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By M Costa, L Polizzi

Process optimisation and continuous improvement are usually acknowledged when making a process more effective, efficient and transparent. During the last few decades, thousands of companies around the world have used total quality concepts in order to establish a continuous improvement process in their companies. Typically these companies apply some kind of Kaizen-type tools and expect results in the short term; however, the great majority of companies are poorly implementing these continuous improvement programs.Usually the most common reasons for failure of the program are lack of commitment from leaders, lack of discipline and engagement from the team to follow process and lack of clear targets for the program. When the results do not come at the expected timeline, it is common to simply drop the current process and apply a different approach from another company or consulting firm.This paper will explore some successful cases of companies that have invested time and effort to establish a reliable and sustainable process of continuous improvement. The focus will be case studies of mines and smelters around the world that use the plan–do–check–act (PDCA) cycle to increase productivity with the best services and lowest costs. The main tools and processes used by these companies will be discussed, as well as results achieved.CITATION:Costa, M and Polizzi, L, 2014. Introducing and sustaining a continuous improvement program in mines and smelters, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 55–62 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

The New Broken Hill Consolidated Airshaft is the first major undertaking in the development of New Broken Hill Consolidated Ltd's. property, which adjoins that of The Zinc Corporation Ltd. on the latter's southern boundary.The Zinc Corporation ore-body has a southerly pitch. The Zinc Corporation's New Main Shaft is 1000 ft. north of the common boundary, and the general plan of development of the New Broken Hill Consolidated property is by driving south from this shaft on the lower levels. No downcast airway from the surface was available south of the Zinc Corporation's New Main Shaft; this shaft acts as the main downcast to the bottom of the Zinc Corporation mine, the general air flow then being northward and upward to the upcast shaft at the extreme north end of the Zinc Corporation property.Rock temperature is 920 F. at 2000 ft., increasing by 10 Fahr. each 72 ft., the rock temperature at 3000 ft. being estimated at 1060 Fahr. With the general air flow northward from the Zinc Corporation's New Main Shaft, adequate ventilation under these temperature conditions would not be practicable for any great distance south of this shaft without another main airway from the surface. Accordingly the New Broken Hill Consolidated Airshaft is being sunk at a point 1000 ft. south of the common boundary, i.e., 2000 ft. south of the Zinc Corporation's New Main Shaft, to ventilate future New Broken Hill Consolidated workings and that part of the Zinc Corporation mine between the boundary and the New Main Shaft.

Jan 1, 1940

Accurate geometric models of orebodies establish the framework for reliable mineral resource estimates that provide a basis for further exploration and mine planning, as well as for financial models that ultimately determine the economic viability of a deposit. Traditional, explicit geometric modelling techniques that are utilised for resource modelling by the general mining software packages, such as MineSight«, involve manually digitising interpreted ore outlines that must be carefully linked to create valid geometric solid models. An alternative, implicit modelling method, employed by LeapfrogTM software relies on a fast method of global interpolation, which offers several advantages over traditional modelling techniques. Although previous case studies have documented the relative efficiencies of the two approaches, the accuracy of the two methods has not been previously quantified and compared. This study quantifies the accuracy of solid models created using explicit and implicit methods, and compares the differences between the models. Solid models of the Doris Hinge vein gold deposit (located in the Hope Bay district, Nunavut, Canada) are constructed from preliminary and follow-up drilling data using both modelling techniques. The accuracies of the solid models generated using preliminary drilling data are determined by measuring the 3D distance between the surface of the models and the actual contact location defined by the follow-up drilling data. Additional comparisons based on volume, cross-sectional area and surface differences were made between both phase 1 solid models and solid models constructed from phase 2 drilling information. The overall results of this study find that the MineSight« and LeapfrogTM solid model accuracies are virtually the same, and that their volume, cross-sectional area, and surface differences are comparable. This study concludes that the implicit modelling technique generates accurate solid models that can be used in place of explicit models as ore shells for resource estimation in certain circumstances.

Jan 1, 2006

By S Q. Liu, E Kozan

This paper proposes a new multiresource multistage scheduling problem for optimising the open pit drilling, blasting and excavating operations under equipment capacity constraints. The flow process is analysed based on the real-life data from an Australian iron ore mine site. The objective of the model is to maximise the throughput and minimise the total idle times of equipment at each stage. The following comprehensive mining attributes and constraints have been considered: types of equipment; operating capacities of equipment; ready times of equipment; speeds of equipment; block-sequence-dependent movement times of equipment; equipment-assignment-dependent operation times of blocks; distances between each pair of blocks; due windows of blocks; material properties of blocks; swell factors of blocks; and slope requirements of blocks. It is formulated by mixed integer programming and solved by ILOG-CPLEX optimiser. The proposed model is validated with extensive computational experiments to improve mine production efficiency at the operational level. The model also provides an intelligent decision support tool to account for the availability and usage of equipment units for drilling, blasting and excavating stages.CITATION:Kozan, E and Liu, S Q, 2014. An Open pit multistage mine production scheduling model for drilling, blasting and excavating operations, in Proceedings Orebody Modelling and Strategic Mine Planning Symposium 2014 , pp 329–334 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 24, 2014

City Resources Limited selected Vanuatu as a target area for epithermal gold mineralization because of its relatively unexplored character and its location on the southwest Pacific rim. During 1985 a systematic program of reconnaissance prospecting was completed on six islands within the Vanuatu group, using a helicopter and a specially designed exploration support vessel with on-board assay laboratory. Within a period of 4 months, reconnaissance prospecting of all six islands was completed, two previously unknown epithermal gold provinces had been discovered, and six major prospects warranting detailed exploration had been identified. Factors which contributed to the success of the program include (i) a flexible management approach, (ii) the mobility and access provided by the support vessel/helicopter combination, (iii) rapid assay turn-around, and (iv) adherence to basic prospecting techniques. The relative merits of various sampling media are discussed.

Jan 1, 1987

Dimension stone is the term generally given to rock used in building construction. During early European history in Otago, locally available dimension stone products were easily obtained. Crude rock shelters built on river banks with schist rock within Central Otago soon gave way to more established and sophisticated permanent homesteads constructed with the same materials. Victorian architectural achievement is celebrated in Otago with many fine bluestone block buildings. When the University Council decided to build substantially in stone, it narrowly escaped disaster. It was well known at the time that brick in Dunedin was of an inferior quality and that it soon wasted. Rev Dr Stuart said before the 1879 Commission that æthe Council had some old-world notions and liked to have the University with some architectural styleÆ. Contemporary utilisation of dimension stone is generally restricted by expense to a simple veneer. Stone products produced from Otago quarries have found ready markets in other areas in New Zealand , particularly prior to the share market crash in 1987.

Jan 1, 1992

The paper continues an account, begun in a previous paper, of experimental work carried out by the author whilst a member of the metallurgical staff at the Cockle Creek Works. The general method of the description of the plant and works practice adopted previously has been followed.The paper is a short account of the methods used in and the results of an investigation of the fume losses from the various parts of the plant.MEASUREMENT OF VOLUMETwo independent methods were used. The first depended on a number of pitot-tube measurements of velocity. These readings were taken in the stacks leading from the various furnaces at a considerable height above the ground so as to obtain as regular conditions as possible at the points where the readings were taken.Three openings were made in each stack and the pitot tube inserted into each opening in turn and readings taken at the centres of imaginary areas of equal size. The average velocity in the stack was thus obtained.After four tests had been made at the smelter stack, which removed the gases from all blast furnaces in use, the centre of velocity of the gases for each test was calculated and was found to be practically constant in position. The previous procedure was varied in subsequent tests on this stack by taking a succession of readings at the centre of velocity instead of at various points...

Jan 1, 1925

This paper puts the view that, for one gold deposit in Victoria at least, the Australasian Code for the Reporting of Identified Mineral Resources is severely deficient. The author questions whether or not the Code constrains the proper dissemination of information relevant to resource valuation. The author offers a view about the estimation of inferred resources, and provides data believed pertinent to the proper valuation of Ballarat Goldfields Ltd Ballarat East Project.

Jan 1, 1990

By B Manda, K L. Sandvik, K Musiwa

Mining and processing of pyrite ore at Iron Duke Mine, north east of Zimbabwe, generates large quantities of acidic mine water as a result of the oxidation of iron sulfides on exposure to air and water used in the drilling and blasting operations. The acid mine drainage (AMD) contains elevated levels of dissolved Fe, Al, Mn and sulfate and has characteristic pH values ranging from about 0.50 to 3.00. Handling and disposal of such a drainage places significant impacts on the economics of the mining operation due to the corrosive nature of the drainage on infrastructure, the limitations placed on water reuse and discharge to the environment under a new law governing effluent discharge. Treated sludge at Iron Duke is chemically unstable, changing pH from ~7 to ~3 within four days after deposition in the evaporation ponds. The effluent does not meet the permitted level of neutral pH, 500 mg/l sulfate and less than 2000 mg/l total dissolved solids. Excessive acid seepage from the evaporation ponds has resulted in contamination of the ground water below the ponds area, which shows high mean annual levels of iron (368.67 mg/l), sulfate (1702.89 mg/l) and low pH (2.86) in addition to other pollutants. This poor quality seepage infiltrates into the nearby Yellow Jacket River, contaminating the public water source. Furthermore, a deterioration of the land area and vegetation adjacent to the tailings dump is also observed. Understanding the controls on the neutralisation of acidic drainage and long-term sludge stability after placement in evaporation ponds is essential to minimise costs of closure requirements and for the protection of environment and human health. This study examined the effects of the master variables pH, redox potential, acidity and alkalinity on acid neutralisation. The results indicate that ferrous hydroxides are not as stable as ferric hydroxides and that proper oxidation of iron also leads to better sludge stability, higher treatment efficiency and a manageable sludge viscosity. Metal hydrolysis and secondary mineral formation at the evaporation ponds under a wide range of pH and redox conditions is responsible for equilibrium shifts in metal reactions, resulting in high potential for metal leaching and mobility. Mechanisms of metal attenuation are also discussed.

Jan 1, 2006

By Grano S. R, Ralston J

It is the perennial problem most metallurgists face when examining data collected from laboratory float tests and plant surveys - there are more numbers than we know what to do with! The objective of this paper is to analyse and interpret a set

Jan 1, 1994

By C Chen, T Kan

The distribution ratio of Pb (LPb s/m) between three types of slags (FeOx–SiO2, CaO–FeOx and FeOx– CaO–SiO2) and molten copper after equilibrium was measured at 1300°C and oxygen partial pressure (pO2) of 10-10–10-6 atm. Results showed that for FeOx–SiO2 slag, the LPb s/m increased from 0.024 to 2.57 with pO2 increased from 10-10 to 10-6 atm. The LPb s/m with CaO–FeOx slag was lower than the FeOx–SiO2 slag at the same pO2, ranging between 0.015 and 0.53. Using the FeOx–CaO– SiO2 slag generated LPb s/m values (0.02–1.6) in between. The oxygen partial pressure in the investigated range had no obvious effect on the activity coefficient of PbO (γPbO) which was averagely 0.44, 1.70 and 0.71 for FeOx–SiO2, CaO–FeOx and FeOx–CaO–SiO2 slags, respectively. The increases in the (CaO+MgO)/SiO2 mass ratio of the FeOx–CaO–SiO2 slag induced the decrease in the LPb s/m and the increase in the γPbO value. However, the variation in the Fe/SiO2 mass ratio didn’t exert obvious effects.

Jun 19, 2024

By C Harwood, EáWestman, K Luxbacher

Testing of in situ seals in underground coal mines is critical to determine seal integrity and to provide safe working conditions. In the wake of the 2006 Sago Mine explosion, the United States of America (USA) promulgated the Mine Improvement and New Emergency Response (MINER) Act (USDOL, 2006) which required mines to install 827 kPa (120 psi) rated seals or monitor and maintain the atmosphere behind existing 345 kPa (50 psi) seals. The purpose of developing the regulations was to prevent the breaching of seals in the event of an explosion in the sealed area.While seal design and construction is carefully regulated in practice, the construction of seals is difficult to monitor, as many are constructed under various mine conditions and the methods rely on prescribed placement of the seal material. Further examination of installed seals is limited to two-dimensional visual inspection and atmospheric and convergence measuring devices. These methods do not accurately reflect the integrity of the seal and cannot detect changes, deterioration, or defects within the seal.If detection of defects, deterioration and damage is not possible, unexpected communication between the active and sealed areas may result. Additionally, the ability of the seal to withstand explosions may be compromised. Non-destructive testing (NDT) of underground mine seals is necessary to investigate if the seal properties have been altered and if the seal remains functional as a barrier between active areas and sealed areas of the mine. This paper gives a preliminary assessment of proposed NDT methods for seal evaluation using radio frequency (RF) technologies and tracer gas methods.CITATION:Harwood, C, Luxbacher, K and Westman, E, 2013. Non-destructive testing of in situ underground mine seals - Initial technology assessment, in Proceedings The Australian Mine Ventilation Conference , pp 299-306 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 1, 2013

By C Vejrazka1

The occurrence of airblasts is one of the principal mining hazards in caving operations between the time of cave establishment and breakthrough of the cave to surface. As such, it needs to be managed continuously and risk assessments need to be reviewed on a regular basis for applicability to changing conditions. The likelihood of an airblast occurring is based on a range of geotechnical factors over some of which engineers on-site only have limited control. However, the impact of an airblast to the underground mine, if it does occur, can be managed by following established safety guidelines for the production from the cave.This paper outlines how the Caving Airblast Simulation Tool in Ventsim was used to determine a risk management strategy for a sublevel and a block cave at a mining operation in Australia. The block cave has a footprint of 14 500 m2 with the extraction level located 1250 m below surface while the sublevel cave currently has a footprint of around 18 000 m2 operating between 660 m and 800 m below surface. Both caves are currently in their early operational periods. The risk analysis provided valuable information for the production planning of the caves including confirmation of extraction ratios for the block cave undercut, locations of airblast walls and maximum allowable air gaps for different muck pile heights to ensure safe operation is achieved.

Oct 12, 2022

Although the mining of metals was well established by the time of the Roman Empire mining skills did not really advance greatly for many centuries. Miners did not have the scientific knowledge to distinguish minerals, to process them, and to obtain the best recovery. Each mine essentially developed its own methods in isolation, most of them dangerous. However, with the beginning of the industrial revolution in the early 18th century there was a rapid increase in mining activity in Central and Western Europe and an accompanying need to educate professionals in the developing fields of science and technology. There was also a need for specialised schools (for example, Schools of Mines) to accomplish this since the universities of the time, formed as early as the first half of the 12th century, were cloistered institutions, focused on the study of classics, theology and law. The earliest attempts at organised technical education were made in 1702 with the establishment of a School of Mines in Frieberg, Germany (Table 1) to service rich copper mines, and in 1747 with the establishment of a School of Mines in Paris. By this time, the industrial revolution was well under way and other Schools rapidly followed, at Clausthal in the Ruhr region of Germany in 1775; in 1777 at Almanden to service the mercury mines of Spain (later transferred to Madrid); in 1780 at St Petersburg, Russia and at Falun, Sweden in 1819. The academic staff for these new institutions were often trained in the original School at Frieberg.

Jan 1, 2002

By Fawcett M

Pine Creek Goldfields Limited (PCG) is rehabilitating the Enterprise Pit to an aquatic habitat and potential water resource. This paper discusses the development and implementation of that plan. Pine Creek Goldfields Ltd's Enterprise Mine is located approximately 230 km south of Darwin. Open cut mining of the orebody commenced in 1985 and continued for eight years with 14 million m3 of ore and overburden extracted. Geochemical testing of exposed rock types in the pit has demonstrated a propensity to produce acid, and dissolved metals. A plan of management has been developed and implemented to minimise the risk of acid formation and improve the overall water quality in the final void. In developing the plan prime consideration was given to reducing the potential for pit water to impact upon the regional groundwater. An interception system was constructed on Pine Creek to divert approximately 9 km2 of upper catchment into the northern end of the Pit. Construction of the diversion system was completed in December 1993 and a comprehensive surface and groundwater monitoring program initiated. The monitoring program and associated studies are also discussed.

Jan 1, 1994

By Stewart R. D, Lawrence W, Youl M. J

The trend towards contracting by major coal mining companies such as BHP Coal and MIM Ltd is examined. Reasons why this trend is occurring are discussed and the concept of partnering is examined. Two case studies are given: the Mt Owen Mine in the Hunter Valley, NSW and the South Walker Creek Mine in the Bowen Basin, Queensland.

Jan 1, 1997

By Dolan P

Various operating practices have been developed over many years to ensure safe and efficient production from the 1100 orebody. Some of these practices are described.

Jan 1, 1982

By F Phillips, E Deucker, J Kato

It is challenging to determine the optimal mining strategy to maximise value when a mine plan includes mineralised material which does not meet the full cost of mining but has value exceeding the variable cost of mining (‘marginal material’). Mining too much marginal material dilutes the operation’s head grade and undermines profitability. Conversely, leaving too much metal behind fails to achieve the full value of the endowment. Finding the balance between the two will maximise value delivered from the asset. This dilemma has traditionally been approached by calculating a suite of cut-off grades to define the grade of material that meets economic targets for an orebody (or zone within) and should therefore be included in the mine plan. A problem with this approach is that individual mining blocks within the zone have different costs, value and confidence levels, with each having economic co-dependencies between them. Blocks of identical grade but different mining contexts will have distinctly different economic outcomes. For example: • a block may be a low-grade increment or shell around a higher-grade stope; • a block may be available to be mined when there is spare mining capacity; or • a block may defer access to significantly higher cash flow material. Each of these circumstances would result in different value from the blocks if included as part of the mine plan. Cut-off grades calculated as averages over zones of material, or in isolation from schedule-based information, are missing the entire mining context that determines the ultimate economic outcome of making a mining decision. There are tools and techniques available to address this for open pit mining, however underground mining has different nuances. There are more intricate economic and physical dependencies between potential ore blocks, and importantly, the decision to leave material in situ can be made at any time. The case study in this paper explores a new methodology for underground mining, targeted towards strategic planning applications. It examines whether the economic logic usually applied via cut-off calculations can be implemented in the schedule so that optimal economic decisions can be made on a block-by-block basis, taking into account the mining context of the block, with the objective to maximise asset value. The results of the case study scenarios in Table 1 demonstrate the magnitude of the potential improvement in NPV that can be attained by a block by block valuation approach

Mar 15, 2021

The Porgera mine and treatment plant are located in the Enga Province of Papua New Guinea. Gold in the Porgera deposit is found free and in association with the primary sulphide mineral pyrite. The refractory nature of the gold in the pyrite r

Jan 1, 1997

By H Dehghan Jan Abadi, K Shahriar

The iron ore district of Gol-e-Gohar (GEG) is located 60 km south-west of the city of Sirjan, in the Kerman Province of the Islamic Republic of Iran. Six exploration targets have been identified and iron ore has been mined from one area with dry and wet concentrate products sold. Prior to mining commencing in 1999, the proven reserves were estimated at 265 million tonnes (Mt) in 2004 and 40 Mt of 100 Mt overburden has since been mined. Of the six exploration targets, the largest anomaly in the GEG district is Deposit No 3. This paper discusses economic considerations focusing on mine extraction and construction of a concentration and pelletising plant to process ore from Deposit No 3 of GEG. Planned capacity of 10 Mt product (concentrate and pellet) per year is targeted to commence in 2011, and nominal capacity by 2014. The economical evaluation and analysis is one of the most important stages in the feasibility study of mine development. Financial calculations including the provision of financial resources, operation period revenue, loss and profit statement, cash flow, net cash flow, internal rate of return and net present value have been undertaken as part of the feasibility study. The feasibility study operating plan assumes a large open pit mine containing proven reserves of approximately 250 Mt. The feasibility study assumed an economic return of $80 per tonne iron pellet. The economic study determined that Deposit No 3 of GEG can be economically developed by open pit mining followed by magnetite separation and flotation to generate iron concentrate and pellets.

Jan 1, 2007