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At the LKAB, Iron Ore Mine, Kiruna, Sweden a preliminary investigation into the reliability characteristics of a fleet of load-haul-dump machines has shown that the hydraulic system is one of the most critical parts. Therefore, hydraulic system was selected for study and analysis through condition monitoring devices so that failure can be controlled or at least the failure consequences can be minimized.The hydraulic system has two different problems; one is that the contamination level is too high and the other is high temperature during operation. At high temperature, seals and tubes are a problem, because they stiffen due to carbonization, which leads to increasing leakage. The pumps and restrictions were responsible for the main temperature increase.

Jan 1, 1991

By Woodcock J. T, Rummel P. H, Sparrow G. J, MacRae C. M

A rapid automated search method, developed for the location of native gold grains in polished sections with a scanning electron microscope (SEM), has been extended to locate platinum group elements (PGE), in particular platinum and palladium, and their minerals down to 1 ¦m in size. Problems associated with the search for PGE minerals are discussed and examples of PGE minerals located with the facility in drill core sections, crushed ores, and metallurgical test products are given.

Jan 1, 1991

At many locations in Australia the decommissioning of mining operations will require the disposal of excess water. If the water is contaminated its disposal may be restricted by government guidelines. The timing of water disposal may be critical to the schedule of close-out. The uncertainty of the annual rainfall input to the water storage and disposal system may determine the success or failure of close-out. The uncertainty associated with any outcome can be used to determine the reliability of the system, or inversely its risk. The technique of Monte Carlo simulation, using the uncertainty in annual rainfall, is applied to quantify the risks associated with water disposal as part of the requirements for close-out in two case studies. In both case studies it is assumed that water disposal is via evaporation only. The first case study is the Nabarlek operation, located about 270 km east of Darwin. This project is required to complete the engineering work associated with its close-out by December 1995. The second study investigates the situation of close-out for the Ranger Uranium Mine, about 250 km east of Darwin. It should be noted that the Ranger mine was examined as part of the annual update of its contingency rehabilitation plan and the probability of implementing the plan is extremely small. The probability of success for the Nabarlek case varied from less than ten per cent to greater than 95 per cent depending on the management strategy. Four possible strategies were investigated for the Ranger mine with the chance of success varying between 20 and 95 per cent. The estimation of the evaporation rate and the area allocated to evaporation was critical in both cases. By applying seasonally based evaporation pan coefficients determined on site, rather than an average monthly value of 0.75, the chance of success was improved by up to 35 per cent for Ranger. Simulation modelling is able to provide information on the likely response of mine water management systems and the level of risk. This information is required to efficiently plan and manage the disposal of water for close-out.

Jan 1, 1994

By Yongjin S

Datong coal Mine suffers from delays and sudden caving of its massive competent conglomerate roof. Detailed geological studies of the nature of pebbles and matrix of the conglomerate and its sparse bedding, joint and fracture structure, gave rise to investigation of water injection to destroy its strength and to control caving. Comparative investigations, including porisity, permeability, compressive strengths and water injection of conglomerate and sandstone led to empirical expressions relating various properties and to guidance for effective injection and caving practice. This new safe roof control practice should be even more improved with further research, including Modelling.

Jan 1, 1992

By Noakes M. J

Research and development into alternate gold and precious metals adsorbents has resulted in the development of a new technology named the AUROSAVE adsorption process (ARGOSAVE'" for high silver con- tent ores). Adsorbents called VITROKELE'" can be tailored for either Gold I (cyanide leach) or Gold III (halide leach) applications. VITROKELE consists of a chemically synthetic adsorbent carried on an inert substrate, often a polystyrene bead. It is suitable for both in- pulp and in-solution use. VITROKELE adsorbent offers certain advan- tages over both carbon and ion exchange resin adsorbents. This paper describes testwork on Australian ores and commercial solu- tions obtained from operating Australian plants demonstrating the kinetic loading characteristics, elution methods and other operating parameters of VITROKELE adsorbent in the cyanide system. Brief reference is made to VITROKELE in the Gold III system.

Jan 1, 1988

By Jeffrey IC

This paper presents a method of measuring field power consumption of shearers and deriving specific energy consumption versus shearer haulage speed performance curves. A description of a computer program which simulates the cutting action of a shearer drum is presented. A comparison between the field specific energy curves and the computer simulation results is made. The simulation results compare well with the field data where all the coal seam is being cut by the shearer. The computer simulation results give back-calculated field pick force cutting characteristics, which allow the performance of the shearer to be predicted for other operating conditions, e.g. effect of changes to pick lacing, effect of changing the drum rotational speed, allows the calculation of power requirements for a particular production rate.

Jan 1, 1992

By Bowdler RJ, Lowson RT, Sarbutt JV

There have been few long-term studies of sulphide oxidation under controlled conditions. The object of this study was to investigate the oxidation and leaching characteristics of pyritic mine material under conditions that were commensurate with field conditions but which could be controlled and monitored on a long term basis. The test material - overburden from Woodlawn Mines Pty Ltd - was packed into a 300 cm high column and leached with water at an infiltration rate of 256 mm y-1 for 5 years. Chemical conditions within the column were continuously monitored by sensors embedded in the overburden and leachate from the base of the column was analysed weekly. The study examined the relationships between heavy metal release and gas, moisture, and chemical conditions in the column.

Jan 1, 1988

The first stage in the refining of lead blast furnace bullion is the removal of copper and this is normally done as a batch process in open kettles,A number of attempts have been made in the past to establish fontinuous processes operating in reverberatory type furnaces, but the growth of accretions in the furnace has always presented a serious problem.This has been overcome in the plant of the Broken Hill Associated Smelters Pty Ltd at Port Pirie by the construction of a reverberatory furnace and ancillary cooling system of novel design.Although a number of mechanical and metallurgical problems still remain to be solved, it is claimed that a workable continuous copper drossing process has been established.

Jan 1, 1963

Interaction between rock and fluid plays a critical role in rock engineering ventures such as stimulation of oil and gas wells, geothermal energy recovery and nuclear waste isolation. Robust and reliable design of the related services and underground facilities is based on understanding of the mechanics and chemistry of the coupled hydromechanical- thermochemical processes. This paper explores the application of the theory of such processes in minerals engineering, with particular reference to rockburst mitigation, in situ solution mining and cavity completion of coal-bed methane production wells.

Jan 1, 1995

Rajasthan of western India blessed with rich base metal and phosphorite deposits. The biogeochemical and geobotanical methods of mineral exploration are greatly used in parts of Rajasthan Zawar, Khetri and Ambaj multi-metal project Gujarat and Jhamarkotra phosphorite deposit. These principles are exclusively based on certain assumptions about the anomalous chemical composition in plants and distribution and migration of indicator elements. Biogeochemical studies for lead zinc deposit of Zawar group of mines were carried out to locate the probable accumulators which could help in prospecting for these metals. The important roots of Impatiens balsamia plants contain 735 mg. of cadmium and crotolaria linifolia 603 mg., melhania futteyporensis 626 mg. lindenbergia muraria 443, celosiu argentia 360 mg. In the Khetri copper belt the vegetation is scanty and the species includes Acacia arabica, zyzypus jujuba and cactus euphorbia.

Jan 1, 1988

By D Monaghan

Pumping water for dewatering and water supply is a major component of electricity consumption at mining operations and hence is a significant contributor of greenhouse gas emissions. Pump systems at a typical mine site can be broadly split between above ground centrifugal pumps (generally used for water transfer) and submersible borehole pumps (generally for dewatering and/or water supply). In contrast to above ground pumps, submersible borehole pumps can be subjected to varying duty points (total pumping head and flow requirements) as a result of changing bore water levels and yields, particularly in mine dewatering bores. Typically, much higher pumping rates are required at the commencement of dewatering to remove groundwater storage and to intercept sufficient groundwater throughflow to achieve target drawdowns. Once target drawdown levels are reached it often only requires much lower pumping rates to maintain target drawdowns. Pumps sized to remove the large initial volumes of stored groundwater often end up too large for the lower flow rate required for æmaintenance pumpingÆ. This often results in pumps operating inefficiently, a problem which can be made worse when pumps are throttled to reduce the pump output to better match the reduced bore yield. Current standard operating practice places little emphasis on the electricity consumed by pumps, with the focus often being on minimising capital expenditure (æIf it ainÆt broke donÆt fix itÆ). Submersible pumps can have extended service lives of ten to 20+ years. However as the capital cost of a pump typically represents only five per cent of the life cycle cost, the vast majority of the life cycle cost is energy usage.Through the implementation of a regular review of the operation of borehole pumps, significant reductions in electricity use and associated greenhouse gas emissions can be achieved without impacting the dewatering schedule. In most cases, the capital cost of replacing pumps is more than offset by savings in operating costs. These potential savings become even more significant when considering proposed future carbon tax levees.This paper presents examples of the opportunities for significant reductions in energy, greenhouse gas emissions and overall costs that can be achieved for a range of dewatering scenarios.

Jan 1, 2009

By T Hausler

The pitfalls, pleasures and management issues associated with international and remote projects are diverse.However, no problem is insurmountable and if an engineering team chooses (by luck or good planning) to push through the difficulties, success can mean an extremely satisfying experience for individuals and a significant, positive result for an organisation.International projects are not for the faint hearted or inflexible. Working in foreign lands with people who may or may not speak English and who may not initially respect you can become mentally and physically tiring.Sometimes the challenges are not fully explained to individuals in advance. Individuals then often learn about the challenges ù and discover solutions ù on the job. While this initially puts great pressure on individuals, matters improve eventually, especially when the locals come to understand that you are on site to make a positive difference.This paper will discuss aspects of a recent international project including meeting international clientsÆ expectations, dealing with cultural differences, social reckoning, environmental issues, and personal challenges. Specifically, it will cover aspects of working within a Russian cultural setting and overcoming social barriers.The paper also presents coping strategies for long periods of time spent away from home in remote places with extremes in weather beyond the normal experience of most Australians. For example, dealing with the effects of the spring thaw and coping with temperature ranges of -45 to +45¦C.Lastly, and possibly most importantly, there will be a focus on the role of translators. They have the power to make an engineer everyoneÆs best friend or, on your behalf, to order cold chicken liver and heart salad for lunch. If an engineering team can establish a working relationship with translators, they can become an invaluable asset and both on and off site.CITATION:Hausler, T, 2013. Achieving success in large-scale, remote area metallurgical plant projects, in Proceedings MetPlant 2013 , pp 539-552 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 15, 2013

Faced with low prices and weak demand in an oversupplied market, the Australian coal industry must seek to further reduce its costs. The paper examines minesite competitiveness of the open cut coal industry in Australia with some references to the coal operations of M.I.M. Holdings Limited. The make-up of F.O.R. mine costs is analysed in order to identify where efforts should be directed to maintain competitiveness. The scope for mine site improvements through changes to working practices, the application of new technology and cost management is examined.

Jan 1, 1987

In the Illawarra District of New South Wales, Mines were traditionally developed from the seabord. The advantages were close access to the working faces and a minimal depth of cover. Travelling times to the working faces have become prohibitive in many cases due to progressive westward development of the mines. As a result, additional vent- ilation shafts were sunk to service existing mines and new mines were established west of the Illawarra escarpment. Mining operations west of the escarpment are now being conducted at an increasing depth of cover and can be effected by gas related problems such as high seam gas emission rates and gas outbursts.

Jan 1, 1983

By J Barnes

During September 2000, Nabalco management identified the need for a corporate system to deliver its key performance indicators (KPIs). In June 2001, a need was also identified to replace the existing metallurgical accounting system. After a review of the technologies available, the decision was made to develop the systems in-house, in preference to purchasing commercial software packages. This would allow much greater control over the structure, and provide for an iterative, concurrent development process between software and key business developers. This has proven invaluable in the development process. The purpose of the KPI system is to provide a unified reporting tool for all performance indicators. These indicators include production, safety, health and environment, personnel, costs, continuous improvement initiatives and opportunity losses. All of these disparate measurements are brought together into the KPI system and used to determine the performance for each department or area. The general principles of the balanced scorecard business approach (Kaplan and Norton, 1996) are applied to achieve a performance measurement for each area within Nabalco. The new metallurgical accounting system (MA) is a SQLServer database with web page and Excel interfaces. The database is structured around daily inputs of all measurements and calculations. The data is stored and adjustments and reconciliations can be made to this data as required. The focus is on accounting rigour, with all adjustments recorded in the database to allow for full auditing. The structure of the data focuses on the five input/output streams (bauxite in, caustic soda in, fuel oil in, residue out, and alumina out). In-circuit inventory provides a secondary measurement on which to check and calibrate the MA system. The KPI and MA systems were developed using Web technologies and are available to any internet-enabled device with Internet Explorer installed. This removes the need for software rollouts and user training. This will promote the wide use of the systems throughout Nabalco and Alcan.

Jan 1, 2002

A metallurgical balance drawn around a mineral processing plant or smelter must involve all process streams crossing the plant boundary. Modern sampling theory, as formulated by Gy, and sound statistical method can be used to determine the uncertainties in the observed assays for the set of balance analytes and in the mass flow rates of the process streams for the balance period. These uncertainties can then be used together with the material balance equations to arrive at adjusted component mass flows that satisfy the material balances exactly. To determine whether or not the data is consistent with the level of uncertainty in the data and with the material balance equations, a goodness of fit test is applied. This goodness of fit criterion is the principal tool to quantify the quality of the material balances. The mathematical structure of the statistical material balance problem poses a number of challenges. For example, while the variances of the adjusted component mass flows do not vanish, the variances of the sums of the adjusted component mass flows about each balance node do vanish, simply because the balancing computation demands that the balances close exactly. Even though it can be shown that the variances of the adjusted component mass flows are always lower than the estimates for the corresponding unadjusted component flows, it is still not possible to construct a confidence interval on the component mass flow into (and out of) a balance node using the adjusted component flows. On the face of it, such a confidence interval is exactly what is most desired from the balance calculations. The problem arises because the balance problem is a data adjustment rather than a parameter estimation problem. It is possible, however, to calculate the recovery of a component to a product stream and determine a confidence interval for the recovery value. It is also possible to calculate an uncertainty in the mass flow of any balance species in any process stream, before and after balancing.

Jan 1, 2005

The face of project evaluation is changing continuously, making it ever more critical to get a clear understanding upfront of the objectives, decision-making processes and criteria of the project proponents. Requirements are usually significantly different for emerging æjuniorsÆ compared with long established major mining houses and companies in developing countries compared with western companies. Requirements are also different for different types of evaluations, such as due diligence studies compared with feasibility studies of æownedÆ projects and there are often key misunderstandings around the use of the term æbankableÆ. Further, it has become increasingly important with increasingly remote and lower quality resources to understand risk relativities such as infrastructure compared with the core processing facilities. This has also driven the need for more trade-off studies to determine the best balance between critical issues, such as optimisation of the interface between mine and processing plant, capital versus operating cost and automation versus labour. In every project evaluation, it is also critical to consider emerging trends and changing requirements and standards such as sustainability and community interface. Finally, the inescapable drive to reduce time to market has driven changes such as increased use of more standardised designs and innovative approaches to the transition from project development to execution. This paper begins with a brief review of the different objectives and risks of each project development stage to establish a framework for subsequent discussion of the different requirements of different types of companies in different locations, different types of evaluations and different types of projects and project components. This is followed by a review of changing requirements and standards and some innovative developments in sustainability and community interface are presented. Finally, the paper outlines a number of developments in the area of operational readiness planning that focus on minimising the time to achieve maximum return on investment.

Jan 1, 2009

Mineral resource classification is essential because it is required for public disclosure. The resources must be binned by a qualified person into measured, indicated and inferred categories using an appropriate methodology. The classification methodologies used have long been a topic of research and discussion. There are various traditional and geostatistical methods used in practice. Some are more popular than others. Because of the uniqueness of each ore deposit, it seems almost impossible to have a single industry-accepted norm for mineral resource classification. Therefore, some experts have adapted the methodologies tailored for the deposits they are working on, but many simply use the methods they and their clients understand and are comfortable with. In this paper, a new approach is presented to classify the mineral resources using a data geometry index. This index combines both traditional and geostatistical aspects of resource classification based on the data configuration around the block interpolated. It is a function of several variables such as kriging variance calculated for a block, distance from the block to the nearest sample and the average distance of all samples used to interpolate the block. Thus the approach using this index takes into account the spatial data configuration around the block being estimated, as well as the traditional distance criteria. The data geometry index and how it is calculated is explained. A case study for a gold deposit is presented to see how the classification based on this index compares to the existing methodology used in this deposit for mineral resource classification.

Sep 26, 2011

Australia, with its fast-growing economy and high standard of a~ living, has a high and rapidly increasing per capita consumption of energyIn total terms, Australia's energy requirements are doubling every 15 years, and among mature Western economies Australia ranks behind only Italy-and Japan in the rate of increase of energy consumption.The use of energy is often accepted as a yardstick of development and on this basis Australia might well congratulate itself on its high energy consumption. However, it is less well recognised that the resources absorbed in the production of energy represent a real cost to the* community, and that just as we strive for industrial efficiency or farm productivity we should strive for economy in the use of energy fuels.Australians spend annually an estimated ú500 million.on all forms of energy, a sum which represents about seven per cent of the Gross National Product. In all, energy production and distribution absorb the employment of more than 100,000 persons. In addition, the annual capital investment by.the oil industry amounts to some E55 millions, by the coal industry about ú12 millions, and by electrical and gas authorities some E108 millions, in total representing more than ten per cent of annual investment in other than private motor cars and housing,

Jan 1, 1962

Hindered settling devices (teeter bed, up-current) are widely used in the mining industry to classify mineral streams into various size fractions and to separate minerals. In the coal industry these devices are extremely successful in separating coal of low densities from shale and pyrite. In the beach sand and in the iron ore industry, this equipment is used to beneficiate minerals either as stand alone units or lately as classifiers in spiral circuits. The challenge that these applications give to metallurgists is to be able to simulate the equipment by using mathematical models with or without the aid of small bench scale tests. In any green fields and many brownfields projects, limited amounts of samples make pilot plant tests difficult. Although there are mathematical approaches available, the accuracy is of such a nature that it can not be used for design purposes. This refers to the use of StrokeÆs law, NewtonÆs and the so called intermediate law as is widely published. Research done by the author indicates that in most applications none of the above laws apply. Using the original data as published by Perry and Chilton (Chemical Engineering Handbook, pp 5-64, 1973) and re-plotting it indicates that the settling velocity of particles is a function of (particle diameter)n where n varies between 1.2 and 1.6 which is different from that predicted by the intermediate law that suggests that n = 1.18. Another way of describing the relationship between the drag force and the Reynolds number is done by iterating between settling velocity and the Reynolds number. This needs more computer time but the accuracy obtained from this does add value to simulations. A small but simple test is suggested to determine the settling velocity of particles to enable metallurgists to determine variations from the theoretical calculations to determine the influence of viscosity and particle shape.

Jan 1, 2008