Search Documents

Real-time data collection and plant historians are becoming common place in mining and processing plants. This vast quantity of data must be turned into easily accessible and actionable information for all levels of the organisation.Queensland Nickel use a combination of Microsoft and SAP business intelligence tools to collect, cleanse, aggregate and present plant information to the appropriate people for supporting decision making in the business. SAP Business Objects, for visualisation, and SAP MII, for integration, allows complex and accurate metrics to be delivered as real-time dashboards. Designing a rigid data management architecture to segregate the data collection, integration and logic and visualisation into distinct logical layers, allows for rapid report development and greatly assists with IT maintenance, while also minimising the complexity of any customised programming. This type of architecture ensures a common data source for all business reports, ensuring one version of the truth. The past few years at Queensland Nickel have seen process and maintenance engineers spending considerably less time collecting and integrating data and spending more time analysing what is happening in the plant. Real-time reports and dashboards have been developed around the business needs rather than around the data. Two years ago Queensland Nickel introduced an employee bonus scheme based upon meeting monthly performance targets; an easy to use dashboard that allows everyone, from operators through to management, to monitor these metrics day-to-day.

Sep 26, 2011

By R Barritt

Remedial options for a waste rock dump (WRD) were considered as part of closure planning studies at an active mine in Western Australia. To minimise the impact of any seepage from the landform it was determined that placement cover system utilising the moisture ‘store-and-release’ concept was appropriate. The purpose of the cover system was to:•Reduce net infiltration of meteoric water to attenuate peak concentrations for contaminants of concern in natural receptors to levels that can be assimilated without adverse impact to the surrounding ecosystem; •Provide a growth medium for establishment of a sustainable vegetation canopy; and •Improve current quality of surface water runoff from waste storage areas.The project comprised several phases of work: materials characterisation, numerical soil-plant-atmosphere (SPA) modelling and finally cover system construction and monitoring equipment installation.CITATION:Barritt, R, 2018. Conclusions from long-term cover system performance monitoring – a case study, in Proceedings Life-of-Mine 2018, pp 101–105 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 25, 2018

By L Dubron

This study details a mineralogical and textural characterisation of West African iron ores with an emphasis on their behaviour during mineral processing. By means of both qualitative and quantitative characterisation, a simulation of the beneficiation process applied to these iron ores is performed. A series of different analytical tools are used, including:X-Ray Diffraction (XRD) for qualitative mineralogical analysis;• qualitative optical microscopy (phase identifi cation, description of micro-textures) and (semi)• quantitative optical microscopy (counting of particles, phases and textural types); and• chemical analysis.All the information provided by these analytical methods are combined into a quantitative mineralogical and textural analysis, here called ‘modal analysis’, which enables us to simulate the capability of West African iron ores to be benefi ciated by magnetic and gravimetric separation techniques.On one hand, both qualitative XRD and optical microscopy have revealed the presence of the following mineralogical phases: magnetite, haematite, goethite and quartz. On the other hand, the chemical analyses provide us with quantitative inputs expressed as oxides. We have converted the oxides into mineralogical contents expressed as magnetite, haematite, goethite and quartz. In this way, we build a simple quantitative mineralogical analysis.Beside this, the semi-quantitative approach of the characterisation by optical microscopy also provides us with a liberation study, enabling us to split the gangue-bearing content between two types of particles:1. liberated gangue-bearing particles, and2. composite particles composed by both iron (oxhydr) oxides and gangue-bearing minerals.We have assumed that we could anticipate the behaviour of these two kinds of particles through a mineral process, by simulating the removal of at least the liberated particles of gangue. Optical microscopy also revealed a trend in the weathering profi le of the Tokadeh ore horizon with a decrease from bottom to top of magnetite and an increase of both goethite and martite showing a higher level of oxidation and hydration in the upper ore horizon.We have applied this removal extent upon the quartz content of the mineralogical quantitative analysis and we have re-calculated the quantitative mineralogical analysis considering the expected decrease in the quartz content. Finally, by converting the re-calculated (oxhydr) oxides contents into iron grades and summing them, we do obtain a fi nal simulated iron grade for the upgraded products.

Jul 11, 2011

By L Alem

In the field of mineral extraction, complex technologies are being introduced in mines, operators/technicians rely on assistance from an expert (or more) in order to keep their machines functioning. Personnel with such expertise, however, are not always physically on-site. There is a growing need for innovative technological solutions to support effective delivery, just in time, of remote guidance between an offsite expert and an on-site maintenance operator. To meet this need, we have, as part of our Human System Integration project within the CSIRO’s Minerals Down Under (MDU), Transforming the Future Mine theme, explored the usefulness of a number of emerging technologies including: augmented reality, wearable systems and touch table interfaces. This paper presents ReMoTe, an augmented realty system for remote guiding using a touch table interface for the expert station and a combination of augmented reality and a wearable system at the operator end. In designing this system we were interested in exploring the extent to which it can increase the productivity and safety of maintenance personnel. This paper also presents Mobile ReMote, our recent development of a fully mobile remote guiding system. In Mobile ReMote, both the expert and the operator are using a near eye display and wearing a light computer in a back pack. The expert is able to guide the operator using his/her hands on the virtual display, while the operator is able to see the instructions on the rear eye display. Workers in the mining industry are highly mobile, a mobile expert and operator station will meet this need.

Nov 22, 2011

By A Nigam, K Biswas, R Sarkar

Because of the problems with 1st and 2nd generations of Advanced High-Strength Steels (AHSS), a 3rd generation of AHSS steels has become prominent and these steels have properties in between the 1st and 2nd generations of AHSS. However, although the 3rd generation of AHSS is a promising candidate as a replacement for its predecessors, there remain some challenges in processing these steels which are essentially medium Mn (Mn content ~ 5–7 wt per cent) and high Al (Al content ~ 1– 3 wt per cent) steels. The use of conventional casting powders based on the CaO-SiO2 system is unsuitable for high and medium Mn/Al steels. This work investigates the development of CaO-Al2O3- based mold fluxes for casting third-generation AHSS steel. Mold fluxes, with otherwise similar compositions but different C/A ratios, are tested and their crystallisation behaviour is examined using differential scanning calorimetry (DSC). A calcium aluminate phase having a composition Ca12Al14O33 was found to be the main crystalline phase in the mold fluxes. A decrease in crystallisation temperature was observed as the CaO/Al2O3 ratio increased from 1.00 to 1.33. The effective crystallisation rate constant exhibited an increase with decreasing crystallisation temperature, indicating a potential influence of nucleation rate on the overall crystallisation rate and suggesting an anti-Arrhenius behaviour in the crystallisation process of these mold fluxes.

Aug 21, 2024

By M Rayner, C Tsouris, A Komelkov

X-ray fluorescence (XRF) is a widely accepted technique for the elemental analysis of iron ores and their concentrates. Wavelength-dispersive, or WDXRF, and energy-dispersive, or EDXRF, spectrometers offer distinct advantages for particular applications, elements and concentration ranges and are, therefore, more complimentary than people might realise. A key example is the ability of EDXRF to identify, and often quantify, unexpected elements in production samples that would typically be missed by routine WDXRF. In this paper we discuss recent technological advances in XRF and present a novel application example that demonstrates the additional technical and practical benefits of using both EDXRF and WDXRF to characterise iron ores and concentrates.CITATION:Tsouris, C, Komelkov, A and Rayner, M, 2015. A novel approach to the characterisation of iron ores and concentrates using recent advancements in wavelength- and energy-dispersive x-ray fluorescence spectrometers, in Proceedings Iron Ore 2015, pp 591–594 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

By J Shillabeer

Paste backfill has been adopted by many underground mines in North America and a growing number elsewhere. Paste offers a number of advantages. This paper suggests wider applications of paste technology to surface tailings disposal and water management. Advantages include improved overall stability, potentially easier permitting, smaller water inventory and earlier reclamation. It may be feasible to use the same plant to prepare backfill and to dispose of surplus tailings. Example cost models are given to illustrate potential applications.

Jan 1, 1998

By R Cox, S Pandey

The coal seam gas (CSG) industry is expanding rapidly in the Surat and Bowen basins. CSG production involves pumping water from the coal seams to release the gas adsorbed to coal particles. The reduction in water pressure in the coal seams will cause some reductions in water pressure in overlying and underlying aquifers because there will always be some interconnectivity between the formations. The Surat Basin is a sub-basin of the Great Artesian Basin, which contains aquifers of high economic, environmental and cultural value. The Condamine Alluvium is also an important water resource, which overlies parts of the eastern margin of the Surat Basin.Under the Queensland (Qld) regulatory framework, an area of intensive CSG development involving multiple CSG operators can be declared to be a cumulative management area. For such areas the Office of Groundwater Impact Assessment develops assessments of future impacts on aquifer water pressures and develops and manages arrangements. The results are published in underground water impact reports.The Surat underground water impact report (QWC, 2012) was approved in December 2012. This paper summarises the place of the report in the Queensland regulatory framework, the content of the report and progress in its implementation.CITATION:Cox, R and Pandey, S, 2013. Managing groundwater impacts in the Surat Basin, in Proceedings Water in Mining 2013 , pp 169-174 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 26, 2013

By P G. Bourke, A Yáñez, G J. Jameson, N M. L Kupka

The kinetics of fine and ultrafine particles in conventional mechanical flotation cells are limited (Feng and Aldrich, 1999; Trahar, 1981; Wang et al, 2016). Accordingly, even limited recoveries with such machines require long residence times. Theoretical investigations into the rate of capture of fine particles by flotation, have indicated that a key parameter is the rate of shear in the fluid surrounding the bubbles and the particles. Achieving fast flotation rates of ultrafines requires a new method of bringing the particles and bubbles into contact, utilising the beneficial properties of highly dissipative flows to break through the water boundary layer. In 2010, a new type of flotation cell known as the Concorde Cell was described, in which bubbles and particles are brought together in a sonic shock wave (Jameson, 2010). Earlier research had shown that when a dispersion of fine bubbles in liquid passed through a converging nozzle at the local speed of sound, the resulting shock wave downstream generates a mass of even finer bubbles in the flow as it passes through the shock wave. The fluid within the shock wave is highly turbulent, and an environment is created that is very favourable to particle-bubble collision and capture. In this paper, we briefly describe the Concorde Flotation Cell and give examples of its use.

Aug 24, 2022

By T Seifert, P Krolop, K Niiranen, S Gilbricht

The Per Geijer iron oxide apatite deposits (IOA) display significant potential mineral resources for Luossavaara-Kiirunavaara AB (publ), known as LKAB. LKAB continuously mines magnetite/hematite ores in northern Sweden for almost 130 years. The Per Geijer deposits reveal a high phosphorus content and vary from magnetite-dominated to hematite-dominated ores, respectively. Furthermore, they show a large variation in texture, mineral composition, and relation to wall rocks. The high phosphorus concentration of these ores results from highly elevated content of apatite as gangue mineral. Reliable, robust, and qualitative characterisation of the mineralisation is required as these ores inherit complex mineralogical and textural features. For this purpose, comminution tests at laboratory scale in combination with scanning electron microscopy-mineral liberation analysis (SEMMLA) were carried out. Based on this work, significant information on the modal mineralogy and degree of liberation of minerals of economic interest (eg magnetite, hematite, and apatite) were obtained. Results show that there is a difference in the degree of liberation of magnetite and hematite between ore types. This seems to be dependent both on the size fractions and the dominance of each iron oxide in the individual ore type. The amount of gangue minerals seems to have no significant impact on the degree of liberation after comminution. Apatite is generally best liberated in ore types associated with silicates, regardless of magnetite or hematite dominance. Based on the results of this study it can be inferred that a high degree of liberation of the minerals of economic interest can be achieved. However, results need to be verified with further beneficiation steps such magnetic separation, apatite flotation and possibly reverse silicate flotation.

Nov 8, 2021

By J Schrank

Double-stack trains in the United States date back to the early 1980s, starting about the time deregulation of the rail industry occurred. Freight rail became increasingly more competitive to trucking and barge or ship, and led to major investments in railroad infrastructure. Since most railroad tunnels in the United States were constructed between 1880 and 1930, they were not built tall enough to accommodate modern double-stack intermodal railcars. Therefore, as double-stack trains became the norm, existing tunnels became bottlenecks, and railroads wanted the tunnels made larger without impacting traffic. This need to increase the clearance while not impacting rail traffic launched a very specialised industry: the design and construction of replacement lining systems in existing tunnels.Several large multitunnel railroad clearance improvement projects have been completed in the country in the last decade, and they have all been done under ‘live track’ conditions. Live track conditions consist of work windows, often anywhere from four to 12 hours, that are provided to the contractor to complete the construction work. By the end of each work window, the tunnel must be secured so that the railroad can run trains.In addition to improving the clearance, these projects provided the railroads with an opportunity to improve the general condition of the tunnels, including structural, seepage, drainage and icing conditions. This paper discusses the design considerations, tunnel assessments and construction methods used for these live track railroad tunnel projects. Seepage and drainage improvements that were incorporated into the clearance improvement projects are also discussed.CITATION:Schrank, J, 2014. Live track railroad tunnel repair and clearance improvement in the United States, in Proceedings 15th Australasian Tunnelling Conference 2014 , pp 619–628 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 17, 2014

By E S. Weiss, S P. Harteis

The Pittsburgh Research Laboratory (PRL) of the National Institute for Occupational Safety and Health (NIOSH) has conducted full-scale explosion experiments, to evaluate the strength characteristics of various seal designs, used for safely isolating worked-out areas in underground coal mines. Large-scale explosion tests conducted within the multiple entry section of PRLÆs Lake Lynn Experimental Mine (LLEM) is currently the only accepted test method used by the Mine Safety and Health Administration (MSHA), for deeming a seal design suitable for use in American mines. These explosion tests are labour intensive, expensive to conduct, and can interfere with other critical underground safety and health research programs conducted by NIOSH. The PRL has developed an alternative seal evaluation method, based on a hydrostatic pressure loading concept, that can facilitate the in situ testing of seals in an operating mine. Two chambers within LLEM and one within PRLÆs Safety Research Coal Mine (SRCM) were used for hydrostatic pressure loading various seal designs. The results from these chamber tests compare favourably with those from the large-scale explosion tests in the multiple entries. In addition to testing seal designs at the required 20 psi static pressure level, the chamber test approach also allows for the determination of the sealÆs ultimate design strength. Size-scaling relationships for predicting the strength of seal designs as a function of entry size are also presented.

Jan 1, 2005

By S Whitton, W Wimmler, L Wimmler

“Given the increasing scrutiny of the mining industry and its relatively poor record with regards to mine tailings management, increased requirements to minimise water usage (often accompanied by very high costs of water) and the need to demonstrate achievable long-term closure strategies, it is likely that the option of a filtered tailings system will need to be considered in many operations in future.” (Australian Centre for Geomechanics, 2018). Given such a statement as a conference introduction, it is only appropriate that a range of potential technologies are investigated and compared, to create awareness for even underrated but appropriate technologies. The advantages and disadvantages of all technologies need to be considered and analysed. Suppliers are swift to promote their technologies advantages; however aspects of sustainability are not always fully understood. Perhaps a combination of two filtration technologies is appropriate. This paper delves into the technical details, good or bad, of four mechanical dewatering technologies in tailings dewatering and provides insight on an undervalued and, in the author’s opinion, young technology – the screw press.

Jul 1, 2021

By A L. Bennett

It is well understood that designers and constructors must protect the existing surroundings of tunnel construction, particularly in the selection of excavation methods, ground support and waterproofing systems. However, while this can readily address the existing conditions, the tunnel owner and the designers need to consider the changes that are likely to occur during the life of the tunnel. It is typical for transport infrastructure to have a design life of at least a century. While the effects of constructing the tunnel on its surroundings are a short-term effect, the converse case, the protection of the tunnel, and the need to maintain its integrity, will affect developments over and adjacent to the tunnels beyond the foreseeable future. Decisions made during the design phase have the potential either to facilitate development or to hinder it for the long term.Examples principally from Australia, New Zealand, Singapore and Hong Kong show that the provision for future development is addressed in different ways. These have ranged from making no specific provision, putting the onus onto developers to ensure that the tunnels are not affected adversely, to including a loading allowance for future development in the performance specification or contract documents for a tunnel project.These two contrasting approaches have strong points and risks. A highly prescriptive definition of permissible loadings around the tunnel can provide unambiguous guidance for the approving authority and the developer, but runs the risk of being overly conservative to allow for all the envisaged works, while still missing a detrimental combination of effects that theoretically complies with the specified requirements. In contrast, a general requirement to not cause detriment is open to interpretation and potentially difficult negotiations to reach agreement between the tunnel owner/operator and developer and finally the appointed contractor (probably with no contractual relationship with the tunnel owner).In practice, a combination of prescriptive and performance requirements is likely to provide the optimum combination of clarity and flexibility. The author provides examples and recommendations on how such provisions could be structured.CITATION:Bennett, A L, 2014. Protection of ?tunnels in their future environment, in Proceedings 15th Australasian Tunnelling Conference 2014 , pp 495–500 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 17, 2014

By L L. Kuhar

The AMIRA International P843A Geometallurgical Mapping and Mine Modelling (GeMIII) project is an interdisciplinary research collaboration between 17 global mineral companies and four research organisations aimed at providing support for the emerging industry trend of geometallurgy. The main aim of the project is to develop predictive geometallurgical indices which can be incorporated into a resource block model to maximise the commercial value of an orebody and to minimise the social and environmental impact of mining operations.Researchers at the Parker Centre/CSIRO have been focusing on the development of predictive hydrometallurgical indices for the GeMIII project via rapid, small-scale, cost-effective tests and protocols for comparative ranking of attributes relevant to leach performance. The focus of the small-scale leach tests has been to determine the leach index (relative indication of leach performance), recovery, impurity deportment, reagent consumption, effect of size/degree of liberation and mineralogy of samples for their relative ranking. Predictive tests for heap leach hydrology (related to agglomerate characteristics) and slurry rheological behaviour are also being developed.

Sep 5, 2011

By F T. Suorineni

Empirical methods are deeply rooted in geomechanics. This is a consequence of the recognised complexity of the nature of the rock mass. The usual assumptions of material continuity, homogeneity, isotropicity and linear elasticity often assumed for soil, concrete and steel are difficult to justify in a rock mass except for mathematical convenience. These assumptions form the bases for most mechanistic, analytical and numerical methods in geomechanics. Believers in empirical methods argue that the complexity of the rock mass and its interaction with structures developed in it is adequately accounted for in empirical methods, which compensate for our ignorance.Franklin (1993) defines empirical design as quantified judgement based on experience. He further states that empirical methods often prove ‘closer’ to the ‘truth’ than the apparently more precise predictions of theoretical analysis, adding that based on real data empirical methods provide a standard against which theoretical predictions are measured and can be judged. This paper takes a critical look at the common empirical methods in geomechanics – rock mass classification systems (Bieniawski, 1973; Barton, Lien and Lunde, 1974; Hoek, 1994a), Laubscher block caving design rules (Laubscher, 1994), the stability graph (Mathews et al, 1981), pillar design equations (Salamon and Munro, 1967; Hedley and Grant, 1972; and their derivatives), pillar design chart (Lunder and Pakalnis, 1997) and failure criteria (Hoek and Brown, 1980; and its derivatives). The common thread in the application of these methods is that in most cases they are often applied blindly without an understanding of the underlying assumptions and database limits. This paper emphasises that users of these methods need to know the underlying assumptions, database limits and inherent hidden risks that are often unmentionable for their satisfactory use. Finally, suggestions are provided for the efficient use of empirical methods and how they can be improved.CITATION:Suorineni, F T, 2014. Reflections on empirical methods in geomechanics – the unmentionables and hidden risks, in Proceedings AusRock 2014: Third Australasian Ground Control in Mining Conference , pp 143–156 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 5, 2014

Leaving the relatively simple life on a uni student and venturing off in to the outside working world is a big step. There are two paths to follow, the æContikiÆ style graduate program where you pick up your new lease vehicle and set forth on two to three years of planned activities, or can pack everything into one bag, stick a copy of æthe rough guideÆ in your pocket, and set off on your own graduate adventure. I took the path less travelled.The less followed method of developing yourself isnÆt for everybody. Parts of the journey are difficult and sometimes it feels hopeless, but itÆs all a learning experience. Along the way you might not get to all the graduate ætourist stopsÆ like dragline, truck-shovel, or drill and blast. But youÆll see most of them and pick up a lot more of the local culture such as people management, operational knowledge, quality control, and the black arts of project financial management.

Jan 1, 2004

By S Garnes, W Austerberry, S Fraser

Despite significant investment in safety in the mining industry (mostly focused on processes and systems), many companies are unable to sustain and further improve their performance resulting in continued workplace incidents. The problem persists despite the best efforts of companies and allocation of resources to achieve Zero Harm. A DSS survey in 2019 found that two out of five companies that cannot manage risks and face disaster, leave the market within five years. All safety/risk management systems have the common steps of risk identification, prioritisation, design of controls consistent with risk tolerance, and verification of implementation/operability of controls. This is then complimented with improvement to one or more of the above elements through learnings obtained from incident investigations. In principle, the above process should work to reduce risks to, and keeping them at, a risk level consistent with risk tolerance in the organisation.

May 5, 2022

By J Maxlow, M J. Woods, M P. Sandy

The Newcrest Mining Limited Telfer operation comprises both open pit and underground operations producing gold and copper. The underground operation is made up of three production areas, the sublevel cave (SLC), M Reefs narrow vein open stoping and Western longhole open stoping areas. With stoping situated on the abutments of a mature and active sublevel cave, the interaction between mining areas is often complex. This is particularly evident in the M Reefs orebodies with high levels of extraction in all four reefs, and reliance on pillars to maintain local and global stability. A key concern was the potential for a cascading pillar failure to develop and rapidly progress through the M Reefs stoping area. The monitoring plan needed to capture any change in overall stability and identify if deformation was caused by pillar failure within the M Reefs and hanging wall closure, or shear on the reefs caused by SLC influence.

Nov 29, 2022

By M I. Pownceby, A Guiraud, S Purohit

Sticking and breakage of iron ore pellets during high temperature reduction can result in several operational challenges during shaft furnace ironmaking. With the shift to H2-based DRI processes and decreasing iron ore quality, this issue becomes more prominent. It is therefore important to understand how the iron ore chemistry and mineralogy affects the sticking and breakage of pellets inside the shaft furnace. This study provides a review of the mechanisms that lead to sticking and breakage of pellets inside the shaft furnace. The sticking index of pellets is related to the rate of metallic iron production as well as the precipitation morphology of product iron. Sticking of pellets is also enhanced by the formation of low-melting slag phases. The breakage of pellets inside the shaft furnace is often associated with the mechanical load of burden and pellet swelling, which is caused due to iron whisker or protruded iron formation. This paper investigates how the composition of iron ore, particularly the presence of different impurity oxides such as SiO2, Al2O3, MgO, CaO and alkali oxides in the pellets, influences the sticking and swelling indices. The effect of ore mineralogy on these adverse behaviours is also discussed.

Sep 18, 2023