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By H Wang, D Wang

Mine dust is the most serious occupation hazard in coalmines. And many coal workers suffer from pneumoconiosis because of long-term inhalation of respirable dust. Reducing the dust concentration of workplaces by effective technical means is an important way to prevent coal worker’s pneumoconiosis (CWP). In order to overcome deficiencies in existing dust control technology for underground mining, especially the disadvantage of water spray technology mounted on roadheaders or continuous miners, the authors developed an integrated dust suppression technology utilising foam for fully mechanised heading faces. This paper presents an overview of the principles, materials, equipment and application of this technology. Among these, a jet type foaming device and a green foaming agent were developed, which can realise the goal of efficient preparation of foam. In addition, an arc fan nozzle used for foam spraying was invented, which can effectively cover and enwrap the dust produced by the roadheader at the cutting point and achieve the goal of efficient utilisation of foam. This dust suppression application of the proposed foam technology was investigated on fully mechanised heading faces. The results show that the dust concentration was cut down significantly with a dust suppression efficiency of greater than 85 per cent, an increase of over 30 percentage points compared to the water spray system. This study demonstrates that this foam technology can play an important role in dust suppression on fully mechanised heading faces, which provides an important method to improve the working environment and protect coal workers’ health.CITATION:Wang, D and Wang, H, 2015. Technology of dust suppression by foam for fully mechanised heading face, in Proceedings The Australian Mine Ventilation Conference, pp 177–182 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 31, 2015

Continuous improvement in environmental management assists in the achievement of sustainability goals for the processing of minerals. The use of regular internal environmental audits (scored or unscored) which form an integral component of an Environmental Management System (EMS), provide demonstrable evidence of this improvement. Case studies are presented for a number of major coal mines in the Hunter Valley, where regular internal environmental audits have been undertaken every two to three months, over periods varying from 18 months to five years. Examples of the benefits of improved environmental performance (driven by the audit process) to sustainable development are provided.The auditing process as described here for coal mines, and coal handling and preparation plants, is equally applicable to the processing of other mineral ores, metalliferous mines, quarries, and oil and gas projects.

Jan 1, 2004

By A Jyoti, J R. Black, R R. Haese, E O. Ansah

Copper (Cu) is a critical metal in the transition to a low-carbon power supply. Presently, low-grade copper sulfide ores account for almost 80 per cent of the global reserves. Large amounts of water are required to process these low-grade copper ores. The mining industry utilises lixiviants from recycled water from different sources to conserve water, whilst enhancing Cu recovery. Some utilise intermediate to pregnant leach solutions, sea water, and processed water from electrowinning circuits with highly variable concentrations of ions. Previous studies have highlighted the formation of precipitates that passivate the surfaces of minerals in these low-grade copper ores and/or block flow paths for lixiviant during heap leaching. In this study, we utilised concepts of phase replacement to devise an innovative means of controlling precipitation and increasing copper recovery using industrial brine as opposed to freshwater. We propose the formation of Al-rich phases (such as AlSO4 + or alunite) to replace iron sulfate and iron hydroxysulfates (such as jarosite) during the chalcopyrite dissolution-precipitation mechanism. The rationale is to have available Fe3+ throughout the chalcopyrite leaching process. We tested this method by carrying out various batch experiments using CaCl2, AlCl3, and NaCl industrial brine types compared to freshwater and explored the capacity to leach Cu from chalcopyrite. There is higher Cu recovery during oxidative leaching of chalcopyrite in industrial brine with 91 per cent recovery using AlCl3-rich brine, 84 per cent with NaCl-rich brine, and 56 per cent with CaCl2-rich brine as compared to 35 per cent recovery using freshwater. In the absence of Al3+, various forms of iron sulfates, and jarosite are formed, reducing the availability of Fe3+ for chalcopyrite dissolution. The introduction of Al3+ leads to the formation of AlSO4 + species, thus lowering sulfate activity and the tendency for K-jarosite formation.

Aug 24, 2022

By G R. Ballantyne, G Lane

Dry milling circuits that include high pressure grinding rolls (HPGR) or vertical roller mills (VRM) and air classification have replaced dry ball milling in cement production, but how do they compare to wet milling and classification circuits in mineral processing plants? Two case studies are presented that compare the energy efficiency, wear, liberation and capital cost of dry and wet milling circuits. In both case studies the VRM and HPGR consume half the energy of a wet tumbling mill for the same duty. However, the dry classification system tends to significantly erode the energy benefits. A number of improvement opportunities are presented that have the potential to improve the energy and capital efficiency of dry milling circuits. These improvement opportunities focus on the dry classification system that consumes significant energy in heating and fan power requirements and requires a large proportion of the footprint.

Aug 24, 2022

One of the earliest and continuing challenges in driving sustainable development in large scale resource industry projects is around the issue of assessment û how do you measure the sustainability of a mineral operation? One of the key road blocks when confronted with this challenge is the temptation of technical folks to reach for a definition of sustainability or sustainable development. But definitions, by definition, have boundaries and limitations that serve to constrain thinking û they limit the thinking of what we can achieve with sustainability (it also acts as a barrier that constrains innovation). Rather than seeking definitions, better understanding of the core perspectives around sustainability and their application to the minerals industry provides a much more powerful platform from which to conduct assessments. But it is only when these perspectives are combined with the right framework and supporting techniques that the complex becomes doable. With the support of the perspectives and the framework, various assessment and measurement methodologies can be used; the challenge is communicating to stakeholders the sustainability character of the project in ways that are meaningful and to which people can connect. Assessment is not about finding the best or most accurate methods that fulfil strictly academic and possibly abstract requirements. The challenge is to help people understand what the impacts are, and what the value contributions will be, in a format and language that make sense in their world-view.

Jan 1, 2009

By Merry N, Cocks T

The mineral exploration industry is increasingly aware of the importance of the relationship between mineralogical data and geochemical assay results. However, until recently, the cost and time constraints of most techniques for analysing alteration mineralogy have precluded detailed alteration studies. These impediments have been reduced by the development of the Portable Infrared Mineral Analyser (PIMA), a field portable infrared spectrometer that allows rapid (in field) and cost effective analysis of alteration minerals including subtle variations in mineral crystallinity and Composition.

Jan 1, 1995

By G M. Hoffmann

Utilisation of lower grade (Jigging technology has progressed to a point where SishenÆs 50 to 60 per cent Fe run of mine (ROM) material, once considered as waste, can be beneficiated to produce a saleable 64 per cent Fe product. This has been confirmed through appropriate beneficiation testwork. Consequently, Sishen can now produce saleable product from material not currently included in the resource definition, significantly increasing the resource base of the mine and ensuring higher resource utilisation. Mine planning utilised the geological models to produce detailed planning schedules, reflecting the current and SEP plants separately, optimised to comply with product specifications of both the current and SEP plants and to confirm the viability of the low-grade resources identified as SEP feed material. The SEP product specifications have been derived by optimally matching iron ore market requirements with the revised resource base. A 64.0 per cent Fe lump product and a 63.5 per cent Fe fine product are the optimal SEP products. The SEP plant will be able to produce 10 Mtpa at an average yield of 60 per cent and a lump to fine ratio of 62:38. The plant consists of five major sections: namely crushing, material preparation, beneficiation, final product handling and quality control services. Maximum integration with the current Sishen plant was considered. Kumba currently has an agreement with Transnet to rail up to 23.5 Mtpa through the Sishen Saldanha iron ore export channel (IOEC). Transnet and Sishen Iron Ore Company have signed a Definitive Agreement that deals with the expansion of IOECÆs capacity, which increases KumbaÆs entitlement from 23.5 Mtpa to 35.0 Mtpa. The detailed enviro-legal impact assessments for the SEP indicated that the project has low enviro-legal risk as a result of it being a brownfields project incorporated into the current Sishen operations.

Jan 1, 2005

By M Monaghan, B S. Gregory

The Geita Gold Mine is located 80 km southwest of the town of Mwanza in the north-west of Tanzania and is 100 per cent owned by AngloGold Ashanti Limited. Open pit mining commenced at Geita in 2000. In 2011, the operation produced 494 000 oz at a cash cost of US$536/oz. This is a significant improvement from 2008, when 264 000 oz were produced at a cash cost of US$742/oz.A period of relatively poor operating performance at Geita was recorded over the period from 2006 to 2009. A period known at Geita as æthe turnaroundÆ commenced in 2009, and has been remarkable to say the least. Over the last couple of years the mine has embarked on a journey, which saw various interventions and initiatives. Among the key initiatives were Project ONE (which focuses on business process framework, systems for people and safety transformation), asset integrity, fatigue management and contract mining of satellite pits.Since the commencement of the turnaround at Geita, gold production has matched market guidance. The mine has returned to positive cash flow on the basis of strong performance on cash management, improved production and increased gold price.This paper explains some of the details of the mine operationsÆ improvements, how they were implemented, their relative contributions to improved mining performance and the path ahead to best practice. Observations will be made about some improvement rules that can be applied generally in open pit mining.CITATION:Gregory, B S and Monaghan, M, 2012. The path to best practice at Geita Gold Mine, in Proceedings Eighth Open Pit OperatorsÆ Conference , pp 41-48 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 18, 2012

The diverse nature of inadvertent mine fires does not lend them to general treatment. But evolving from the unfortunate fires over past years is a simple principle in dealing with all fires to bring combustion under control. Control, in brief, means that the products of combustion, themselves possibly still with fuel values, are not revitalised by addition of fresh air. There are problems with fire- fighting, especially with water, as this may lead to production of CO and H2. Panel ventilation upstream of the fire must be controlled to direct all air over the fire. Some advantages in fire fighting are found by the use of "sails". Early diagnosis of fires and early treatment are essential for safety of personnel and safeguarding and recovery of property. Preparedness extends to up to date documentation, but first hand knowledge also is invaluable to the diverse personnel gathered to fight a fire, and in the decision making Involved.

Jan 1, 1981

By G Sartor, A Rich, D Grimsey, R Forzatti, M White

An in-depth process model was developed for the pyrometallurgical, off-gas systems and water balance of the Kalgoorlie Nickel Smelter. This model was used to assess plant capacity with changing concentrate grades, increased throughput and tighter environmental emissions under a range of potential future operating conditions. Comparison of modelled results allowed for flow sheet optimisation across a range of metrics including sustainability, processing capacity and costs. Process modelling software, METSIM® (ver 2020.06 by METSIM International), was used to simulate the flash furnace, integrated electric slag cleaning furnace, Pierce-Smith converters, matte granulation, waste heat boiler, hot gas handling equipment, wet gas cleaning plant and acid plant. The METSIM® model was divided into three separate, yet interconnected models: metals, off-gas and water balancing. This allowed for improved modelling efficiency and traceability while minimising manual error. The METSIM® model was supported by inputs from other specialised software. Chemical thermodynamics software, FactSage™ (ver 8.2 by GTT Technologies), was used to establish relationships for the flash furnace fluxing strategy and determine the operating temperature. Arena® (ver 16.0 by Rockwell Automation), a discrete event modelling software, was used to simulate material movements within the aisle as well as Pierce-Smith converter operation, allowing for integration with upstream and downstream systems. A dynamic data exchange (DDE) was used to connect the results of each software package, interfacing through Excel® (version 4203 by Microsoft). The integration between models provided a streamlined approach to test capacity, bottlenecks, water consumption and emissions under a range of operating conditions, enabling a more robust process. Further downstream modelling techniques were used to assess mechanical equipment. METSIM® outputs provided key parameters for combustion assessments using computational fluid dynamics and finite element analysis for the furnace mechanical design.

Aug 21, 2024

By M Robertson

3D photogrammetry is a powerful tool for data capture and interpretation, utilised at all Australian underground MMG sites. In personnel constrained mines, 3D photogrammetry can free up personnel time, improve data quality for resource modelling, as well as benefit other mining departments.At Rosebery one of the challenges faced by geologists was no longer data capture but, rather, avoiding paralysis by analysis from the sheer abundance of information currently available to the department. Although the data had been interpreted, the structural model was cluttered; the geological block model was not incorporating any geological domains captured by 3D photogrammetry, nor was it being utilised by other departments such as geotechnical engineering.The geology department is now focusing on utilising all the interpreted data gained from each photograph heading into an uncluttered, easily understandable model for geologists and other mining departments.Our solutions involve integrating the Leapfrog modelling suite into the process, streamlining the structural model, tailoring the data interpretations for future updates of the block model and training other departments to improve utilisation of the interpreted data. This process also uncovered other benefits for near-mine exploration, and improving our understanding of the deposit’s origin.CITATION:Robertson, M, 2017. The practical use of underground 3D photogrammetry data at MMG Rosebery polymetallic mine, Tasmania, Australia, in Proceedings Tenth International Mining Geology Conference 2017, pp 409–412 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 20, 2017

By T Weldon

In the last 15 years, it has become increasingly popular to win gold and silver from carbon strip solutions with electrolytic æsludgeÆ cells. The precious metal sludges produced in the cells are washed to the cell bottom and pumped into filters. Most new operations are specifying sludging cells, and many older operations are being retrofitted with up-to-date electrolytic sludge cells and filters. The new sludging cells are generally more energy efficient than older cells, but more importantly, the cell operations to remove product are much less labour intensive, cleaner, and the operator need not have physical contact with the electrolytically produced metal. A case study of a major North American gold producer (50 000 kg/yr) that removed old style stainless steel wool cathode cells and installed new sludging cells and sludge filters is presented. The effect of various impurities is discussed.

Jan 1, 2005

By K George

The Dugald River lead-zinc-silver deposit is located approximately 60 km north-west of Cloncurry and 87 km north-east of Mount Isa. The development project is expected to turn operational in 2018. The resource is estimated to contain 61.1 Mt at 12.6 per cent zinc, 1.9 per cent lead and 34 g/t silver, with a projected mine life of 25 years. The evolution from exploration project to development project has presented multiple challenges for the technical team. Understanding and modelling the structural complexity of the deposit has been one of these challenges.Historically fault zones were logged as a lithology, with structural measurements recorded in a separate database table. When underground drill programs and development commenced in late 2012, it was recognised the deposit was more structurally complex than had been modelled. The extensive number of fault zone lithologies in core logging, made it difficult to identify fault trends and model faults in 3D software packages.In 2014, a structural project was conducted to produce a fault model for the deposit. The project highlighted that by logging the faults as a lithology, a shortage of fault characteristics was being recorded. Additionally, structural information could not be filtered to identify different fault sets due to the lack of information available to filter on. One of the major outcomes of the study was to change the methodology for the structural logging of drill core.Faults are now logged in a separate structural log. The structural log collects two types of information: interval data and point data. The interval data represents the damage zone of the fault in the surrounding rock and the point data the plane of movement for the fault. The faults are further characterised by their intensity on a scale of one to five, the type of fault structure (fault breccia, fault vein etc), the minerals present on the fault surface and structural measurements when available.The new data set allows fault data to be filtered based on fault characteristics, making implicit and explicit modelling of the faults more timely and accurate. The data set can be used to produce fault wireframes as single surfaces from the point data or hanging wall and footwall surfaces from the interval data. The logging method and how its applied in fault modelling form the focus of this paper.CITATION:George, K, 2017. A new approach to logging and modelling faults at the Dugald River Pb-Zn-Ag deposit, North West Queensland, in Proceedings Tenth International Mining Geology Conference 2017, pp 315–320 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 20, 2017

By M Akop, G Phillips, L Elliott

An estimation geologist has many tools in their kit and using the correct one for the job is vital for creating a useful model. Reconciliation is a key step to monitor the performance of a resource model and to ensure the correct tools have been selected and appropriate parameters are set. This paper presents an example of refining the estimation methodology for a Channel Iron Deposit (CID), resulting in an improved model. Rio Tinto Iron Ore (RTIO) CIDs are unique iron ore deposits located in the Pilbara region of Western Australia and contribute a significant volume to the world’s seaborne iron ore market. A problematic feature of these deposits is the irregular dispersion of clay pods that cannot be delineated with confidence within the resolution of the exploration drilling. Resource to grade control reconciliation showed an over-prediction of high-grade material in the resource model. A fresh approach was required to improve grade and tonnage predictions. Historically, clay pods were delineated using traditional wireframing techniques and estimated using ordinary kriging with hard boundaries. The new method utilised indicator kriging to estimate the probability of clay. Probabilities generated from the indicator kriging estimate were used as an additional weighting following the ordinary kriging of grades. Results showed indicator kriging improved global high-grade tonnes reconciliation, however, as expected, it did not improve the spatial prediction of clay. Based on improved reconciliation results indicator kriging has now been adopted as a suitable alternative for analogous CIDs at RTIO. These improvements benefit the mine planning process, but do not replace grade control models.

Mar 22, 2022

Exploration and mining title administration in the Northern Territory has changed dramatically over the last 20 years. These changes have occurred due to legislative amendments, technological developments, and the changing face of the mining industry. The first legislation to control mining in the Northern Territory was the Northern Territory Gold Mining Act (1873) of South Australia. In 1911, control of the Northern Territory was passed from South Australia to the Commonwealth. As a result of the mining boom which followed the discovery of gold in Tennant Creek in 1932, the Commonwealth passed the Mining Ordinance of 1939. This legislation was amended 39 times and stayed in force until July 1982, when the self-governing Northern Territory passed the Mining Act 1980. This Act is still in force and is continuously under review. The first computerised mining titles system, REGIS, was created in 1984/85 and was, to all intents and purposes, just a computerised index. Various modifications ensued, and in 1989 the Titles Database was unveiled. The database has developed to be one of the most sophisticated yet user-friendly mining titles databases in Australia. In excess of 50 companies have access to the database from their own offices. Work continues on its development and fine-tuning. The paper outlines the development of the database since inception.

Jan 1, 1994

By Hughes CA

The need to recover metals from low grade deposits, old tailings, etc., combined with improvements in equipment design and the development of new extractants, has resulted in solvent extraction (SX) metal recovery reaching new importance (Webster & Ferron, 1993). The basic principle of solvent extraction is the use of an equilibrium system in which a metal ion is transferred from an aqueous phase into an organic phase, (Equation 1), (Ritcey, 1984). M + E ME . (1) The organic extractant (E) is usually specific for a certain metal ion (M) and forms a metal complex in the organic phase, leaving the impurities behind in the aqueous phase. To recover the metal, the equilibrium is reversed and the metal ion is transferred back from the organic to another aqueous phase in a process called stripping. The metal is then recovered from the aqueous strip solution, usually by electrowinning.

Jan 1, 1990

By Mowat B. A

I lamata is within the Morobe Goldfield (7¦ 25' S, 146¦ 39' E) on the Wau (SB 55-14),1:250,000 scale map sheet (Fig 1). The deposit is 13 km SW of Wau, within the headwaters of the Upper Watut River, at an average elevation of 2000 m. The steep mountainous terrain is covered by dense tropical rainforest and access is by helicopter or by foot track. The deposit has been described previously by Wells and Young (1991) and 1)enwer. Leach and Mowat (1995). Data collected to late 1996 have been used to estimate an Inferred Resource of 9.2 Mt at 3.1 g/t gold using a cutoff of 0.5 g/t. This contains a high grade portion for which an Inferred Resource of 1.2 Mt at 9.7 grt gold has been estimated using a 5.0 g/t cutoff.

Jan 1, 1997

Nordberg has conducted extensive research, during 1982-85, on the effects of cone crusher variables such as speed, throw and cavity design on the productivity of the crushers. Simultaneously, Nordberg's engineers have developed advanced design and testing techniques that ensure efficient and reliable crusher designs. Combination of this knowledge has resulted in a design of the MPI000 (1000 hp) crusher which fits on the existing 7ft Symons foundation and yet is capable of producing twice the ton- nage of the 7ft. In this paper the development of the MP1000 crusher and its performance compared to the 7ft heavy duty and super heavy duty crushers will be discussed. Also, substantial cost savings resulting from the application of such a high performance machine will be presented.

Jan 1, 1988

By S Hapugoda, A Edenton, L Lu

The blast furnace cohesive zone has a profound impact on hot metal productivity and quality, fuel consumption, operational stability and the lining life of the blast furnace. The high temperature properties of ferrous burden materials determine the configuration and location of the cohesive zone and have therefore attracted particular attention. While numerous standard testing methods are in use to assess the quality of ferrous burden materials for the blast furnace, these simple tests are generally conducted under fixed conditions, which often represent the extreme situations encountered by the burden materials in the blast furnace. Furthermore, none of these simple tests provides information on the high temperature properties of the burden materials, such as their softening and melting properties. CSIRO is equipped with a fully computerised testing facility to characterise the high temperature properties of ferrous burden materials under realistic conditions similar to those encountered in the blast furnace. This paper will first review the CSIRO softening and melting test method and then discuss the softening and melting properties of a variety of blast furnace burden materials, including sinter, pellets and lump ore, and their implications for blast furnace operation.

Nov 8, 2021

By T Baumgartl, R I. Maczkowiack, O White, P D. Erskine

Queensland legislation, industry codes and policies relating to mine rehabilitation and closure create the expectation of successful progressive rehabilitation and that the post-mining environment is being returned to a condition suited to a pre-agreed, beneficial end use. Yet none of the rehabilitated mined land in the Bowen Basin has been certified as successful by authorities suggesting there is a gap between current rehabilitation and the full environmental outcomes that the legislation could deliver. We tested the veracity of this perspective and reflect on where responsibility for any discrepancy lies.We first reviewed current Queensland legislation and industry codes relating to stakeholder engagement, rehabilitation, closure planning and post-mining land use. We tested the accessibility of the documentation trail for several recent coal-mining projects in the Bowen Basin and examined the level of detail in approval documentation. We then assessed the rehabilitation performance reports of these mines in relation to the contents of their approval documents. Legislation, guidelines and codes repeatedly emphasise the need to plan for closure before mine operations begin and to progressively perform rehabilitation with an agreed end-use in mind. Early stakeholder involvement in these processes and transparency of actions and outcomes are also encouraged by government publications. Overall, in terms of transparency, we found that relevant documents are generally available to the persistent enquirer. However, the rehabilitation and closure undertakings given in both mine company and regulator documentation were commonly generic and rehabilitation obligations were not explicitly incorporated into rehabilitation plans. Rehabilitation reporting was also weak in that no distinction is required between successful and unsuccessful revegetation, nor to closure objectives and mine completion criteria. Responsibility for the apparent disconnect between regulatory intent and actual performance appears to begin with the regulator too readily allowing generic information and in not requiring performance reporting to correspond with approved post-mine conditions. As a result, companies may have a much greater rehabilitation and closure risk than mine management expects. More poignantly, the checks and balances that are in the legislation are not yielding the environmental outcomes of which they are capable.CITATION:White, O, Maczkowiack, R I, Erskine, P D and Baumgartl, T, 2012. Walk or talk - Is the current mine approval process in Queensland delivering rehabilitation and closure success?, in Proceedings Life-of-Mine 2012 , pp 59-68 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 10, 2012