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By M Byrne, P Newman, M Lindqvist

SomincorÆs Neves Corvo Mine, one of the largest copper producers in Europe, is currently constructing a paste backfill plant in order to replace cemented rockfill in its bench and fill stopes and possibly replace hydraulic sandfill in the drift and fill stopes. A 250 m flow loop was constructed at the mine and the flow properties of various paste blends were investigated. Cycloned tailings and total tailings were both pumped successfully as pastes and were also combined with waste rock for additional testing. The pressure losses in 102 mm and 154 mm diameter pipeline were recorded at flowrates up to 60 m3/hr and are presented at slumps from 120 mm to 250 mm. The data showed the sensitivity of paste mixtures to slight changes in consistency, confirming the need for accurate control during paste production and distribution. The flow results clearly showed the different paste behaviour between cycloned and total tailings pastes and the change in properties at low and high slumps. In addition to pressure loss data, strength testing was done on 38 mm and 82 mm diameter samples. Further strength testing is ongoing at the mine using fly ash as a supplement to cement, reducing the overall binder cost. Preliminary engineering for the underground distribution system is briefly discussed, with reference to the siting of the plant. The Neves Corvo Mine is particularly shallow and alternative methods to pumping were sought in order to ensure sufficient hydraulic head for underground distribution. The comparison of options had to take into account the capital and operating costs, the operation of the plant and the impact on the future expansion of paste fill utilisation at Neves Corvo.

Jan 1, 1998

By E Claridge

There are a number of major infrastructure tunnelling projects currently underway or proposed in New Zealand, including construction of new road and rail facilities and the refurbishment of existing road tunnels. These new projects have triggered a rethink of traditional practices in underground fire and life safety and local regulation.While there is a current surge in activity, tunnels have been a signifi cant part of New Zealand’s transport infrastructure for over a century. Despite this background, the new projects commonly face challenges that are symptoms of a national regulatory environment that has aspects that are inappropriate for underground environments. There are inconsistencies in local regional regulation and an absence of national guidance and standards relating to tunnel design. Historically, New Zealand has looked across the Tasman for guidance. Although recent overseas tunnel designs present learning opportunities, the adoption of international best practice and standards may not necessarily address local expectations or needs.This paper explores a number of specific matters affecting the design of road and rail tunnels in the New Zealand context, namely; the Building Regulations and associated local consenting processes and parties, and the responsibilities and needs of the New Zealand Fire Service.The discussion highlights the importance of a collaborative approach involving the designer, asset owner, regulators, emergency services, and other parties, and ensuring up-front clarity in design responsibility and ownership of residual risk.

Mar 8, 2011

By S J. Neethling and, S J. R Simons

In this paper the effect of humic substances (natural surfactants), electrolytes and solid particles on bubble coalescence, and as a consequence on froth stability, have been investigated. In this study two bubbles of equal size were formed and forced to collide using a novel experimental apparatus. The interactions were recorded by a high-speed camera, the images of which helped to determine the coalescence frequency and the coalescence time, as well as the mechanisms of the interactions. Two types of humic substances were used, along with three different electrolytes. Humic substances appeared to have a considerable effect on bubble coalescence, while the effect of electrolytes was minimal. Moderate and high hydrophobic glass spheres were used between two bubbles. Very hydrophobic spheres promoted fast bubble coalescence, while moderate hydrophobic spheres had no effect. Data of coalescence frequency and time is presented, as well as images of the coalescence events. The coalescence frequency was used to validate a parameter, Pf, known as the film failure frequency, used in a simulation model to predict foam height in a gas-sparged vessel. Predictions determined using Pf were then validated by experimentation.

Jan 1, 2005

By D J. Kilkenny

Work practices involved in shaft construction can be aligned with current industry standard operating practices. However, the working environment during conventional shaft construction introduces unique conditions which can not always be overcome by hard engineering controls. To provide an improved working environment, future shaft diameters will generally be greater than has historically been the case for the Australian hard rock mining industry. This paper aims to explore both what can be constructed from the contractors perspective, and how does an owner extract maximum business efficiency from an asset that in many ways is likely to be larger, more complex and more expensive than initially envisaged.Newcrest Mining Limited, or an associated company, has constructed two major shafts over the last seven years. In both cases, Byrnecut Mining, or an associated company, was the contractor engaged for the shaft sinking activity. The first is the 1127 m deep, 7.0 m diameter production and intake airway at the Telfer Gold Mine, the second is a 295 m deep, 5.5 m diameter split shaft at the Gosowong Gold Project in Indonesia that was primarily designed as both an intake and exhaust airway. Importantly both shafts are designed to provide emergency egress from the respective underground operations.From an Australian shaft sinking perspective, the construction of these two shafts resulted in the following learnings: •constructability is of equal importance to desired functionality;•allow six months of interactive design between the owner/engineer/contractor/regulator to get it right;•shaft sinking and equipping are intimately entwined, therefore engineering of both needs to be complete prior to any activity commencing; and•the mobilisation of both equipment and experienced personnel to a new shaft sink takes up to eight months.Shaft sinking is not extinct in the Australian hard rock mining industry. But, if you are considering constructing a shaft, approach it as a long life asset, front end planning to a high level of detail is required to unlock its full value. Think – plan – think and remember it’s going to take 12 months to get from the whiteboard to firing the first cut.

Mar 21, 2011

By A Mehrani, F Zamani, A Dehghani

Vibrating screens play an important role in the dry classification circuit of Gol-e-Gohar iron ore processing plant. This circuit was designed to classify the autogenous mill discharge and produce a suitable feed, with K80 about 450 ¦m, for dry magnetic separators. Three parallel vibrating screens produce more than 50 per cent of the separatorÆs feed. The efficiency of the magnetic separator is greatly affected by feed size distribution. In this work, the JKSimMet 5.1 software was used as an analysing tool to assess the flow rates and USIM PAC3 software as the simulation tool to control and optimise the vibrating screens. Samples were collected and the circuit was mass balanced. Then the vibrating screen was simulated and adjustment parameters such as cut-point, bypass and imperfection factor were determined. The product streams of vibrating screens can also be predicted.

Jan 1, 2007

By B Nielsen, H Lehto, B Musuku

"The demand for fine and ultra-fine grinding associated with the processing of more challenging, finer grained orebodies and the global driver of minimising energy consumption has been an increased focus in our industry. Outotec’s stirred milling technology, the high intensity grinding mill (HIGmill™), was launched in 2012 in response to this industry need. First Quantum Minerals Ltd selected HIGmill™ technology for its Kevitsa mine in Northern Finland. The 700 kW mill is grinding copper rougher concentrate to improve copper/nickel separation and copper recovery. Selection of the HIGmill™ followed mineralogy analysis and laboratory and pilot testing for HIG milling in parallel with flotation tests to determine optimum grind size and energy input.The paper discusses the challenges and successes of the test work, manufacture, installation, commissioning and subsequent operation of the mill. Grinding performance is presented and a comparison between predicted and operating energy efficiency is made. In addition, the various steps to optimise wear rate and minimise maintenance and downtime are made, with particular reference to internal geometry of the mill.Citation:Nielsen, B, Lehto, H and Musuku, B, 2016. Design, Installation, Commissioning and Operation of Fine Grinding Technology at the Kevitsa Mine, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 59–66 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

Structural analyses of oriented bore core sections from the West Wallsend No.2 Colliery Holding together with investigations in adjac- ent collieries and on the surface delineated structural phenomena. The rocks examined are anisotropic due to strongly developed bedding planes and the presence of penetrative joint planes. Joints, in this context, are regarded as mechanical discontinuities, they are genetically identif- ied wherever possible and their spatial attit- udes are determined and geometrically related to the regional structure. Identifiable anisotropies in the roof- and floor-strata of the Borehole Seam render favour- able mining directions for longwall and bord and pillar layouts.

Jan 1, 1972

By L Mikhael Gurieff, D Baas

The Phu Kham Copper-Gold Operation (Phu Kham Operation) is located in the Lao People's Democratic Republic and is owned and operated by the Lao-registered company, Phu Bia Mining Limited (PBM). Australian-headquartered copper and gold producer, PanAust Limited holds a 90 per cent interest in PBM; the Government of Laos owns the remaining 10 per cent. The Phu Kham Operation was commissioned in 2008 with an initial concentrator nameplate throughput of 12 million tonnes per annum (Mt/a). Subsequent improvement projects, including the Phu Kham Upgrade Project (PKU), completed in 2012, and the Phu Kham Increased Recovery Project (IRP), completed in 2013, increased the design throughput to 18 Mt/yr. In 2016, the actual mill throughput exceeded 19 Mt/a, this throughput is budgeted to be maintained until the end of 2020.The concentrator flotation circuit upgrade, completed during the IRP, called for a non-selective bulk sulphide concentrate to be generated from the rougher circuit. This in turn caused the mechanical flotation cells in the cleaner circuit, particularly those in the second cleaner bank, to become volumetrically overload. The overload reduced the cleaner circuit performance to approximately 92 per cent copper recovery at a 23 per cent copper concentrate grade, below the expected 95 per cent recovery. This bottleneck restricted copper units entering the plant to approximately 14.5 tonnes per hour (t/h) due to uncontrolled recirculating load build-up in the mechanical cleaning circuit.Maintaining the operating methodologies would have led to a copper production shortfall beyond 2016, to address this shortfall the Phu Kham Operation looked to optimise the Jameson Cell and mechanical cleaner circuit performance. The work included fundamental application of flotation practice and modelling, mineralogical analysis, bubble size analysis, plant surveys and test work. The results were used to develop and implement an innovative automated control system strategy incorporating flotation theory and operating strategies. The automation has the ability to quickly adapt to disturbances in the circuit and maintain optimised performance with little or no intervention by flotation operators.Upon completion, cleaner recovery increased to 95 per cent at a final concentrate grade of 23 per cent copper, and copper units entering the plant increased to 17.5 t/h.CITATION:Baas, D and Mikhael Gurieff, L, 2018. Developing flotation circuit control and automation for the Phu Kham Copper-Gold Operation concentrator, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 37–58 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

By D Adhikary, M Khanal, B Poulsen, H Guo

During longwall mining, the ability to reliably estimate the height of longwall mining-induced fractures is critically important in order to effectively manage mining-induced water inflows and aquifer interference. The extent of mining-induced subsurface deformation, fracture, surface subsidence and aquifer interference is largely controlled by local lithological conditions, mining methods and mine layouts. Therefore for the purpose of quantifying mining impacts it is imperative to incorporate the local geology and mine plan parameters in a mine scale model. Two different numerical models based on 3D continuum (Finite Element Method) and 2D discrete (Discrete element method) domains, respectively, are developed to incorporate the mine site parameters of a study site in Australia. Both the models are calibrated and validated with measured mine data. The continuum numerical modelling method is used to investigate the change in permeability of the overburden strata due to underground extraction considering the full 3D nature of geology and mine layout. The discrete element modelling method is used to simulate the initiation and propagation of fractures, allowing the caving of overburden strata to be represented in a realistic manner, and the permeability enhancement of the strata overlying the goaf to be calculated from first principles. Permeability enhancement in the discrete element model is a direct function of the fractures induced in the deformation/caving process; fracture location, extent, aperture and connectedness. From the numerical modelling under the simulated condition for the mine studied here, it is predicted that the permeability of the caving zone from the goaf to five times the mining height increases by almost six orders of magnitude. In the fracture zone to approximately ten times the mining height, the change in permeability is predicted to be around two to three orders of magnitude. At the height of more than ten times the mining height the magnitude of permeability increased is predicted to be one to two orders of magnitude. CITATION:Khanal, M, Poulsen, B, Adhikary, D and Guo, H, 2018. Modelling of height of connective fractures during longwall mining, in Proceedings The Fourth Australasian Ground Control in Mining Conference (AusRock), pp 254–265 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 30, 2018

The cost of power is an important matter to mining companies generally and this thought that the members of the Australasian Institute of Mining Engineers, as well as the engineering and mining professions generally would be interested in any proposal for the reduction of that cost-has led to the presentation of this paper.The writer trusts that the description will be found clear and increase the interest in this exceedingly interesting subject. In the working up of the electrical arrangements touched on in this paper, the author has had the able assistance of hisfriend Mr. F. J. Mars, to whom he offers his hearty thanks. The selection of the best class of power plant for a mine is a very difficult and large problem and it is quite out of place to dogmatise that anyone of the many systems that offer isbetter than another, eg that the all electrical is better than the partly direct steam-driven and partly electrical, or that a gas plant is better than a steam plant.Such a selection is one that calls for very careful and close consideration, in each particular case, of a large number of regulating factors before it is possible to arrive at a proper decision.

Jan 1, 1911

By J L. Kerr, J Beyer-Robson, S Vink

Driven by an increasing need for water conservation, coal mine operators in the upper Isaac River catchment have placed significant emphasis upon the reuse of water. This initiative led to an overall increase in the salinity of mine waters. The ionic composition of this water differs from local stream water in that concentrations of sulfate are higher than average stream concentrations by ten per cent, while concentrations of bicarbonate and calcium are lower. When this water is discharged into ephemeral streams in semi-arid environments there is potential for this increased salinity and altered ionic composition to impact upon the ecosystem processes mediated by micro-organisms in river sediments.We have measured nitrification, denitrification and methanogenesis rates in a series of lab experiments using sediments from Isaac River catchment streams and found that salinity affects these processes in different ways and to different degrees. Process rates were shown to differ seasonally between samples taken from the same location and habitat type and also between different habitat types at the same time and location. Both aerobic and anaerobic process rates were higher in surface sediments and it is likely that this activity is associated with surface biofilms. Furthermore, we have shown that the ecosystem processes we have measured are limited by the availability of carbon in the sediments.The management implications of these findings for mine releases into ephemeral streams will be discussed.CITATION:Kerr, J L, Vink, S and Beyer-Robson, J, 2013. The effects of increased salinity on microbially mediated ecosystem processes in ephemeral streams, in Proceedings Water in Mining 2013 , pp 121-134 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 26, 2013

Continuous improvement in environmental management assists in the achievement of sustainability goals for the mining and 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. The audits described in this paper involve working with site personnel to develop and implement major improvement projects, providing advice on how to improve environmental practices and facilities, and disseminating innovative ideas and practices across the site and to other operations within the same group. Essentially the lead auditor assumes the role of a æskills coachÆ as opposed to a æpolicemanÆ, which is quite often the case for many audits. The audit process has been developed from involvement with 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 and more recently, with a metalliferous mine in the Northern Territory. Examples of the benefits of improved environmental performance (driven by the audit process) to sustainable development are provided. The auditing process as described is applicable to metalliferous mines, the processing of mineral ores, coal mines, coal handling and preparation plants, quarries, and oil and gas projects.

Jan 1, 2004

By Y Zhu, W Liang, P Knights

In recent years, Chinese companies have invested billions in Australian mineral exploration, development and processing. In 2008 - 2009 alone, the Foreign Investment Review Board approved $26.4 B of investment. Much of this investment has been by merger and acquisition (M&A) of Australian resources companies. This paper sets out to investigate how Australian CEOs perceive the cultural and institutional challenges in operating Australia mining companies recently acquired by Chinese interests. HofstedeÆs cultural dimensions and institutional theory from management science were used to develop a structured questionnaire, which was subsequently used to conduct telephone interview of the CEOs of six recently acquired mining companies. Analysis of the survey results indicated that, in all cases, few changes were made to the operational management of the Australian companies post-M&A. The three major benefits for Australian companies as a result of the M&A are the ability to; access long-term debt at lower cost; secure finance for growth plans in financially volatile times; and maintain existing management structures. Some perceived negatives involved longer and more convoluted decision-making as a result of Chinese state approval required for investment decisions. The study identified building æGuanxiÆ and an aversion to losing æfaceÆ as important cultural learnings for Australian CEOs. Maintaining effective communications is regarded as key for successful cultural integration.CITATION:Liang, W, Zhu, Y and Knights, P, 2012. Cultural challenges in Chinese/Australian mining mergers and acquisitions - A CEOÆs perspective, in Proceedings International Mine Management 2012, pp 251-260 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 20, 2012

By Hill G

The Boddington Gold Mine (BGM) is managed by Worsley Alumina Pty Ltd (Worsley) and is located 110 km south-east of Perth, Western Australia. The gold mine, which has operated since mid-1987, was originally constructed to treat 3 Mtpa of gold bearing oxide ores, has subsequently been expanded to treat 7 Mtpa and is presently one of the largest gold producing operations in Australia.During 1990 a Supergene/Basement Plant was constructed to treat 250 000 tpa of copper supergene and hypogene ores and basement ores which contain significant gold grades and which are encountered at the lower levels of the existing oxide orebody. The SupergeneBasement Plant has the versatility to treat a wide range of ore types, producing both gold bullion and copper-gold concentrates. It is a stand-alone facility adjacent to the existing 7 Mtpa gold plant.

Jan 1, 1992

By T Krull, T J. Donohue, D Ilic

"Problematic issues in materials handling applications are often amplified in the iron ore industry due to the relatively high density of the ore as well as the abrasive nature of the product. One of the main issues arising from the handling of iron ore is excessive wear, with two applications typically suffering accelerated wear issues being transfer chutes and conveyor belts. These wear issues are problematic due to additional capital costs, but mainly due to the associated downtimes resulting in the accelerated wear. This study will focus on the modelling of iron ore in practical applications where design work was undertaken in order to reduce the wear rates of different materials handling equipment.CITATION:Donohue, T J, Ilic, D and Krull, T, 2013. Modelling of iron ore in materials handling applications with a focus on wear, in Proceedings Iron Ore 2013, pp 355-362 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Aug 12, 2013

By A Mooney, J Marsden, H Grosser, G Dunstan

Carrapateena is a copper-gold deposit hosted in a brecciated granite complex, located 500km North of Adelaide, South Australia. The deposit is being mined using the Sub Level Caving (SLC) Mining method at a rate of 4.25 MTPA. The Carrapateena SLC construction was completed in Q4 2019, with ramp up to a mine production rate of 4.25 MTPA completed within 12 months; ~ 6 months earlier than originally planned (OZ Minerals, 2020b). Traditional SLC designs have had issues with safety interactions on production levels, namely at the perimeter drive, as well as presented challenges for the application of automation due to frequency of activity required to achieve ring turnover rates. Safety in design provides an opportunity to learn from experience at recent modern SLC operations and by considering hazards early in the design process minimise exposure and improve safety, productivity and automation of mining activity. This paper discusses the work carried out during the Carrapateena feasibility study and optimised during project execution; to update the SLC production level mine design, with a layout known as the Carrapateena Crows Foot Level Layout. This paper focuses on: • An introduction to the Carrapateena Operation and mine plan. • An overview and historical challenges of traditional level layout. • An introduction to the Carrapateena Crows Foot level layout, including production level design parameters as well as development metres and productivity comparisons. • Outlines the benefits of the Crows Foot design for safety in design of SLC operations. Provides a roadmap for improved production efficiency, level operational philosophy and the application of automation within the SLC.

Mar 15, 2021

By J Cook

In this paper we present a case study of the challenges and opportunities associated with the development of cultural heritage management strategies at the Lihir gold mine in Papua New Guinea. We discuss the contextual drivers and constraints, and outline the ways in which Lihir Gold Limited is aiming to set new industry bench marks for the region through the development of values-based best practice cultural heritage management programs. This approach is largely based upon a compliance partnership with a local stakeholder group. We argue that such partnerships are a prudent means of mitigating company risk, while constituting a far more necessary tool for local people in the reconceptualisation and negotiation of the experiences of significant social change and modernisation experienced in the context of recent resource development.

Jan 1, 2009

By T Laurencont, C Unger

The Mount Morgan minesite, located approximately 40 km SW of Rockhampton in Central Queensland, comprises 270 ha of unrehabilitated land which is the currently the major source of acid mine drainage run-off and seepage to the adjacent Dee River. Additionally, the minesite hosts an Open Cut Pit which contains 9000 ML of acidic and metal-rich water. In the absence of active management of water in the pit, there is a 50 per cent probability of an uncontrolled spill occurring in future years. The development of a contingency plan for management of overflow from the pit in the short term, has incorporated findings from numerous studies relevant to the Open Cut Pit including, but not limited to, water balance, contaminant source identification, toxicity testing, water quality profiling and limnological modelling, and estimates of probability of overflow. Extensive stakeholder consultation and peer review were also undertaken during the formulation of the contingency plan. The medium-term goal of lowering the water level in the pit to reduce the current high probability (50 per cent) of uncontrolled overflow to acceptable levels of risk is proposed to be achieved by a campaign of chemical water treatment. The treated water will be discharged to the Dee River, and sludge returned to the pit. The methodologies used for the selection and development of the water treatment process, that is proposed to involve treatment with lime, are described. Water treatment is the short- to medium-term component of a long range rehabilitation plan for achieving a negative pit water balance, and sustainable management of acidic water across the whole site. Achieving this ultimate goal will involve: reducing the inputs of water to the Open Cut Pit such that the annual water balance is zero or net negative, thus removing the need for water treatment in perpetuity; maximising, by surface rehabilitation works, the quality of run-off reporting to the Dee River; and minimising the volume of acidic seepage reporting to the seepage interception system. Possible strategies for achieving this long range goal consistent with overall site rehabilitation objectives are currently being developed and costed.

Jan 1, 2003

By T Ireland

The Rosedale Outfall Project utilised an earth pressure balance (EPB) tunnel boring machine (TBM) for only the second time in Auckland. Although the tunnel was excavated fully through East Coast Bays Formation (ECBF), the downhill gradient along with some unexpected areas of extreme water posed some significant challenges during construction.The Rosedale Waste Water Treatment Plant Outfall Tunnel project was commissioned in response to the growing needs of North Shore City, New Zealand. The outfall tunnel comprises a 3 km long segmentally lined tunnel and a 2.1 km buried marine pipeline, and discharges 2.7 km offshore. The capacity of the new outfall is 6 m3/s compared to the existing outfall capacity of 1 m3/s.Following previous project experience, and with the tunnel located along its full length in the bedrock weak sandstone/siltstone bedrock of the East Coast Bays Formation, tunnelling conditions were expected to be benign. However during construction six high inflow events were encountered, including a full face (3.4 m diameter) of Albany Conglomerate over a 48 m length of tunnel. This material comprised cobbles in an uncemented sand matrix, and inflows were recorded at over 25 L/s.This paper describes the design challenges on the project including the design of a steel fibre reinforced segmental lining for internal pressures. The specification of the machine is discussed including the modifications required to enhance the risk mitigation measures already in place. The ground conditions encountered are discussed and have improved the knowledge of the range of conditions that can be expected in Auckland.Despite the challenges presented during construction, excellent progress rates were achieved and the tunnelling was successfully completed ahead of program.

Mar 8, 2011

Designing for early access to deep orebodies is an essential driver for improved project payback. Vertical shaft sinking techniques have been developed to allow concurrent mine level excavation while continuing to sink. Project cash flows can also be improved when simultaneously deepening existing shafts beneath operating hoisting systems. Further economic advantage has been realised through creative sinking sequencing in twin ventilation/service shaft projects. A fourth technique to reduce project schedules involves partial shaft barrel equipping allowing unrestricted access to construct stations and continue with level installations. This approach reduces interference with barrel sinking activities to insignificant proportions. This paper reviews how these approaches have added significant value to actual shaft sinking projects, as assessed from a contractorÆs perspective, and discusses some of the practical issues to be addressed when planning future projects. Designers need to take cognisance throughout all project engineering phases of the adage that you are only sinking when cleaning the face. Cleaning can only be sustained when there is sufficient hoisting capacity.

Jan 1, 2005