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By Z Li, A Fleming, S Webster, L Snyman

Northparkes Mines is developing the E26 Lift 1 North block cave mine, which is adjoined to the existing E26 cave. This paper presents the challenges and methods used to design the ground support system during the feasibility study. Calibrated numerical simulations were conducted to forecast the levels of rock mass damage and to assist the ground support design. Generally, low to moderate rock mass damage is forecast on the extraction and undercut levels. However, poor ground conditions are expected in sheared and preconditioned zones adjacent the existing E26 cave. This will result in difficult ground conditions during development, undercutting and drawbell establishment. Empirical assessments were conducted to make sure the ground support system is able to handle both the static and dynamic load demand, and to accommodate the deformation values. A safety factor of 1.5 was used for the designs to cover the unknown rock mass conditions and potential for larger seismic events. Learnings from the E26 Lift 1 and SLC, also mining against the E26 cave, are incorporated into the design. Fibrecrete, mesh and resin bolts / mechanical anchors are the primary ground support system used, and cable bolts for intersections with a span of more than 6 m. Following undercutting and during the operating life of the mine, secondary ground support and rehabilitation will be required.

Mar 15, 2021

By R W. Shaw

The MTM Process targets treating lower grade and/or problem concentrates that are not attractive to smelters. The process has been developed at laboratory scale for copper and is based on a related development for zinc that has been extensively developed both in the laboratory and through pilot testing. The basis of the process is novel ammonia-ammonium chloride leach chemistry adapted to give high copper extraction whilst being selective over iron, arsenic and many other elements. The preferred flow sheet depends on location, especially infrastructure and utilities. These impact upon the leach and crystallisation stages more than copper reduction.

Aug 24, 2022

By A J. Morrison, K Demir, J Kohmuench, K Runge, C Evans

The Eriez HydroFloat® is a flotation device capable of recovering significantly coarser and lessliberated particles than is possible using a conventional mechanical flotation cell. Originally developed for industrial and bulk mineral beneficiation, the HydroFloat® is attracting increasing interest as a means of increasing the required grind size for metalliferous ore flotation. Doing so would reduce the costs of processing complex ores, either by decreasing the energy required to grind the flotation feed or by increasing the throughput achievable with a given comminution circuit. Processing coarser particles would also result in coarser waste streams, potentially improving the mechanical and hydraulic performance of the waste dams that they are sent to. Recent work at pilot – and industrial-scale has proven the potential of the HydroFloat® technology to achieve these gains in metalliferous applications. However, in order to realise the full potential of the HydroFloat® technology, it is necessary to understand not just its performance but also the drivers for that performance. Doing so will allow the design and operation of HydroFloat® devices to be optimised for different ores and applications. For this work, a HydroFloat® pilot rig was deployed to a coppergold plant in Australia and was used to investigate the effect of stream and operating conditions for treating the tailings stream of one of the plant’s rougher flotation cells. Under each set of operating conditions, samples were taken of the HydroFloat® feed, tailings and concentrate streams, and processed to yield the grade and recovery achieved by the device. At the same time, the bubble size and bed behaviour inside the device were measured. This paper presents preliminary relationships observed between the operating conditions and the performance of the HydroFloat® cell, and thus suggests a range of possible drivers for the measured coarse particle flotation performance.

Aug 24, 2022

By Q Qu

Reliable prediction of longwall gas emission sources and rate plays a critical role in mine ventilation and methane drainage capacity planning. Over the years, Australian longwall mines have been using the historic Winter method and the Flugge method in modelling specific gas emissions (SGE). The predicted results often experience high discrepancies from the operational reality. To improve gas emission prediction, post-mining gas contents were measured in several mines in Qld and NSW by safely drilling core holes into the longwall goaf. The results revealed many new insights into gas emission characteristics from different coal seams and the drawbacks of the European methods in their use in high-production gassy Australian longwall mines. Based on measurement data, a new, time-dependent gas emission prediction model has been developed. Considering several factors such as caving, desorption and production rate, the new model can predict more accurate and meaningful gas emissions to meet today’s needs in mine gas emission management. A case study is provided to demonstrate the application of the new SGE model.

Oct 12, 2022

By A Valero, G M. Mudd

There is active debate and research around the most suitable indicators to assess the sustainability of mining. The most common approach is to report a range of data for a given mine site (or less preferably, a company total), such as inputs, outputs, benefits and potential costs. The most popular protocol in use (and growing rapidly) is the Global Reporting Initiative (GRI). However, these measures are numerous and still do not allow a single over-arching indicator to be developed. Other measures, such as known mineral resources over time, do not account for critical challenges such as declining ore grades, increasing wastes and poorer quality ores or more difficult mineralogy. By adopting a thermodynamic approach to sustainability, through the concept of æexergyÆ, it is possible to incorporate into a single measure the effective quality of mineral resources. Exergy involves the assessment of the minimum energy costs involved in producing a mineral resource with a specific chemical composition and concentration from common materials in the environment. The exergy of a mineral resource is evaluated from mineralogic composition, concentration (or ore grade) and, of course, quantity, by multiplying the unit exergies with the tonnes of the resource produced (or consumed). Since exergy is a thermodynamic quantity (ie energy or joules), it is additive across different minerals, such as iron ore to gold to copper or even oil and gas or coal û making it an ideal indicator to assess mineral resource sustainability at the industry scale rather than the individual mine scale. This paper briefly outlines the theoretical basis for exergy, and then presents a range of commodity case studies showing the application of exergy to the Australian mining industry. Overall, the usefulness of exergy is clearly demonstrated for use as a broad indicator of the sustainability of mineral resources at the national or even global scale.

Jan 1, 2009

By Z Fu, E Topal, O Erten

"Mine waste rock management involving waste rock movement and placement, is a critical aspect in the planning of open pit mining operations, as the waste rock haulage cost can be the largest portion of the mine operating cost. The concept of sustainable development in the mining industry also encourages environmentally friendly waste dumps that have zero hazards to people and the surrounding environment. Therefore, a detailed waste management schedule must satisfy economic and environmental considerations. However, the available tools in the market cannot provide optimal waste dumping schedules to meet all these constraints. This paper introduces a user-friendly and automatic tool to optimise the waste dumping schedule, which minimises the haulage cost, and covers the encapsulation of reactive materials to minimise acid mine drainage problems. This tool has been developed by using a new mixed integer programming (MIP) mathematical model that considers both single-lift and multilift dumping scenarios. The application of the proposed tool on a data set collected from a gold mine shows that the multilift dumping scenario has provided a more flexible and economical waste dumping schedule than the single-lift scenario, and both scenarios satisfy environmental requirements.Citation:Fu, Z, Topal, E and Erten, O, 2016. A Modified Software Tool for Mine Waste Rock Dump Planning, in Proceedings Ninth AusIMM Open Pit Operators' Conference 2016, pp 229–242 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Nov 15, 2016

By B Clements, R Dunne, J Dioses, S Hart

In April 2003 plant upgrades in the æLow GradeÆ Cadia Hill circuit were undertaken in order to improve concentrate quality and metal recoveries from the flotation circuit. The major changes involved: circuit reconfiguration to allow all concentrates to be reground to less than 38 ¦m prior to final cleaning; increasing ball charge in the regrind mill to fully utilise all of the installed power; desliming of the cleaner scavenger concentrate to improve the circuit water balance; and the inclusion of a gravity concentrator in the regrind circuit to recover more free gold to bullion.Once the flotation circuit had stabilised under the new operating conditions concentrate launder modifications and increased froth crowding on the scavenger flotation cells permitted the introduction of stronger collectors without compromising concentrate quality or circuit stability.Twelve months on, the copper concentrate grade has increased by two per cent and metal recoveries increased by three per cent and seven per cent for copper and gold respectively. The project capital outlay of approximately $2.0 million has been repaid in less than three months. This paper will review the project from the design, construction and commissioning perspective as well as the subsequent debottlenecking exercise that was required to eventually yield the full benefits of this upgrade.

Jan 1, 2005

By A Murphy, D Lauder, J Miranda

Minera Alumbrera Limited operates the Alumbrera concentrator, treating a nominal 80 000 tpd of porphyry gold/copper ore. It is located in Argentina, 1200 km north-west of Buenos Aires in Catamarca Province, at an elevation of 2550 m above sea level. Treatment facilities consist of crushing, SAG and primary ball mill grinding circuits, rougher flotation, ball mill regrinding, gravity recovery and cleaner flotation. It is one of only a small number of concentrators in the world, which uses Jameson Cells alone for cleaner circuit flotation. Plant design was started in June 1995, with commissioning commencing in July 1997. Following a successful ramping up to design tonnages and recoveries, a number of options were reviewed to improve gold and copper recoveries. This paper concentrates on a detailed size by size flotation recovery project, commenced in May 1999. Utilising optical microscopy, scanning electron microscopy and analysis of surface chemistry it has allowed losses by size fraction to be quantified and options for enhanced recoveries to be developed. Coupled with extensive circuit surveys it has also provided an insight into previously unknown properties of Jameson Cell operation. Among these are unique residence time and bubble formation reactions to reagent and pulp flow variations, which has permitted a number of novel changes to the operation to maximise capacity and recovery.

Jan 1, 2000

By W Roy

When it comes to plan implementation and securing success in organisations in the 21st century, if there was such a thing as the secret to success it would be effective communication. Commoditisation brings financial, operational and cultural advantages to organisations that use effective communication. Effective communication tools turn æpeople problemsÆ into system control solutions, removing personality clashes that hide procedural malfunctions. By introducing communications frameworks available in the market place today, and case studies of their use, this paper provides insights into the successes available to organisations courageous enough to redefine their communications for the 21st century.

Jan 1, 2006

The optimal production of the metals needed by society is best achieved by a close synergy between concentrate production and smelting. For over 75 years commencing in 1923, such a close relationship was enjoyed between the Sullivan Mine in Kimberley, British Columbia and the Trail zinc-lead complex. An effective program of continual change and improvement at the Sullivan concentrator was achieved through a strong entrepreneurial spirit. This spirit was in part maintained through a favourable location in south-eastern British Columbia that resulted in a dynamic local community that has survived the closure of the mine. Innovations to be reviewed include feed forward reagent control, the use of column flotation to zinc and lead cleaning and the application of ultrafine grinding coupled with concentrate dewatering using hyperbaric filter technology.

Jan 1, 2005

By J Tiihonen, J OÆCallaghan, T Haakana

Outotec is today capable of providing technologies, process equipment and engineering for the construction of pressure oxidation leaching (POX) plants in any location in the world. Outotec works with customers from mine to pure metal, participating in plant design from the process development phase (including test work execution/supervision) to plant commissioning and operations. Either key equipment technology packages with basic engineering or entire POX plants can be supplied.The addition of pressure oxidation equipment to OutotecÆs product portfolio adds to and complements already existing significant experience in general hydrometallurgical process and proprietary equipment design and supply.In addition to providing key pressure vessels, piping and valves to a POX plant, Outotec can offer an enhanced and proven autoclave agitation system that maximises oxygen mass transfer and utilisation. Novel energy and water recovery technology can also be tailored to a customerÆs specific needs. Importantly Outotec owns and operates extensive test work facilities and can provide test work to ensure the optimum POX flow sheet and materials of construction. Outotec ensures that best available technology (BAT) concepts are used in POX design to improve the availability of the process and minimise unpredicted shutdowns.CITATION:Tiihonen, J, Haakana, T and OÆCallaghan, J, 2013. Outotec pressure oxidation - more out of sulfide ore, in Proceedings World Gold 2013 , pp 197-206 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 26, 2013

This paper reviews recent advances in geophysical tools for mineral exploration. It does not restrict comments to methods which are usually applied in the tectonically active belt surrounding the Pacific Ocean, where geophysics has often been secondary to geological prospecting (eg visual recognition of surface alteration) and drainage geochemistry; but considers geophysical tools applied to a broader range of both deposits and terrains. For example, the subdued topography of much of Australia and Canada has lent itself to the development and extensive application of airborne methods. In Australia, deep weathering and transported cover have necessitated the use of geophysical methods to not only detect anomalies but also to map and understand basement geology. This same weathering has caused specific problems, particularly for electrical methods, but recent improvements in instrumentation, processing and visualisation have largely overcome them. A great deal of geophysical data is now being collected by government agencies, often from the air, and made readily available to explorers. In several Australian states it is free, often on line, and in almost all cases it is relatively cheap. These regional data sets are often augmented by more detailed local surveys in areas of interest. Although æanomaliesÆ are still important much more is being done with the high quality data which is now available The results are used for geological mapping, to test geological hypotheses, to construct detailed 3D geological models and, together with fluid flow modeling, to predict optimum locations for mineralisation.

Jan 1, 2004

By D Engelhardt, G Lane

The Cadia mine has shifted from an open pit operation to the Cadia East underground panel cave. The resulting increase in milled tonnes, more competent ore and the decrease in fines production through shifting to panel caving were predicted to require an increase of over 25 per cent in installed power. This expansion was accomplished via the installation of secondary and high pressure grinding rolls (HPGR) crushing of the ore, with the semi-autogenous grinding (SAG) mill receiving a combination of primary, secondary and HPGR crushed feed. This design, criteria and rationale for selection was presented at the SAG Conference 2011. This paper reports on the initial impact of secondary and HPGR crushing on the circuit performance with the new panel cave feed.CITATION:Engelhardt, D, Lane, G and Powell, M S, 2014. Cadia expansion – the impact of installing high pressure grinding rolls prior to a semi-autogenous grinding mill, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 233–240 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

By R Strand, L Reading, G Keir

A major challenge in managing coal seam gas (CSG) water is predicting how much water will be produced as the industry develops. Klohn Crippen Berger Ltd (KCB) was commissioned by the Queensland Department of Natural Resources and Mines (DNRM) to develop a tool to forecast where, when and how much CSG water will be produced in the Surat and Southern Bowen Basins under various industry expansion scenarios.The water production tool (WPT) uses the Theis equation, a non-equilibrium groundwater flow equation that accounts for the effect of pumping time on well yield in confined aquifers, to predict water production volumes. Where multiple pumping wells are in close proximity, the required pumping rates for coal seam depressurisation are reduced. Therefore, pumping effects are projected spatially to assess interference effects between wells. Water production is then upscaled to the projected scale of the CSG industry within the Surat and Southern Bowen Basins.Two modifications were made to address the dual phase nature of CSG extraction (a transmissivity reduction factor) and the impact of weathering at the eastern margin of the Surat Basin (a ænear edge effectÆ factor). These factors modify relevant hydrogeological parameters in a consistent and defensible manner to more closely match observed water production.The WPT was verified by comparing results to equivalent Theis equation calculations and to type curves provided by CSG proponents. Calibration was achieved by varying the spatial distribution and intensity of the near edge effect factor in conjunction with a chi-squared analysis of residuals.The tool, which is now being maintained and further developed by the Centre for Water in the Minerals Industry (CWiMI), was built to balance numerical complexity against relative flexibility and simulation speed. The result is a tool that can produce statistically relevant results of prescribed scenarios to plan water handling and treatment requirements in discrete zones of operation.CITATION:Strand, R, Reading, L and Keir, G, 2013. Water production simulation tool for coal seam gas operations in Bowen and Surat basins, in Proceedings Water in Mining 2013 , pp 311-320 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 26, 2013

By R Dunne, J Dodd, J Snyder, F Roberto

Energy costs are steadily increasing worldwide while the availability and quality of water are becoming contentious issues between the users (municipalities/households, agriculture, manufacturing and mining). Refractory gold ore treatment - pressure oxidation, biological oxidation and roasting (ultra-fine grinding, or UFG, will not be discussed here as this process only reduces the particle size of the feed prior to cyanidation) - requires substantially more energy and water quantity and quality are vastly different compared to the standard and simple flow sheets used for treating non-refractory ores This paper will provide an overview of the energy and water requirements for treating refractory gold ores, a topic which does not appear to have been considered previously in the literature.CITATION:Roberto, F, Snyder, J, Dodd, J and Dunne, R, 2013. Energy and water requirements in the treatment of refractory gold ores, in Proceedings World Gold 2013 , pp 527-532 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 26, 2013

By T Goswami, G Brent

In response to concerns over greenhouse gas (GHG) emissions and an imposed cost in some jurisdictions, many mining houses have committed to reductions in their GHG emissions. However, mining faces particular challenges in this regard, notably from increasing strip ratios. Furthermore, mining activity around the globe is not expected to decrease in the foreseeable future as mineral demand is driven up by the aspirations of rapidly-developing nations. Novel approaches will thus be needed if any reductions in energy consumption and GHG emissions of mining are to be achieved.This paper presents some directions for the mining industry to pursue in reducing their GHG impact, focusing on the difference that blasting methods can make. Importantly, large productivity and revenue gains can also be realised from these methods.Key directions considered here include optimising resource recovery and quality through:reducing coal damage and loss from throw blastingrecovering thin coal seamsproducing cleaner coal with less dilution.Blast design can also significantly improve the productivity of surface mining by:improving muck pile shapingimproving mine equipment productivityimproving scheduling.We show how a particular blasting method can eliminate coal loss in overburden throw blasting and can lead to large increases in coalmine profitability. Thin seams that were previously wasted can also be recovered with this method. Furthermore, the method has been implemented to combine several separate drill and blast cycles into a single cycle, leading to productivity gains.An illustrative example is given to show how increased coal recovery can increase revenues and more than offset any potential GHG emissions liabilities. Overall mine energy and GHG emission intensities can thus be reduced.CITATION:Goswami, T and Brent, G, 2015. Blasting approaches to increase mine productivity and reduce greenhouse gas emissions in surface coal mining, in Proceedings 11th International Symposium on Rock Fragmentation by Blasting, pp 635–644 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 24, 2015

This paper talks about the experiences of groups we have worked with over the last few years in the Asia-Pacific region (Australia, Canada, New Zealand and Papua New Guinea) and the ways that they have worked to bridge the divide between traditional and introduced structures, governance at a regional level and the introduction of traditional values into monitoring and evaluation practices. In doing this these groups have created structures and processes which have helped them engage both more effectively with external stakeholders while maintaining the legitimacy of their own operations with their own constituents. These are important ideas for those involved in the mining industry that could provide a number of very tangible benefits to mining firms and their engagement with these kinds of groups.

Jan 1, 2009

By L O’Connor, S C. Dominy

"Geometallurgy is an important addition to any evaluation project or mining operation. As a discipline, it seeks to maximise the net present value (NPV) of an orebody while minimising technical and operational risk. It also aims to promote sustainable development and initiatives by ensuring that all stages of extraction are performed in an optimal manner from a technical, environmental and social perspective. To achieve these goals, development of innovative technologies and approaches along the entire commodity value chain are being established (Glass, 2016). Geometallurgy has been shown to increase operational stakeholder collaboration, creating an environment for knowledge sharing and improved data acquisition and interrogation, with the end result being the integration of such data into mine planning and scheduling. All of these aspects create better business optimisation, utilisation of staff and targeted and realistic key performance indicators.The mining industry faces numerous challenges including, but not limited to:declining ore gradesgeometrically and/or internally more complex depositsdeep-seated deposits, with potentially high in situ stress regimesincreasing quantities of mine waste that needs to be managed appropriatelyhigher energy, water and chemical costsprocessing of more challenging and refractory ores – textural complexitiesstricter environmental/permitting conditions – so-called ‘licence to mine’increasing demand for specialist metals (eg rare earth elements, In, Ge, Te, Rh, Se, Ga and Li)commodity market volatilitya difficult funding environment.Given these challenges, geometallurgy provides the opportunity to control or at least manage some of them.CITATION:Dominy, S C and O’Connor, L, 2016. Geometallurgy – Beyond Conception, in Proceedings The Third AusIMM International Geometallurgy Conference (GeoMet) 2016, pp 3–10 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Jun 15, 2016

By A Hall, D Kratochvil, P Littlejohn

Economic recovery of gold from complex gold ores, including poly-metallic deposits, is impacted by the presence of cyanide-soluble base metals. These base metals can create both a metallurgical challenge plus waste handling and disposal challenges. Base metals such as Cu and Zn compete for the cyanide reagent and often increase the total cyanide consumption to the point of making precious metals recovery uneconomic. In addition, the accumulation of base metals in cyanide solutions represent a challenge for cyanide detoxification and waste water treatment as these metals report to waste sludge. Such sludge requires safe handling and disposal, with possible long-term liabilities.Base metal interference can be removed with sulfidisation-acidification-recycling-thickening (SART) process technology. SART liberates the base metal from the cyanide complex and precipitates the metal as an insoluble sulfide product that can be recovered as a commercial grade concentrate. With the base metal precipitated, the cyanide can be regenerated as free cyanide and recycled to the gold extraction circuit.BioteQ completed laboratory testing for two projects, one employing cyanide leaching of copper-gold sulfide flotation concentrate and one employing a Merrill Crowe process, to determine the effectiveness of SART to remove and recover Cu and Zn in high-grade sulfide concentrates and to reduce the impact of cyanide-soluble metals on gold recovery and cyanide consumption. This paper will provide an overview of the testing methodology and results along with a review of the potential for SART to be applied to complex gold ores with poly-metallic deposits to improve project economics, operability and waste management.CITATION:Littlejohn, P, Kratochvil, D and Hall, A, 2013. Sulfidisation-acidification-recycling-thickening (SART) for complex gold ores, in Proceedings World Gold 2013 , pp 149-156 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 26, 2013

By M Spiteri, S Woth, J Caratti, K Henley

Blasting is an essentially violent process aimed to disrupt and loosen rock for productive excavation and downstream processing. Dilution of the orebody to some extent is the inevitable result, particularly in narrow vein gold mines. A small change in gold recovery is usually a strong lever on revenue generation. As a result blast designs are carefully engineered to both minimise and control the direction of rock movement. Traditionally blast designs in gold mines have used the minimum powder factor that will still permit rock excavation. This now conflicts with the recent industry trend to optimise the total process flowsheet from the mine to the mill. Numerous mines have achieved success in reducing total mining cost by increasing powder factors. Not only is explosive energy cheaper than mechanical comminution energy requirements, the increased blasting effect may deliver benefits across all downstream processes of digging, hauling, crushing and milling. Kalgoorlie Consolidated Gold Mines (KCGM) Fimiston operation is the largest gold mine in Australia, located in the heart of the Kalgoorlie Goldfields. Blast dilution has been reduced at KCGM by managing location of blast boundaries and by firing along strike to choked faces. Significant economies of scale have resulted from application of a bulk mining methods. The bench height of 10 m is the largest in the Western Australian Goldfields, and is typically mined in a single pass with large face shovels. Recent increases in production rates in both the mine and mill has been partly attributed to a 30 per cent increase in powder factor. KCGM then examined the benefit of a further 18 per cent increase in powder factor to 1.0 kg/BCM. A concern though was the impact of very high powder factors resulting in excessive blast movement and subsequently ore dilution. This was the subject of a project conducted with Orica Explosives. OricaÆsDMC(Distinct Motion Code) blast model was applied to understand the effect of not just further increases in powder factor but also blast geometry and explosive type. The modeling work demonstrated that high powder factors may be applied with minimal increase in ore dilution provided the combination of blast geometry and explosive type is optimised. These results are currently being implemented to achieve further reductions in total mining costs without a significant impact on recovery.

Jan 1, 2001