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By X Li, R Chu, X Deng

The hot-dip galvanising industry is the largest consumer of zinc, with over 40 per cent of the world’s total annual production of zinc used for galvanised steel. The dross generated in the hot-dip galvanising coating process is a valuable co-product, since it contains high quantities of recyclable metal. A new method to recover the metal from the industrial galvanising dross was proposed using supergravity separation. During the hot-dip galvanising process, the presence of zinc dross has a serious impact on the surface quality of the hot-dip galvanised sheet, forming zinc dross defects. To reduce the impact of zinc dross, the zinc dross on the surface of the zinc pool needs to be manually or mechanically removed at regular intervals. However, during the dross removal process, a large amount of metal zinc is inevitably carried out, resulting in low zinc utilisation rate and high zinc loss rate. This article proposes an efficient and low-cost technology for the recycling and utilisation of hotdip galvanised dross, which uses super-gravity technology to recover hot-dip galvanised dross online. The metal in the hot-dip galvanised dross returns to the zinc pot in situ, while a small part of the dross remains in the super-gravity equipment, which can reduce the amount of zinc dross by more than 60 per cent and achieve a reduction in zinc loss from 17 per cent to less than 7 per cent.

Jun 19, 2024

By G Simpson, S Dressler, A E. Levett

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

Aug 2, 2023

By P J. Bangerter, J Pan

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

Aug 2, 2023

By K Brand, M J. Ind, M Rynhoud

Water management at a tailings storage facility (TSF) presents one of the major risks to the safe performance of the facility. International and domestic dam safety guidelines assess a dam’s hazard category based on the consequences of a dam failure and the subsequent downstream damage to the environment and communities.Often a rigorous risk assessment is undertaken during the design stages to identify and control hazards associated with water management through life-of-mine (LOM) phases. However, as experienced during the recent downturn in commodity prices, early closure of a mine can occur rapidly and unexpectedly. Although guidelines such as the Australian National Committee on Large Dams Incorporated (ANCOLD) recommend that one of the key objectives of integrated TSF planning is to ‘plan all phases of a tailing dam’s life to ensure adequate storage capacity including early closure ’ (Australian National Committee on Large Dams Incorporated (ANCOLD), 2012) this is often overlooked by owners who are focused on fulfilling the mine’s potential and early closure is not on their radar.CITATION:Ind, M J, Rynhoud, M and Brand, K, 2016. Life-of-mine spillway strategy – managing risk associated with surface water at a tailings storage facility, in Proceedings Life-of-Mine 2016 Conference, pp 209–211 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jun 28, 2016

By A Grant, H Thomas, C Clarke, B Fuller

Native seed and plants are often a core input into the rehabilitation process of mine closure. Native plant establishment rate and performance is a function of many input elements including seed quality (purity and germination percentage), processing, treatment, storage, supply chain handling, application and ongoing management. Traditionally native seed has been supplied with very limited supporting information which in some cases has led to establishment failures, repeated attempts at successful plantings, and biosecurity issues, leading to increased rehabilitation costs for mining companies. Product procurement scrutiny, and sustainability credential requirements, in all supply chains is increasing the need for transparent, accurate, verified, and certified information. This collectively continues to evolve towards a social license to operate in all industries, including mining. The Australian Seeds Authority (ASA), in partnership with native seed supplier AustraHort, traceability software company Trust Provenance and supporting partners including Transport for NSW and Queensland Transport and Main Roads (TMR), were recipients of a DAWE National Traceability Grant. The project team has developed a framework and traceability software platform currently being piloted within the Australian native seed industry. The framework and platform allow for all critical-tracking-events along the journey of a native seed batch to be easily captured utilising a smart phone application (APP) and the global standard for data capture. The platform provides a unique identification for each batch of seed and critical tracking event. The batch ID belongs to that batch and all supply chain stakeholders can contribute to batch traceability by providing more information/data to increase information integrity. This gives the end user, and other stakeholders, increased levels of trust in the product to support value, increase efficiency and reduce costs. For mining companies these efficiencies and cost reductions are in the form of information availability across site/company, potentially improved vegetation establishment, less rework and efficient monitoring. Ultimately this contributes to safe, stable and sustainable rehabilitation. By capturing data on harvest, logistics, storage (including temperature and humidity), aggregation/blending, treatment, application and ongoing management, the native seed industry and end utilisers of native seed have a greater level of product integrity, brand integrity and information integrity.

Aug 2, 2023

By G Anderson, V Lawson, P Voigt

Glencore operates zinc concentrators at both Mount Isa and McArthur River. Both orebodies have a history of complexity and required the development of new technologies to maximise the value from these long-life assets. The Mount Isa orebodies were plagued since operations started in 1931 with complex mineral textures making separation challenging and many areas uneconomic. Examples are given in Figure 1 with different grain sizes from the same orebody in different areas. The McArthur River deposit, located in the Northern Territory, was discovered by Mount Isa Mines geologists in 1955 (Logan, Murray and Williams 1990). The extremely fine-grained nature of the ore was quickly recognised and the difficult separation of the minerals was soon obvious. The geographical, metallurgical and economic factors resulted in the orebody not being developed until the technologies for the mineral separation had been developed. The development of the IsaMill allowed for an economic mineral separation flowsheet to be developed and ore treatment commenced in May 1995 (Nihill, Stewart and Bowen 1998). CITATION: Lawson, V, Anderson, G and Voigt, P, 2018. Developing technologies for a complex orebody, in Proceedings Complex Orebodies Conference 2018, pp 116–118 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 21, 2018

By A Krishnan, C Garcia, I Luna-Berbesi

The discovery and exploration of deposits are progressively shifting to extremely remote regions and greater depths. As a result, exploration costs and the economic risk of a bad investment increase. Current megatrends in the exploration and mining sector indicate a growing demand for the implementation of automation, digitalisation, and machine learning techniques. The implementation of a multi-sensor-based core logging device (DMT, 2024) was done on 400 m of drill cores to optimise interdisciplinary processes in terms of time and quality, by using interlinked and consistent data in real-time, to obtain reliable predictions that support and speed up decision-making. The results are consistent with the laboratory data previously obtained by the mining company, highlighting the benefits of introducing ANCORELOG into their core logging procedures.

Sep 1, 2024

By N Arrys, A Jani, S Shahin

Optimising pit slope stability and reducing strip ratio of a mining operation are two key tasks in geotechnical engineering. With a growing demand for minerals and an increasing cost associated with extraction, companies are constantly re-evaluating the viability of mineral deposits and challenging their geological understanding. Within Rio Tinto Iron Ore (RTIO), the Structural Geology (SG) team investigate and collect critical data, such as point based orientations, mapping and geological inferences from adjacent pits to remodel deposits where previous interpretations have failed to account for structurally controlled slope failures. This work outlines the key methods utilised by the Structural Geology team which form the foundations of informed orebody knowledge and subsequent geotechnical design recommendations. This publication utilises the results from a recent analysis to highlight the benefits of this methodology and how it has impacted the economics of an operation through optimisation of a pit wall ‘cutback’ and crest relocation.

Sep 1, 2024

By A Maier, M Goldner, C Gimber

Given the ongoing global crises of climate change and nature loss, with the World Economic Forum (WEF) identifying them as the top risks to global economies in terms of both likelihood and impact in the coming ten years (WEF, 2022), there is increasing, pressing demand for companies to demonstrate they understand their climate and nature related risks and look toward contributing genuine beneficial environmental outcomes. Within the mining industry, mine closure is the obvious field in which climate and nature positive strategy can be linked with operations. To do so, there is a need to challenge long-held assumptions around closure in the mining and regulatory context; particularly, to shift the focus from closing individual mines to considering regional opportunity generation and value creation.

Aug 2, 2023

By P Martin, A Somarin, S Bailey

Field-based research was conducted to investigate the performance of field portable X-ray fluorescence (FPXRF) in the analysis of reverse circulation (RC) drill chips in iron ore exploration. For years, FPXRF has been considered unsuitable for iron ore exploration due to the limitations of the elements it is capable of analysing for, in particular its inability to measure light elements (Mg, Al, Si, P, S). With the advent of the use of silicon drift detectors (SDD) in FPXRF, light elements are now measurable elements. However, doubt over the appropriate use of this new technology still exists due to the absence of reliable comparative field data. These doubts concerned the ability of the FPXRF data to correlate strongly with the laboratory assay of the same samples. It was believed that inconsistent grain size and other variables not being controlled would contribute greatly to this perceived unreliability.We tested RC chip samples on-site in the Pilbara, with the portable Thermo Scientific Niton XL3t X-ray fluorescence (XRF) analyser for a range of elements including Fe, Mn, Al, Si and S and then compared the results with laboratory assay data. A strong correlation indicates that the FPXRF results are reliable. Furthermore, to show the effect of simple sample preparation, we also analysed pulps of the same samples in the same way.The correlations were good for all of the elements of interest for the RC chip samples (R2 values between 0.82 and 0.9), and excellent for the pulps (R2 values between 0.89 and 1). The results also showed a direct correlation between sample preparation and improved quality of results with the FPXRF. This indicates that FPXRF can produce data from unprepared RC chips for Al and Si that, when compared with laboratory assays, is reliable for a field application in drilling and grade control. CITATION:Somarin, A, Martin, P and Bailey, S, 2013. Non-destructive analysis of diamond core for light elements using Niton field portable x-ray fluorescence, in Proceedings Iron Ore 2013 , pp 117-230 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 12, 2013

By J J. Van Wijk, A R. Penney

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

Nov 29, 2022

By K White, C Ferguson, M Harding

Understanding watercourses and river processes at a landscape scale is vital for managing risk to mining infrastructure and operations as well as minimising future environmental impacts beyond the life of the mine. Recognising this, Iluka Resources Limited engaged Alluvium Consulting Australia to identify and characterise watercourses across several neighbouring mineral tenements in the Eucla Basin, South Australia (Alluvium, 2013, 2014a, 2014b). The objective of the studies was to inform planning for risk management during mine planning and operation and appropriate landscape rehabilitation for mine closure.Mining operations in the area are by open cut extraction of mineral sands. The extracted resource is processed on-site before leaving the site for export. Several pits are to be developed in stages with simultaneous backfilling and surface reinstatement. Mining is initially taking place in the Jacinth tenement, where up to 100 km of watercourses may be directly or indirectly impacted (refer to Figure 1).The total study area (shown in Figure 1) is approximately 330 km2 and spans three smaller areas that were the focus of separate investigations during mine planning.CITATION:Ferguson, C, White, K, Harding, M and Hardie, R, 2016. Landscape-scale assessment of watercourses in remote arid South Australia to inform mine planning to mine closure, in Proceedings Life-of-Mine 2016 Conference, pp 200–204 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jun 28, 2016

By C Linklater, J Chapman, A Watson

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

Jun 28, 2016

By C Linklater, A Garvie, D Kentwell

Various Australian and international regulatory bodies (Environmental Protection Authority, 2015) require an early assessment of the geochemistry of waste rock. This usually includes estimates of the locations and volumes of potentially acid forming (PAF) materials and requires sampling of the waste rock zones as well as submitting the samples for a series of tests. We know that the required number of samples will vary depending on rock type, mean sulfur levels and spatial variability of sulfur as well as total volume. The key question is how do we know when we have enough samples?This extended abstract describes the application of geostatistical methods to examine how sample numbers and sample locations influence the preliminary conclusions that may be drawn for early stage waste characterisation.CITATION:Kentwell, D, Garvie, A and Linklater, C, 2016. Geostatistics and sample numbers from an acid and metalliferous drainage perspective, in Proceedings Life-of-Mine 2016 Conference , pp 12–15 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jun 28, 2016

By H von Blottnitz, A C. Keith

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

Jun 28, 2016

By R Paterson, A Christensen

The routine use of gravity gradiometry for the detection of orebodies with no outcrop is now being undertaken. The commodities and orebody styles range from banded iron ore formations to volcanogenic massive sulfide (VMS) style polymetallic deposits. This recent innovation of flying gravity gradiometry was pioneered by BHP Billiton and Lockheed Martin with the Falcon technology (Lee, 2001), and now two additional systems, also using Lockheed Martin instruments, are deployed. In South Africa, magnetic gradiometry is being developed and deployed with the same objectives in mind. In this case, a system from Institute of Photonic Technology (IPHT) is being used. The detectable wavelengths from such systems have decreased to less than 200 m in the last year, and it is expected in 2011 that wavelengths to less than 100 m, with anomaly signal strengths of less than 2 Eotvos for gravity gradiometry will be viable. The key to these advances lies in the improvements of processing software and geological modelling. In particular, methods using all the tensor components are starting to be routinely deployed to filter, level and grid the observed signal. These methods do, however, require full insight and understanding of the reference coordinate systems used by the various instrument designers and survey operators. The digital terrain models need also to be observed to an accuracy of better than 20 m cell sizes, using such techniques as Lidar. Then the terrain effects can be modelled. The topographic surface represents the largest and most proximal density contrast encountered in an airborne survey. Hence terrain effects can have significant impact on airborne gravity gradiometry data. A decorrelation of the terrain effect with the observed signal requires a method of best fitting with a regional surface density. A novel technique has been developed for this purpose. This technique uses a tensor algebra to estimate a density between 1 - 4 g/cc that explains the average observed signal. Armed with this result, the anomalous buried bodies can be revealed by subtraction.

Sep 26, 2011

By A Castillo, K Wiese, L Panduro Robles

For decades, organisations worldwide have been working to overcome challenges associated with new technology adoption while keeping up with rapid growth, development, and globalisation. In minerals processing, the challenges in developing and implementing solutions that contribute to the mining value chain are unique from other markets, as mining operations expect that world-class suppliers provide them solutions to gain a competitive advantage in their operation, production, performance as a financial asset, and as a long-term partner as we move into the future of mining. A simple shift in mindset is proven key to successful technology implementation. Change leaders must no longer think of their expertise in the area of application as their only responsibility; they must make a mental shift and see themselves in dual roles that strive to integrate the perspectives and needs of both developers and users. Successful change leaders must: (1) collaborate, seeking user involvement to ensure fit between product and operational needs, (2) demonstrate commitment to receive new technology, and (3) communicate to achieve an eventual shift of ownership from supplier to users that is seamless. Additionally, this strategy contributes to the mining value chain, as it allows developers and implementers to evaluate how change contributes to the asset’s position both within the company and in the commodities market. This paper will explain the shift in perspective for new technology implementation in detail and provide recommendations that operations can emulate, using examples of real challenges and lessons learned during a commissioning of the CYCLONEtrac™ Particle Size Tracking (PST) system at Cerro Verde’s C2 Concentrator. This concentrator has led technological change for plant optimisation, witnessed improved Net Metal Production (NMP), among other benefits with PST, the only technology in the market capable of providing real-time, online, and direct particle size measurement at the individual hydrocyclone level

Aug 24, 2022

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

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

Nov 29, 2022

By E Thomas, L McCallum, G Dale, J Bennett, K Reardon-Smith, S Raine

Sustainable closure of coal mines in Australia to a safe, stable, non-polluting condition remains one of the industry’s biggest environmental and social challenges. A significant proportion of mines in the Bowen Basin of Queensland have dispersive spoil. Based on an estimated area of 20,000ha and a rehabilitation cost of AUD$100,000 to AUD$150,000/ha, the instantaneous rehabilitation liability for the Bowen Basin alone is estimated at AUD$2 to $3 billion.Dispersive spoils present problems in post-mining rehabilitated landforms due to increased potential for surface and tunnel erosion, compromising the ability to achieve fundamental mine closure objectives of a safe, stable, non-polluting and self-sustaining post-mining landform (Minserve, 2004). Dispersion results in clay particles being mobilised and transported in water, even at low flow velocities (So et al., 1998; Minserve, 2004), and blocking of soil pores, resulting in surface sealing, crusting and reduced permeability (DNR, 1997; Vacher et al., 2004) which, in turn, further increases runoff (Dang et al., 2018).CITATION:Dale, G, Reardon-Smith, K, Thomas, E, Bennett, J, McCallum, L and Raine, S, 2018. A process-based approach to mine rehabilitation decision making using Bayesian modelling and risk-based principles for dispersive spoil rehabilitation, in Proceedings Life-of-Mine 2018, pp 106–109 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 25, 2018

The Operation of the LAROX PF-50 Pressure Filter at 'Ellatzite-Med' Flotation Plant, Bulgaria The implementation of Larox pressure belt filter, type Larox PF-50 provided within 6˜8% moisture content of the produced copper concentrate, which allowed good market realisation. The start-up of the pressure filter in 2009 reduced the electricity costs several times and had a positive impact on the technological regime of flotation. This article reveals the investigation results from the operation of the pressure filter according to different situations (density of the pulp, time for filtration, pressure of the material, pressure of the drying air, time for drying with air and other factors). The investment made in the pressure filter application is a guarantee for the successful operation of 'Ellatzite' flotation plant, Bulgaria in the coming years.

Sep 13, 2010