at selective mining unit (SMU) scale. The rank and replace (RR) estimation methodology is designed to reproduce both local block accuracy and true block variability at SMU scale and has shown good results when used with highly skewed unimodal diffusive style mineralisation. This paper examines the use of RR with mosaic style mineralisation typically found in stockworks via a case study using real data from Newcrest’s Telfer West Dome deposit. Resource level estimation results for ordinary kriging (OK), E-Type MIK and RR are compared to close spaced grade control models as the reference reality.Results show that stationarity requirements and declustering can severely impact on the usefulness of the rank and replace technique and that it should only be used where trends are not too strong and data are relatively uniformly spaced. This does not rule out its application to stockwork or mosaic style deposits. However, in this case, the presence of trends and different data densities requires the non-stationary domain to be further broken down into sub domains for the RR technique to be effective.CITATION:Kentwell, D and Finn, D, 2017. Testing new estimation techniques – rank and replace: a stockwork case study, in Proceedings Tenth International Mining Geology Conference 2017, pp 365–374 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 20, 2017

By M J. Nugus

The structural models developed by exploration and mining geologists are most commonly concerned with the ‘main structures’ or key constituents that pertain to the associated mineralisation. To this end, it is recognised that the geological and exploration models, which are developed, are essentially ‘fit for task’ and the scale-related variances are not always realised at an early stage. In fact, in many cases anomalous intercepts along different trends and of variable apparent continuity have often been neglected as ‘back scatter’ and not important. Recognition of the importance of subordinate structures as mineralising hosts suggests that additional opportunities exist outside the primary and main structures. History shows that opportunities are often not realised where gold is hosted in orientations not parallel to the predominant trend of the schistosity, main fault or shear zone.Another reason for the importance of subordinate structures can be understood from their roles in a percolation network. Subordinate structures can access the large fluid fluxes provided by backbone elements, but, as dangling elements, they provide greater opportunities for gold precipitation mechanisms and hence may constitute essential parts of the resource. Therefore, the role, understanding and consideration of the smaller-scale and orthogonal structures should be considered during all facets of exploration, resource development, delineation and mining.

Aug 22, 2011

By D Caffrey

To demonstrate the advantages of using electronic delay detonators over pyrotechnic detonators, a trial using the DNES Dynatronic System was conducted at the KCGM Mount Charlotte operation in 1998. The trial clearly demonstrated that accurate control over the firing delay time between blastholes can lead to fragmentation improvement and ground vibration energy control which are two important issues for the Mt Charlotte underground operation. Excellent fragmentation was achieved by employing a 12 ms delay sequence. Detailed fragmentation analysis has shown a 10 to 20 per cent passing increase for the rock fragment size from 0.1 to 0.4 m compared with the pyrotechnic detonator firing. There was no increase in ground vibration level on the surface with the electronic detonator firing even though the electronic detonator firing had a much shorter blast duration than the pyrotechnic detonator firing. In fact, our energy calculation has clearly shown that much less energy had been propagated to the surface from the blast using electronic detonator firing.

Jan 1, 1999

By A Smith

Rock masses usually exhibit scale dependent mechanical properties primarily due to presence of discontinuities and their inhomogeneous nature. One of the essential preconditions for selection of appropriate strength and deformation parameters of a rock mass in relation to tunnel design is assessment of the scale of the joint network relative to the scale of excavation. In tunnel design practice, scale effects are estimated indirectly using small-scale unconfined compressive strength (UCS) tests and rock mass classification based empirical correlations. Large-scale UCS tests have the benefit of direct assessment of anisotropic and scale dependent properties of a rock mass.This paper presents results of a large-scale UCS test on a jointed siltstone. A 450 mm diameter sample with inclined bedding planes was cored and tested in uniaxial compression until failure with load and displacement measurements. The aim of the test is to determine strength and deformation parameters and correlate them with results of small-scale UCS tests of the same sample. The relationships between the small-scale and large-scale rock mass parameters were validated against published correlations from the literature.

Mar 8, 2011

By Wright G. N

Curragh Queensland Mining Limited, a co-venture of Australian and overseas interests, operates an open cut coal mine 13 km north of the township of Blackwater in Central Queensland, refer attached location map.

Jan 1, 1992

By S Harris, A Bossilkov

The Kwinana (Western Australia) and Gladstone (Queensland) industrial areas are among the few dozens of heavy industrial areas globally that demonstrate significant levels of regional resource synergies. Such synergies are also referred to as æindustrial ecologyÆ or æindustrial symbiosisÆ. Fundamentally they involve the exchange of by-products or sharing of utilities between companies in close geographic proximity to achieve competitive advantage and environmental benefit. A concerted research effort is currently underway to foster greater realisation of regional resource synergies in minerals processing intensive regions, in Australia and internationally. This paper summarises current insights from the foundation research into engineering tools and technologies and enabling mechanisms for regional resource synergy developments. Regional resource synergy developments were reviewed for 16 international and two Australian regions. It was found that Kwinana and Gladstone compare favourably with the well-regarded international examples of regional synergy development. Given the fairly strong evidence that self-organisation is critical for regional synergy developments, an implementation model has been proposed that captures entry points for synergy developments at the level of platform (industry collaboration), process (developing synergy opportunities) and project (assessing and implementing specific synergies). It was also found that regional synergies have so far developed in the absence of specific methods for identification and screening of synergy opportunities. Moreover, very limited attention has been paid to the associated technological and engineering challenges. The current technical research effort therefore targets: the development of a toolset for the identification and development of potential synergy opportunities; and assessment of technology needs and opportunities for regional synergies involving water, energy and materials recovery and reuse.

Jan 1, 2006

By J-P Franzidis

The Floatability Characterisation Test Rig (FCTR) is a self-contained, highly instrumented, mobile pilot plant. It was developed as part of the AMIRA P9 project, primarily to determine ore floatability characteristics and to develop and validate flotation plant modelling, scale-up and simulation methodologies. This paper describes the use of the FCTR in validating the AMIRA P9 flotation model and modelling methodology. In 2001 the FCTR was installed and operated in parallel with WMCÆs (now BHP BillitonÆs) Kambalda Nickel Operation. The FCTR was operated using four different circuit configurations of increasing complexity. Metallurgical surveys, cell characterisation measurements and batch flotation tests were performed around each circuit. This allowed the calibration of a number of flotation models using a combination of data from one, two, three or four circuit configurations. The calibrated flotation models were then validated using predictive validation. To do this, data around a further five FCTR circuit configurations were collected (three of which are presented in this paper). The performance of each of the five circuit configurations was predicted using JKSimFloat V6.1 and the parameters from the various calibrated flotation models. The predicted performance was compared to the experimentally determined performance of each circuit. The validation of the AMIRA P9 model was shown to be largely successful except in the case where the reagent addition (depressant) to the validation circuit was different to that in the calibration circuits. The results also provided information regarding the required complexity of the calibration circuit and how many calibration circuits are required to obtain an accurate prediction of circuit performance. These results have increased the confidence in the AMIRA P9 flotation modelling methodology and have provided important information on what data must be collected to allow the accurate prediction of plant performance using the floatability component modelling approach.

Jan 1, 2007

By Jensen W. S

The Mount Morgan ore-body is intersected by dykes to such an extent that it presents peculiarly difficult problems in extracting ore. These are shown on Plates Nos. LXVII. and LXVIII. Besides ,these dykes there are innumerable "heads," which alsoare a source of danger. Falls of ore occurred in the end of the year 1908, resulting in serious loss of life to miners employed. It was decided, after an exhaustive inquiry, to change the entire system of mining from the" flat backed stope system" to the" square set sectional system ," the latter being more flexible and allowing bad ground to be cut out from a safe position; but it became evident that, whatever system was adopted, there would be more or less danger unless all the dykesand heads known were picked up, and their continuation plotted on a special set of plans on which the general scheme of stoping could be plotted from time to time as work progressed. It is worth while pointing out that, in every other branch of engineering, it is usual to design the work, and that only in mining engineering has it been common to do the work first and plot it down afterwards.The term "sectional analysis" is familiar in most branches of engineering design, and as applied in this paper to mining, may not bear the same meaning, but the general purpose is analagous, and there is no other term used.

Jan 1, 1911

By J Coombes

"In today’s challenging climate of reduced staffing, limited funding and uncertain markets, we are called on to operate more productively and ‘be more innovative’. As an industry, we are quick to identify our practice areas as a mark of our role in the machinery of the mine value chain. We proudly note our profession – ‘geologist’, ‘mining engineer’ or ‘accountant’ – and demarcate our responsibilities and even our physical space. We even subdivide our disciplines into sacred entities such as ‘logging geologist’, ‘resource geologist’ or ‘structural geologist’ to prevent any blurring as though somehow the confusion will cost valuable disciplinary ground. How can we function professionally to heed the call to be more productive and more innovative?The purpose of this paper is to underscore what is expected from project evaluation, examine the ways in which we work as an industry and explore alternatives used in other industries and environments.The paper begins with a summary of project evaluation expectations and the ways in which disciplines typically interconnect when conducting project evaluations. Next, the paper examines alternative work frameworks and making a distinction between multidisciplinary, interdisciplinary and transdisciplinary frameworks. In-practice examples of these frameworks in alternative industries and contexts provide evidence for application as well as an opportunity to examine their pros and cons.The paper closes with a call to re-examine working practices in the mining industry, with a view to enhancing productivity and heeding the call for greater innovation.CITATION:Coombes, J, 2016. Transcending the mining discipline divide – multidisciplinary, interdisciplinary or transdisciplinary?, in Proceedings Project Evaluation 2016, pp 2–10 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Mar 8, 2016

Selective continuous surface mining is a rapidly developing system of mining which will have a significant impact on many present and future open cut mines. In many aspects the technology is in its infancy, whilst in other facets concepts drawn from other sectors of engineering are well proven. Full development of the potential and benefits of this technology will only be achieved if the mining companies and manufacturing companies work together to produce machines which the end user really wants.

Jan 1, 1986