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By T D. Jolly, L A. Balzan, A R. Harris, Z Bauk

"The availability of real-time data in any process control system is critical for effective management of that system. At MMG LXML Sepon Copper Operation in Lao PDR, controlling the copper grade of the feed to the leaching circuit is paramount for maximising both productivity and copper recovery. Since 2008, real-time analysis data has been available to the process engineers from the Geoscan on-belt analyser installed on the Copper Mill feed conveyor, and highly accurate results on copper grade have allowed the process engineers to strictly control blending to overcome the variability in plant feed grade. The availability of real-time analysis data is crucial, as effective sampling of this stream is both difficult and error-prone, being only a snapshot in time of highly variable ore stockpiles, as well as having significant laboratory turnaround delays. Periodic sampling is used to verify the Geoscan data as accurate. Since its installation, the copper result has been the most critical output of the Geoscan. In recent times, the process engineers have sought to utilise other results from the Geoscan to further improve and control the process. One measurement of particular interest involves the real-time measurement of calcium and magnesium as a gauge of ore feed gangue acid consumption. To satisfy this end, accurate measurement of calcium and magnesium is becoming increasingly more important and has been the subject of ongoing collaboration between Sepon and Scantech, the manufacturer of the Geoscan. This paper discusses this work, describing the calibration process and results obtained, while also providing a basis for Geoscan use in operations to enable enhanced process control for all potential Geoscan users.Citation:Balzan, L A, Jolly, T D, Harris, A R and Bauk, Z, 2016. Greater Use of Geoscan On-belt Analysis for Process Control at Sepon Copper Operation, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 231–238 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By S H. Algie, D P. Taplin, S G. Doig

"Suboptimal performance of clusters of hydrocyclones (cyclones), relative to the performance of the individual cyclones that comprise the cluster, is a common phenomenon. The primary cause is well known: uneven distribution of the slurry feed into the individual cyclones. The direct result of uneven distribution is that each cyclone in a cluster performs somewhat differently. Hence, some, if not all, of them do not work at their intended operating points, and the classification is not as sharp as intended. The impact on grade, recovery and milling efficiency will vary depending on the duty of the processing circuit, but the most immediately apparent consequence of uneven distribution is a difference in wear rates in the individual cyclones; this exacerbates the problems of unequal performance of the individual cyclones. In severe cases, and as differential wear proceeds, flows from the individual cyclones may become visibly different. Uneven distribution, once the phenomenon was identified, was seen to be a significant issue in the high-solids hydrocyclone cluster in the ball mill recycle section of Evolution Mining’s Edna May Operation (EMO, Westonia, Western Australia) gold processing plant. In 2012, a FloCEP® hydrocyclone feed distributor system was installed to alleviate the problem. Over the next four years of operation, this innovation has proven its value in the metallurgical and maintenance areas. Individual cyclones now wear at the same rate, greatly reducing the need for operator intervention, as well as increasing overall plant availability through minimising unplanned maintenance. The costs of the installation can be justified by savings in maintenance alone, though the greatest value, as is described in this paper, is in allowing the plant to produce consistently closer to its operational design limits. The FloCEP® system is a low maintenance, readily installed retrofit, based on two patented devices that are combined with complementary proprietary design methodology allowing customisation for specific flow rates and slurry particle properties. Together, these devices produce and distribute a pseudo-homogenous slurry flow without moving parts.Citation:Taplin, D P, Doig, S G and Algie, S H, 2016. Experience with FloCEP® Slurry Flow Conditioning at Evolution Mining's Edna May Operation, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 251–260 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By R Marchant, D Willingham

"Predictive maintenance (also known as PHM or equipment ‘health monitoring’) refers to the intelligent monitoring of equipment to avoid future equipment failures. In contrast to conventional preventive maintenance, the maintenance schedule is not determined by a prescribed timeline; instead, it is determined by analytic algorithms, such as machine learning, using data collected from equipment sensors and/or via simulation.Predictive maintenance offers the following benefits for operators and equipment manufacturers:reduction of equipment downtime by identifying issues before failure, thereby enabling convenient scheduling of equipment service and extending equipment lifetimeautomatic determination of the root cause of the failure, enabling appropriate service to be performed without utilising resources to determine a diagnosis avoidance of costs of unnecessary maintenance and unexpected failures improved safety and product quality.Algorithms and data are critical to predictive maintenance success. Sensor data preprocessing is performed using advanced statistical and signal processing techniques. In the case that data isn’t available for the full range of operating modes, operating scenarios can be simulated. Machine learning techniques are then used to estimate equipment health. Once tested, predictive maintenance algorithms may be operationalised in an IT environment such as a server or cloud. Alternatively, algorithms may be implemented in an embedded system directly on the equipment, allowing for faster response times and significantly reducing the amount of data sent over the network.In this paper, we use both historical and simulated data of the plant under various modes of operation including run to failure, and we then leverage machine learning techniques in MATLAB to estimate degradation and remaining useful life. This technique, of combining both simulation models and machine learning, in the areas of predictive maintenance and equipment health monitoring has been adopted by Safran, makers of aircraft jet engines, since 2007. They now have over 160 modules developed (Lacaille and Aurelie, 2015).Citation:Willingham, D and Marchant, R, 2016. Predictive Maintenance Using Simulation and Machine Learning, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 279–284 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By P D. Munro

"This is a reprise of the paper ‘Back to the Future – Why Change Doesn’t Necessarily Mean Progress’ presented to the Tenth Mill Operators’ Conference in 2009. It was observed that the ‘boom and bust’ cycles of the industry, together with trends in tertiary education and the effects of fly-in fly-out (FIFO) operations raised serious questions about the sustainability of human capital in the mineral processing sector.In 2016 we find ourselves in a ‘bust’ after enjoying a decade of the longest commodity price ‘boom’ in a century. In the ‘boom’ did we:make any technological breakthroughs?put measures in place to improve our human capital, especially in the area of ‘professional formation’?The paper makes observations on the current performance of mineral processing engineers and the organisational milieu in which they operate. It questions whether mineral processing engineers are actually ‘adding value’ at some sites given their organisational and operational practices.Some technical trends are examined and what it might mean for mineral processing engineers.Given the above and demographic trends for mineral industry professionals, changes to the seemingly current laissez-faire model of professional development are proposed.Citation:Munro, P D, 2016. Back to the Future - Still on the Dark Side, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 341–348 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By A Rantala, J Timperi and J Kaartinen, T Maksimainen, O Haavisto

"X-ray fluorescence (XRF) is the most common technique used for online slurry assaying in base metal flotation applications. Typically, assays from feed, concentrate and tailings slurries are used to monitor and control the flotation circuit, with possible additional sampling locations in other main slurry flows inside the circuit. The elemental content detection from the XRF spectrum is relatively straightforward as the spectrum contains element-specific peaks whose height corresponds to the element concentration in the sample. However, centralised XRF analysers measure the elemental concentrations line-by-line, which may increase the sampling interval for an individual line and cause unnecessary response delays, especially in large flotation plants. Reflectance spectroscopy is an emerging technique that can be used to obtain more frequent measurements from slurries. The measurement is based on the mineral-specific absorbance of light in the visible and near-infrared (VNIR) wavelength range. Due to this relatively inexpensive and simple measurement system, it is possible to conduct the measurement simultaneously in several slurry lines. However, the information contained in the VNIR spectra is more difficult to interpret as concentrations of all the minerals in the sample contribute to the measured spectrum and changes in solids content, particle size and mineralogy disturb the elemental content estimation. Therefore, frequent calibration of the measurement is required. This study presents the application of combined reflectance spectrum and XRF measurements for rapid online slurry assaying in a copper-nickel flotation plant. The XRF assays are utilised as calibration samples for the reflectance spectrum measurement, keeping the calibration model up-to-date. The rapid reflectance spectrum analysis is then used to provide an almost continuous estimate of the slurry contents, enabling further improved process monitoring and control.Citation:Haavisto, O, Maksimainen, T, Rantala, A, Timperi, J and Kaartinen, J, 2016. Reflectance Spectroscopy with X-ray Fluorescence for Rapid Online Assaying in a Copper-nickel Flotation Plant, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 85–92 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By M McGrory, A Rodolfo, J Paredes, L E. Manguba, K A Villaspir, G Webb, R Setiagani, H Cardenas

"OceanaGold’s Didipio operation has been in operation for three years. Integral to the flow sheet design is a flash flotation circuit treating a portion of cyclone underflow, consisting of an Outotec SK-500 flash rougher and an Outotec TC10 flash cleaner and a SB-2500 falcon treating flash rougher concentrate to recover fine free gold.Flash copper recovery has been holding steady at 60 per cent, while flash gold recovery at 50 per cent. Gold recovery from the gravity circuit is 22 per cent, bringing the overall flash plus gravity gold recovery to 72 per cent.Operation of the flash rougher is mainly by pulp level control. Control of copper grade in the flash cleaner is mainly controlled by air inflow and flash cleaner pulp level control drives copper recovery. Gold recovery around the circuit is mainly driven by gold head grade.SB-2500 concentrate is scalped with a 250 micron screen with the coarse fraction reporting to a SB-250 falcon, concentrate of which combines with the screen fine fraction to a Gemini table.Citation:Cardenas, H, McGrory, M, Webb, G, Paredes, J, Setiagani, R, Villaspir, K A, Manguba, L E and Rodolfo, A, 2016. Didipio Flash Flotation and Gravity Recovery Circuit, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 123–126 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By T Kojovic

"The index A*b, determined from the Julius Kruttschnitt Mineral Research Centre (JKMRC) drop weight tester (DWT) results, has become well-known in the mining industry as a reliable measure of ore hardness in impact or crushing, having the inferred units of t/kWh. This index evolved from a long history of comminution studies at the JKMRC, including the development of the now superseded JKTech twin-pendulum, the industry standard JK Drop Weight Tester (JKDWT) and the faster alterative JKMRC rotary breakage tester (JKRBT). A reduced version of the DWT, the semi-autogenous grinding mill comminution test (SMC test®), also provides estimates of the A*b though the testing of only one particle size at five specific energies. Experimental determination of A*b using the above devices/tests requires samples, with sufficient mass, to be sent to designated laboratories, registered to conduct such tests. This protocol is fine for bankable and commercial testing, where material characterisation data is used in conjunction with machine specific data in modelling and simulation, and power based calculations. However, for comparative testing, where results are required at the time of sampling (eg for plant troubleshooting or spot-surveys), or for rapid ranking of geometallurgical samples, these existing tests simply do not provide a timely, viable and cost-effective solution. In order to address this critical void in the realm of comparative testing, a new device has been developed, exploiting a central feature of single particle impact testing – that the A*b can be reliably estimated using one precise low energy test. This device, for which a patent is currently pending, called the HIT (Hardness Index Tester), has been precision engineered to allow users to break narrowly sized fragments at a set specific energy, in a safe and easy manner. The manufacturing materials have been chosen carefully to ensure compatibility with the intended use and portability to any site, whilst minimising cost. The device is supplied with a novel quality assurance / quality control (QA/QC) feature, to ensure that the targeted potential energy is consistently delivered. The product from the HIT breakage test can be quickly sized using a single screen to determine the mass per cent undersize, from which the A*b index is calculated directly at site – eliminating the need to send the raw data off-site for analysis. On presized fragments, a single test using 20 fragments takes less than five minutes to complete, and the results are immediately available. The HIT is currently being tested at a major mining laboratory in the US and the results to date have proved it can deliver on all fronts. This paper describes the new prototype device, which offers users a low cost in-house mechanism for estimating the A*b at any mine site, with potential applications on fragments up to 25 mm from drill core, blast chip rejects or the grinding circuit feed. It also outlines the results of field tests carried out by an objective third party mining group and compares the results with those from current industry standard tests conducted on the same material.Citation:Kojovic, T, 2016. HIT - a Portable Field Device for Rapid Testing at Site, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 9–16 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By J Fewings, T McCredden, S Seet, C Fitzmaurice

"Flotation of nickel sulfide ores are generally constrained by nickel grade and impurity concentrations (notably magnesium and arsenic) in the product delivered to smelters. Being a physical separation process, flotation recoveries and grades are limited by the grade recovery curve of a particular operation, where increasing product grades are invariably associated with lower recoveries. Impurities put further pressure on this relationship, as removal of impurities from the final concentrate is almost always associated with nickel losses.Western Areas Ltd are developing a proposed expansion to its Cosmic Boy concentrator to treat an impurity stream, that is high in nickel and would otherwise report to tails. Through the use of BioHeap® technology Western Areas aims to recover the nickel and discard the arsenic to tailings. This expansion will consist of a biohydrometallurgical plant that leaches the nickel arsenic minerals, removing the arsenic as a stable iron/arsenic hydroxide, while recovering the nickel as a high-grade nickel sulfide product (at approximately 50 per cent nickel). This can then be blended with final concentrate to improve nickel grades and recoveries, while simultaneously reducing impurity levels or used to produce high value products like nickel sulfate.The introduction of a small microbial leach plant may be beneficial to base metal concentrators constrained by impurities or grade.Citation:Fewings, J, Seet, S, McCredden, T and Fitzmaurice, C, 2016. BioHeap® - Breaking the Grade/Recovery Curve for Nickel Concentrators, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 361–368 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By R Sinclair, D Landwehr, I Hunter

"The Syama Gold Mine, located in southern Mali, was established in 1990 by Broken Hill Propriety Limited (BHP). The operation began treating oxide, and in 1994 it transitioned to processing hard and refractory ore based on ‘whole-of-ore’ roasting. In 1996, BHP was succeeded by Randgold Resources and the operation ran until 2001, when it was placed into care and maintenance.The Syama ore is classified as a double refractory ore with pyrite occluding the fine grained gold present in the ore and high levels of organic carbon presenting a challenge in terms of preg-robbing behaviour. The ore is extremely competent and this combination of metallurgical features was the main source of metallurgical problems encountered by the previous owners.Resolute Mining Limited (RML) acquired the Syama project in 2004. Following a feasibility study and the development of a revised processing flow sheet the plant was recommissioned in 2008 using a combination of old and new equipment. The revised flow sheet enabled primary sulfide ore to be treated by flotation and roasting of the concentrate to produce a calcine suitable for conventional carbon-in-leach (CIL) processing.Commissioning and ramp up of the plant was a troubled process, with monthly gold production being as low as 3000 oz in 2010. Poor availability of equipment and lower-than-forecast recoveries were the primary contributors.During the last five years, RML has utilised a systematic approach to improve production, focusing on mechanical reliability, metallurgical recovery and process bottlenecks. Modifications to the circuit have been as a result of both innovation and the application of technological improvements. Improvements have been made to the flotation, roasting and CIL circuits and RML has introduced a deslime circuit to treat flotation concentrate, in addition to the very successful commissioning of a new 1 Mt/a oxide circuit in December 2014. These changes have resulted in gold production increasing to more than 20 000 oz per month in 2015.This paper presents the processes, change implementation and outcomes of the modifications made to the sulfide circuit to address the availability and recovery problems.Apart from the expansion of an existing, world-class deposit and discovery of new resources, future improvements on the path to a class-leading gold mine include the continued reduction of the unit cash cost, increase in overall sulfide circuit gold recovery, increased throughput through continued innovation and consistency in the plant’s operation.Citation:Sinclair, R, Hunter, I and Landwehr, D, 2016. Syama Gold Mine - the Journey towards a Class-leading Gold Mine, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 213–224 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By A Giblett, S Hart

"In 2015 operations under the ownership and/or management of all Newmont Mining Corporation subsidiaries (Newmont) produced 5.7 Moz of gold and 619 Mlb of copper from mining operations in five countries, with well over 100 Mt of ore processed by various grinding technologies. Processing methods used in the extraction of metals include flotation, oxidation, conventional cyanidation and heap leaching. The grinding technologies applied in milling operations feeding metal recovery processes include conventional wet grinding semi-autogenous grinding (SAG), rod and ball, dry grinding, concentrate regrinding and ultra-fine grinding, and ball milling of high pressure grinding roll product. SAG/ball (SAB) configurations represent the dominant comminution flow sheet within the company and the circuit configurations employed include SAB, SABC-A, SABC-B and single-stage (SS) SAG milling, with SAG mill feed ranging from run-of-mine (ROM) ore through to secondary crusher product. The collective experiences earned from designing, operating and debottlenecking these various comminution circuits provide many lessons that can be applied to the design and optimisation of future operations. This paper provides an overview of Newmont’s diverse comminution circuits, discusses recent performance and offers some insight into optimisation and design considerations based on recent experience in both endeavours.Citation:Giblett, A and Hart, S, 2016. Grinding Circuit Practices at Newmont, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 293–302 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By T D. H McGrath, O Baker, W P. Staunton, C Ypelaan

"The carbon-in-pulp process has been used extensively in the gold industry since the late 1970s to recovery leached gold from solution. Despite more than 30 years of experience in operating carbon circuits, average gold solution loss has remained at an average of 0.02–0.03 ppm (mg/L), higher than the ‘best practice’ target of 0.01 ppm.Process modelling, such as SIMCIL developed by the Curtin Gold Technology Group (GTG), can provide information on optimum set points; however, manual control of the circuit limits the potential benefits.An automated carbon measurement device, the Scout Carbon Meter, has been developed to allow for automation of carbon concentration measurement, and automated control of the carbon transfer pumps. This paper describes the results from the evaluation of the first two prototypes of the meter.Citation:Staunton, W P, McGrath, T D H, Ypelaan, C, Baker, O and Eksteen, J J, 2016. Optimising Carbon Management - Increasing Gold Recovery and Decreasing Costs with the Carbon Scout, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 225–228 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By D R. Seaman, B Adamson, P Sharman, M McMahon

"The Telfer processing plant commissioned its pyrite regrind and flotation circuit in August 2012. The circuit was designed to regrind pyrite concentrate to a p80 of <30µm then float a gold and copper rich concentrate before tails from the flotation circuit fed the carbon-in-leach (CIL) circuit downstream. Expected benefits were: improved CIL performance that would result from the finer grind and a reduction in cyanide soluble copper to the CIL circuit, as well as a small increase in overall flotation circuit recovery. While the benefits of a finer grind were soon realised, recovery in the post-regrind flotation circuit (named the ‘pyrite recleaner circuit’) was consistently and significantly lower than that expected based on laboratory test work. Selectivity in the pyrite recleaner circuit was virtually nil and copper reporting to the CIL circuit did not change as a result of the pyrite recleaner circuit operation.A pulp chemistry survey of the plant and comparison with the lab showed that the dissolved oxygen (DO) demand in the plant was much higher than that in the lab. Lab flotation tests conducted using nitrogen gas instead of air resulted in recoveries similar to those from the plant. It was identified that the freshly ground pyrite surfaces exiting the regrind mill were consuming oxygen in the slurry and there was insufficient oxygen available for collector adsorption and pyrite depression to occur. Test work, using a pilot regrind mill, showed that a reduction in grind size resulted in an increase in DO demand.A range of oxidising agents were tested in the laboratory and using a pilot flotation rig set-up in the plant. Oxygen was found to be the most reliable and effective agent and options for increasing oxygen delivery to the plant were explored. Scale-up from the lab oxygen requirement to the plant is difficult and efforts to implement a permanent solution for meeting the DO demand in the plant are ongoing.Citation:McMahon, M, Seaman, D R, Sharman, P, Adamson, B and Seaman, B A, 2016. Optimising the Telfer Pyrite Regrind Circuit - Effect of Dissolved Oxygen Demand, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 51–58 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By L P. Gray

"From paving the way in gaining approval for the first metalliferous in-pit tailings storage facility (TSF) in Victoria, to developing a deposition methodology to optimise the storage capacity and provide a final rehabilitated surface which replicates the premining topography, in-pit tailings storage has proven not only to be a cost-effective means for tailings management at Fosterville Gold Mine, but also one which provides significant economic, social and environmental benefits. Coupled with ongoing raising of the existing above ground TSF and commissioning of a new above ground TSF, Fosterville Gold Mine have to date effectively used three open pits for in-pit tailings storage, with one of the pits currently progressing through the capping and vegetation establishment phases of closure.This paper presents the process adopted by Fosterville Gold Mine in their flotation tailings management, from design and operational phases through to rehabilitation implementation. Included within the paper are challenges which have arisen during the process, and a discussion on principals behind the designs and lessons learnt during operation of the facilities.Citation:Gray, L P, 2016. Full Cycle Tailings Management at Fosterville Gold Mine, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 369–378 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By D Hatton, S Wilson, F Orrante, M Taghimohammadi, F van der Walt, N Arslan, M Westcott

"Cayeli Bakir Isletmeleri is an underground copper-zinc mine in turkey. The ore is highly variable with feed grades ranging from 1–4 per cent copper and 1–10 per cent zinc. Due to this variability, ore characterisation and blending strategies are crucial for performance optimisation.This paper presents a case study for a multidisciplinary approach to process optimisation, integrating Geometallurgical and advanced control methods to achieve optimised plant performance. The results from comprehensive metallurgical tests and surveys were used to develop a mathematical model utilising SGS’s Integrated Geometallurgical Simulator® (version number 2.5.24.0). The model was employed to determine the most appropriate operational settings required to ensure that optimised grades and recoveries are achieved for each ore type.SGS’s Modular Expert Technology (MET) expert system was then implemented to target these optimum operational ranges utilising online grade and froth velocity measurements. The successful conversion and deployment of the modelled process parameters into an expert system has resulted in significant improvements in overall recovery and circuit stability.Citation:Arslan, N, Westcott, M, van der Walt, F, Hatton, D, Taghimohammadi, M, Orrante, F and Wilson, S, 2016. A Multidisciplinary Approach to the Optimisation and Control of a Copper-zinc Grinding and Flotation Circuit, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 115–122 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By T Roesch, M Neurohr, S Stratton

"Dwindling commodity prices are forcing today’s mining operations to increase output. Sometimes the solution is to upgrade the existing infrastructure; however, in most cases it has to be achieved with the same or reduced workforce and with the same equipment capacity through improved process efficiency and higher uptime.Measure, Manage and Improveis the mantra for this years’ Mill Operators’ Conference and while this in most cases relates to the above process efficiency, Siemens has set its focus on the availability and uptime aspect since unscheduled downtime is one of the biggest threats to any grinding operation. Pinion misalignments, resonance, unbalance and bearing and gear meshing faults in geared trains, as well as long-term changes in the condition of the mechanical components or structures and auxiliary systems in gearless systems are the main reasons for unscheduled downtimes in today’s mill drive trains. Our paper outlines the efforts that have gone into adapting conventional condition monitoring methods in conventional, pinion driven mill drive trains as well as gearless systems to capture the gradual deterioration of wearing parts or structural changes in the drive train not only on fixed speed application but also on variable speed applications with multiple operating points. The paper further explores the use of condition monitoring systems as a tool to assess spare thermal motor capacity to potentially push equipment beyond its nameplate rating, along with the process that was followed to correlate measured frequency spectra and envelopes to ambient and load data to understand the kinematics of the drive train.Citation:Neurohr, M, Stratton, S and Roesch, T, 2016. Advancements in Condition Monitoring on Mill Drive Trains for Proactive Maintenance and Early Fault Detection Purposes, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 263–272 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By C Munro, S Emery, M Flynn, K Tan

"AEROPHINE® 3418A Promoter is a well-known and widely used collector and is an industry standard for its excellent selectivity and efficacy in the processing of complex polymetallic sulfide ores, particularly those containing silver. Until now, however, it has not found widespread use in primary nickel flotation.In an effort to increase nickel recovery without compromising selectivity over iron sulfides, Western Areas Forrestania Nickel operation trialled the use of AEROPHINE® 3418A as a secondary collector at low dosage. A series of ON/OFF trials were conducted, with the finding that a very low dose of AEROPHINE® 3418A increased nickel recovery by 0.6 per cent compared to using xanthate alone.This paper provides a brief operational history and overview of the Forrestania operations, a description of the trial and an analysis of the results.Citation:Emery, S, Flynn, M, Tan, K and Munro, C, 2016. Aerophine® 3418A Promoter as a Secondary Collector to Boost Nickel Recovery at Forrestania Nickel Operations, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 145–148 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By A L. Zawadski, B G. Putland

"This paper discusses a method to build a calibrated comminution circuit model, using historic operating data and blend information that is useful for forecasting and optimising plant performance, as well as evaluating expansion opportunities. A preferred method for building a calibrated power-based comminution model is discussed and justified based on two case studies, offering low-cost and effective strategies to utilise existing information for the maximum possible benefit.The first example is the Lefa Gold Mine located in Guinea, West Africa operating a semi-autogenous grinding (SAG) and ball milling circuit with recycle crushing (SABC). Daily blend information and operating data was utilised to build and calibrate a power-based model of the comminution circuit. The least squares regression method was used to solve the SAG mill specific energy requirement and the operating work index (Wio) for each individual ore type. The calibrated model was used to evaluate expansion strategies to sustain throughput at higher proportions of fresh ore based on the proposed life-of-mine schedule.The second example is the Ok Tedi Copper-Gold Mine in Papua New Guinea operating a SAG and ball milling circuit (SAB). The circuit limitation would often shift between the SAG mill and the ball mill due to variable ore characteristics and feed blend. Typical SAG mill relief strategies, such as recycle crushing or secondary crushing, required significant capital expenditure and the potential throughput benefit would vary depending on ore type, making economic justification difficult. Daily blend information and operating data was used to build and calibrate a power-based model of the comminution circuit to identify ore types that might benefit from higher blast intensities to increase fines content, thus relieving the SAG mill limitation and increasing overall throughput without a major capital investment.Citation:Zawadski, A L and Putland, B G, 2016. Calibrating Comminution Models Using Operating Data to Forecast and Optimise Plant Performance, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 17–26 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By D Morgan, K Jones

"In March 2015 Northparkes Mines (NPM) installed a process mineralogy facility on-site. The laboratory included a TESCAN TIMA scanning electron microscope (SEM) and was the first SEM facility to be commissioned on a mine site in Australia. While the initial intent of the quantitative mineralogy laboratory was to provide information to drive processing plant improvements, in practice, it has been utilised for so much more and is now serving as an integral link between departments on-site. This multidisciplinary approach to orebody knowledge is a new strategy for NPM whereby all parts of the value chain are aligned towards the common goal of achieving process efficiency and stability while still maintaining high throughputs. The NPM experience is presented as a case study to illustrate how on-site process mineralogy can drive a realignment in business strategy with a common goal of mill optimisation, stability and more realistic forecasting through orebody knowledge and information sharing between disciplines.Citation:Jones, K and Morgan, D, 2016. On-site Process Mineralogy - Linking Departments and Disciplines with the Common Goal of Increasing Plant Performance, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 149–156 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By J King, T Hunter, R Coleman

"The industry that supports operations and new projects is suffering a rapid decline in the currently severely curtailed capital investment environment. This is evidenced by a decline in the number of skilled teams, who are now centred in fewer locations. Other features are an aging and retiring ‘Baby Boomer’ generation, coupled with a low uptake of new graduates and the uncertainty in predicting future capital expenditure programs and requirements. Combine this with a reluctance of cash-poor operations to modernise and adapt in an environment of low metal prices, and there is a real uncertainty in how service providers will meet industry needs as they evolve.The industry that supports operations and new projects is suffering a rapid decline in the currently severely curtailed capital investment environment. This is evidenced by a decline in the number of skilled teams, who are now centred in fewer locations. Other features are an aging and retiring ‘Baby Boomer’ generation, coupled with a low uptake of new graduates and the uncertainty in predicting future capital expenditure programs and requirements. Combine this with a reluctance of cash-poor operations to modernise and adapt in an environment of low metal prices, and there is a real uncertainty in how service providers will meet industry needs as they evolve.Trends amongst service providers will be put forward as well as developing options and alternatives. These embrace a whole gamut of agile alternatives in the areas of partnering, alliances, commercial and shared risk models and mutual innovations. These will be discussed with some case studies and suggested approaches.Particular emphasis will be upon brownfield expansions and upgrades which have emerged recently as a preferred lower capital and focused way to achieve best practical outcome at lowest cost. There are a number of specific features of such brownfields projects including the requirement for very close cooperation between the execution team, operators, maintenance and suppliers and a maximum usage of site resources and ingenuity. Often, required investment hurdle rates are high, downtime allowed is minimal and site resources usage is maximised. This requires mutual trust, good planning and high health, safety, environment and community (HSEC) standards and practice. In many ways the practices and skills needed are the exact opposite of the historical ‘big greenfields’ project with which the industry has been geared for more recently.Another developing area has been with innovative commercial models and practices. These have been as a direct result of the more challenging investment criteria being adopted and the relative hunger of service providers. It has become more common to look at these commercial/costing alternatives very early in the project cycle as an essential project tool and not just as a possible option. These commercial solutions cover such alternatives as leasing and rental, deferred payments, build–own–operate–transfer (BOOT) and build–own–operate (BOO), whole-of-mine preferred spares and maintenance terms, and aggressive performance targets with real assurance penalties. Once again this requires very close mutual dealings and trust, and sufficient time allocation compared to a conventional approach.Citation:Coleman, R, King, J and Hunter, T, 2016. Upgrades, Modernisations and Expansions... Where Will the Expertise, Capability and Skills Come from in the Future?, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 69–76 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By H Thanasekaran, M J. Mankosa, J N. Kohmuench, G H. Luttrell

"Fluidised-bed flotation has been demonstrated over the last 16 years as an effective method for improving the flotation recovery of coarse particles. This technology has been successfully deployed into the industrial mineral sector with multiple installations within phosphate beneficiation plants and potash mills. Due to the minimal mineral surface expression required when utilising this technology, more recent studies have centred on the applicability of using this HydroFloat™ technology for the recovery of coarse sulfides and base metals. Multiple approaches have been investigated to determine the best means for implementing this novel coarse particle flotation system into both existing and new plant circuitry. These include the treatment of tailings to recover values that have been lost using conventional technologies and also the direct treatment of a coarse feed, either within the grinding circuit or by use of a separate split-feed flotation approach. Recent applications of the technology will be presented along with data generated from several test campaigns and ongoing research investigations. The benefits of properly applying this technology, such as reduced power consumption and increased mill capacity will be discussed.Citation:Kohmuench, J N, Thanasekaran, H, Mankosa, M J and Luttrell, G H, 2016. The Impact of Fluidised-bed Flotation for Treating Coarse Sulfides, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 105–112 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016