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By M J. Kelleher

CREAM is an acronym for coal recovery, evaluation, analysis and management and is a business improvement project at BMAÆs Goonyella Riverside mine that is focussed on maximising coal recovered. In August 2003, Goonyella Riverside was set a challenge to quantify coal loss and dilution and their relationship to cost, revenue and ultimately profit. While the mine was confident in its site forecasts of recovery (and loss), it was clear that the traditional measurement and analysis systems were inadequate to firstly, identify key loss areas and mechanisms and secondly, successfully quantify the benefit of various coal recovery initiatives. The path that BMA Goonyella Riverside has travelled to maximise coal recovered can be divided into four key steps: Mapping the process û This step involved the development of a coal flow process map for Goonyella Riverside that stepped through each component of the process from the coal reserve to the customer and identified key measurement points for the purposes of reconciliation. Understanding coal loss and identifying opportunities û This step involved conducting two detailed Reserve to Customer projects at the mine site to track a block of coal from the reserve to the customer and to gain a greater understanding of the relationship of dilution, coal loss mechanisms, revenue and costs associated with recovering additional coal. Coal data systems development û Two important coal data systems have been developed and implemented at Goonyella Riverside in the past twelve months, namely SnowdenÆs Coal Reconcilor and SeamFix. These systems enable coal losses and dilution to be quantified and reconciled back to the initial coal reserve. Implementation of loss reduction initiatives û This step involved the formation of a business improvement project referred to as æCREAMÆ in August 2004, for the purposes of improving pit coal recovery and maximising business value. To date a series of coal recovery trials have been run in a number of pits at Goonyella Riverside that have yielded significant improvements in business value. The key to the success of this project has been the discipline to follow a defined process map, management commitment through resourcing and shared key performance indicators, a successful acceptance strategy resulting in holistic ownership and the implementation of sustainable reconciliation systems. Coal loss and dilution are now quantifiable and their relationship to cost, revenue and ultimately profit is well understood. This paper discusses the process that Goonyella Riverside has adopted to maximise coal recovered.

Jan 1, 2005

Proposals designed to use stockpiles and buffer stocks to achieve price stabilization and better resource use have a long history. They are super- ficially simple to understand. The benefits seem clear. And yet I am well aware that this is not a simple subject: the more one studies it, the more complex it becomes. Worldwide interest in re- source management, while receiving fresh impetus from the OPEC actions, also has a long and chequered history. Those venturing into such ter- ritories must be forewarned of the traps and pit- falls which abound. Interest in these schemes has waxed and waned over the years with the fluctuating fortunes of the producers or consumers. As I write this paper towards the end of 1977, I am acutely aware of the low ruling prices for zinc, copper, and nickel. These sacrifice prices remind me that it is difficult, for example, for a surveyor, to be calm and rational if he is up to his neck in a swamp full of crocodiles. He might be forgiven for forgetting that the aim was to drain the swamp! I am also aware that when swamps are drained, painful and dangerous stumps sometimes stick out. Hence, in looking at the subject of stockpiles and resource management we must not set our sights too high, perhaps not initially hope for perfec- tion, if we want to secure worthwhile changes. My approach is to acknowledge a bias for the market system. We have, however, had experience (remember the 1930s) of some weaknesses in the untrammelled operation of free markets. Thus our international economic relationships over the past 20 or 30 years have been based on a desire to retain as much as possible of a liberal world trading system backed by such organizations as the GATT, IMF, and the U.N. to ensure the necessary cooperation. Some nations have seen this system work only partially in their best in- terests. GATT, for example, has been reasonably effective in liberalizing trade in many manufac- tured goods but far less so in regard to agricultural or semi-processed goods.

Jan 1, 1978

This is the seventh major symposium organised by Illawarra Branch over the past five years and the fifth dealing with various aspects of coal. It is clear that all of you here need no convincing that black is beautiful! This symposium is on a broader canvas, covering the overall field of occurrence, preparation and utilization of black coal throughout Australia. It is thus the most comprehensive treatment of the subject by the Institute since the symposium organized in 1950 by the Sydney Branch with the co-operation of the then newly formed branches in Newcastle, Illawarra, Central Western N.S.W. and Southern Queensland, all of which shared coal as a major interest. The 1950 symposium was adopted as a volume in the series of seven published by the Fifth Empire Mining and Metallurgical Congress in 1953. This historical reminiscence brings to our minds the circumstances in which these new Institute branches were formed. This happened in the year of the presidency of the late Frank Hockey, and at the time the Australian black coal industry was in many ways at a very low ebb. It was the time of extreme shortage of coal following World War II, and the industry was beset by industrial unrest on such a scale that daily bulletins were posted listing the number of idle pits, of idle miners and of tons of lost production. There could not, of course, be any thought of export marketing. Some of the more picturesque bulletins recorded the number of pits at which the ceremonial emptying of billies took place, and the number of pits at which the aroma of the horses' breath was insupportable. At an Institute conference at the time it is on record that the late lamented Austin Edwards, that tireless mineral researcher, author and editor, in his gentle way chided the personnel of the industry and the members of the Institute for having allowed a situation to develop in which a whole generation of Australian children could grow up without ever having seen coal or knowing what it was. It is sad that most children and most Australians have still never seen coal, and think of it as something dirty and uninteresting. The desperate situation of the black coal industry inspired moves by people in industry and in governments, whose plans and efforts have been recorded elsewhere, to modernize coal mining methods, to introduce coal preparation, and generally to restore the mines and the mining communities and to re-cast the steel industry and electricity generation. Amelioration of the traditionally troubled industrial relations was an integral part of this overall programme, and whilst one would wish this aspect had progressed further the situation has, in fact, improved immensely. New investment in exploration, mining, preparation, transport and utilization both by the existing coal mining groups and by new entrants, Australian and overseas, have played a large part in bringing about the transformation of the industry to such a point that Australian needs are being fully met and a large export market is being supplied - a situation that few would have dared to hope for in those dark post-war days. Forecasts of exports from New South Wales and Queensland show coal becoming a dominant foreign exchange earner for an indefinite term. Old King Cole may have vanished from our children's nursery rhymes but King Coal is here to stay, providingthat costs in the industry can be kept within competitive limits. It is all too easy for an industry to price itself out of the export market by inflation, by increased costs for a variety of reasons, and through currency readjustments. A second proviso is that we must continue to encourage a balanced attitude to environmental matters.

Jan 1, 1975

By W A. Ducker, R-H Yoon, M Mao

Froth flotation relies on an attractive force between a particle and a bubble to selectively extract particles from a mixture. The range and magnitude of this attractive force is an area of ongoing investigation. We describe measurements of the effect of dissolved gases on the long-range attractive surface forces between a silica plate and a glass sphere in aqueous octadecyltrimethylammonium chloride (C18TACl) solutions. The measurements follow on the work of Sakamoto et al (2002) who have concluded that long-range interactions occur in air-equilibrated surfactant solutions but not in degassed solutions. In the present work, we have measured attractive forces that have a much larger in magnitude than the expected van der Waals force in solutions that were degassed by the same procedure used by Sakamoto et al (2002). We find that the forces are most attractive at 5 + 10-6 M C18TACl, which is close to the charge compensation point (ccp) of the glass sphere. At this concentration, the attractive force decays exponentially with distance and the decay length is 34 in air-saturated solution, and 38 nm in degassed solutions. In both air-equilibrated and degassed solution, the force is quite sensitive to the concentration of surfactant. The force is also sensitive to the pH. We note that our degassing procedure increases the pH of the solution from about 5.7 to 6.6 (presumably by removal of dissolved CO2). We find that the forces measured in degassed solution can be reproduced by using a solution that was equilibrated in air, then the pH was increased by addition of NaOH. Therefore, we conclude that the main effect of degassing in our experiments is to raise the pH. We show that the range and magnitude of the attractive force decreases in the presence of salt (NaCl). This suggests an electrostatic mechanism for the attraction. Possible mechanisms for the attractive force are examined, including the mechanisms that rely on a patchy coverage of surfactant on the silica surface.

Jan 1, 2005

By P R. G Milne

A risk-based approach to optimising pit wall slope angles was trialled in the design of a 60m deep open pit in extremely weathered and distinctly weathered materials in the Kalgoorlie area. The pit used for this approach was Stage 1 of a three-stage open pit project. The Stage 3 pit will require long term stability, as it will contain the portal for a long life underground project. Information from failures induced by steeper wall angles used in the Stage 1 pit would be valuable in predicting and preventing long-term stability issues in Stage 3. In this approach, the pit wall slopes are based not on the normal factors of safety, but on the assessment of the probability of failure and the direct and indirect costs of dealing with the failure when it occurs. In this example, the benefits and risks of adopting steeper wall angles were compared in a series of graphs. These charted the increasing probability of failure and simultaneous decreasing factors of safety with increasing pit wall slope, and the range in the possible volumes of circular failures for increasing wall angles. These were brought together in a graph showing the potential excavation savings (in BCM) and the probable cost of a failure (probability of failure times the probable volume of the failure). The resulting pit design was based on the project Mining EngineerÆs semi-quantitative assessment of where and when a higher risk of failure was acceptable and where it was not acceptable as it may have unduly affected the integrity of haul roads or production. The design incorporated wider than normal berm widths to accommodate anticipated failures and to enable modification of the wall configuration if required. Several re-designs were required during the life of the project in response to aggressively induced failures. It is considered that this risk-based approach provides a practical route to optimal pit design and operation but it requires an experienced, dedicated and efficient mining team for it to be implemented with benefit.

Jan 1, 2003

By Elber L, Whiten WJ, Cunningham KD, King GL, Bailey CW, Clay PA

The Savage River Mines concentrator treats magnetite ore at about 300 tonne/h, and produces feed for a pelletising plant. The plant incorporates two parallel grinding lines, each consisting of an autogenous mill, in closed circuit with a screen, a rougher mag- netic separator, a ball mill in closed circuit with parallel cyclones, and a finisher magnetic separator. Significant fluctuations in ore grade and grindability make it difficult to maintain pro- duct size in the narrow range desired, and to achieve maximum possible throughput at the same time, using the present largely manual control system. The present paper describes the develop- ment of a control system based on a mini- computer. It has been possible to implement a scheme of on-line estimation of product size which is sufficiently accurate for use in an automatic control system. The size estimation is essentially derived in terms of plant variables which control the ball mill cyclone cut size. Three control functions have so far been implemented and tested. These are control of the feed rate to the autogenous mill, control of water addition to the autogenous mill, and control of the ball mill sump level.

Jan 1, 1978

The use of the heavy media cyclone (HMC) Separation process for the treatment of ores in a particular size range is comparatively new to Australia. The paper describes briefly the principles of HMC operation. Reference is made to early development work, the pilot plant trials and the acceptance of the technique as a mineral dressing process. The Mitchell Cotts pilot plant at Amdel is described briefly and the results of test work on this unit for the processing of a wide variety of ores and ore types are given. Comments are made on the ob- jectives aimed at in the investigation and results are discussed with particular reference to behaviourial differences between ore types. The process is easy to operate, possesses a high capacity-to-unit-size rating and is capable of a high degree of flexibility. Further developments such as specially prepared and graded media for specific applications, automatic media density control and regulation of media consistency by the use of surface ac- tive agents and polymers have increased versa- tility and sensitivity of control to the point where products differing by as little as 0.02 of a specific gravity unit can now be separated with ease.

Jan 1, 1973

On the face of it this is an easily answered question. Modern technology and life as we know it today would be impossible without industrial minerals and the responsible utilisation of mineral resources is essential for the economic wellbeing of the nation. The quarrying industry supplies a high percentage of the industrial minerals used in New Zealand and our role therefore, is to ensure a constant supply of high quality roading and concrete aggregates so that society and the community as a whole can develop. We must do this in a manner which causes the least possible disruption to members of the community, which efficiently utilises all the valuable resources, which causes as little pollution as possible and last but by no means least, creates realistic profit for the operator. It is only by achieving a reasonable profit that we are able to continue in business and therefore play our part in the development of the country. Unfortunately, quarries have a poor image and are not generally popular, as on the whole, they are noisy, dirty and dusty and attract large trucks which create traffic problems. Judging by the amount of restrictive legislation with which we have to comply today, not even government or the local authorities want quarries which presents the industry with some serious problems, some of which will be outlined in this paper.

Jan 1, 1978

The Closure Risk model was developed as a new tool to aid decision makers in the complex area of mine closure. It uses a simple analytical technique that allows the decision maker to simplify what is often a complex mine closure process into more easily managed sub components. This systematic approach ensures that critical factors in the closure process are not overlooked. It also allows the most important issues to be highlighted. The model can also be used to produce quantitative estimates of risk by weighting and prioritising the issues to produce the Closure Risk Factor (CRF). Field trials at several mine sites in the Northern Territory of Australia in 2001 tested the model. The trials confirmed that the model has significant potential as a tool for decision-makers to assess in a structured, systematic manner, the major closure risks at individual mine sites. The risks include not only environmental impacts but safety and health, community, legal, financial, technical and other issues. The trials confirmed the value of a team-based approach and the inputs of key staff including environmental, production, mine planning, and community liaison personnel as well as mine management. Although the usefulness of the qualitative component of the model was established, it was found that, due to the influence of subjectivity, the utility of the prototype model to determine quantitative risk was of limited value. Using a continuous improvement approach, improvements to the model were sought. A refined model, incorporating the Australian Standard 4360 definition of risk and facilitated in-house risk assessment sessions was developed and tested against the data obtained in the field trial. This model, while maintaining the qualitative strengths of the original, allows more accurate absolute and relative quantitative scores to be calculated. This in turn facilitates comparisons between the issues at a single site as well as between different mines.

Jan 1, 2003

By U Rehm

The biggest hard rock double-shield tunnel boring machine (TBM) in the world, with a diameter of 12.4 m, is currently excavating the North-South Bypass, which includes a crossing under the Brisbane River, Brisbane, Australia, to relieve the often congested road traffic in the city centre. Ten years ago a 10.7 m Mixshield giant helped to handle the Olympic Games in Sydney linking the airport with the city centre for an improved transportation of fascinated visitors. In Shanghai, currently the biggest TBM in the world with 15.43 m diameter presents excellent performance rates; and in Paris a convertible Mixshield could be quickly changed from earth pressure balanced (EPB) to slurry type in order to handle the very heterogeneous ground conditions. In Madrid a 15.2 m EPB giant finished its tunnel job four months ahead of schedule. Large-scale TBMs have proved their economic and innovative potential to create the current and future underground architecture of mega-cities. TBM technology has made further large innovative steps in the last decade. State-of-the-art is a TBM for very heterogeneous ground conditions comprising hard and soft rock with additional high groundwater pressure. The machine concept is adapted to the various ground conditions and allows for a quick and flexible application. Ground treatment by means of additives developed to a helpful tool in this connection. To meet the special challenges of urban tunnel projects of nowadays it is of very high importance, beside applying highest developed technology of TBM, to have a comprehensive technical support during the project phase and to develop positive relationships between all participants of the project which last longer than only for one project.

Jan 1, 2008

By McDonald E, Clifford PJ

A mine planning system comprises all elements necessary to carry out the full range of mine planning activities from exploration to operations control. The application of computers as part of a mine planning system has great potential for increasing the efficiency and quality of mine planning and reducing its cost. The introduction of computers to mine planning in open cut coal mines has been hindered by the cost of processing the large databases associated with large coal deposits and the inherent inconvenience of performing an interactive process on a time-shared computer. A dedicated computer is ideally suited for the purpose but reasonably priced micro/ mini-computers until recently have not had the capacity to store the volume of data or the processing capability required. Recent hardware developments have cleared the way for the development of truly interactive mine planning software, covering the complete range of activities associated with open cut coal mine planning, incorporating them into a single system using a common database. The MINEMAP System is a hardware and software package tailored specifically for mine planning of open cut coal mines and is an example of such a system.

Jan 1, 1983

Performance driver trees or KPI trees are reasonably well-known tools for analysing performance in mining operations. However, the tools are often not user friendly. They may be technically correct but they are often clunky. This means they donÆt promote simple management decision-making and donÆt encourage businesses to make them an integrated part of optimising their operations. This paper describes a simple but effective driver tree process and tool that has been successfully implemented and used to aid decision making across a number of mining and processing operations. The important aspects of employing driver trees to assist in management of operations are to ensure that the chosen solution:includes a reporting solution, provides the bottom line impact of the performance indicators, automatically gathers the necessary data that reconciles with existing reports, and is built around a review process that fits with existing management processes. An adequate solution enables operators to identify where there are performance gaps and to quickly prioritise the urgency for addressing these issues. Two case studies are chosen to illustrate the critical success factors of implementing a performance driver tree solution. The first is a large, complex open pit operation. The driver trees, reporting and management processes were initially established for the mining and processing aspects of the operations. Once the initial solution was bedded down, a follow-up project was carried out to establish the equivalent solution for the support areas of the business. The final solution covered stand alone performance driver trees for mining, processing, engineering, maintenance, health and safety, human resources and finance. These individual driver trees were integrated into a total solution that showed how all of the identified KPIÆs impact profit and quantified the dollar impact of all variations. The reporting solution that was put in place automatically creates prioritised lists of variances for the business to address. The second case study is a performance diagnostic project where driver trees were used to assess where gaps in performance were occurring, and then to evaluate the impacts of proposed initiatives.

Jan 1, 2007

By Turco E, Pelizza S, Castellani F, Stanganelli V

Excavation are in progress for the building of tunnels of the waterworks in West Campania (Naples). The works afferent to part II envisage tunnelling through a miocenic clay formation over consolidated by two tunnels whose sections are respectively 50 and 10m2. Tunnel blasting is carried out by mechanical means. An excavator is used in the big tunnel, whereas in the small tunnel a roadheader machine is used for a short tract and a mechanized shield is used over a long stretch. The tunnel feature complex problems regarding stability. This is particularly so for the big tunnel whose face appears unstable. For this reason the clay on the face is sistematically bolted by means of 3-metre and 12-metre bolts. This prevent the use of a TBM for tunnel Excavation.

Jan 1, 1987

For several years, the Geology Department of the University of Canterbury has hosted a series of postgraduate projects in the field of coal studies, supported principally by the Ministry of Energy and to a lesser extent by private companies. These projects have involved mainly West Coast Coalfields, and my own studies have focussed on inorganic geochemical aspects of West Coast coals. Because of the large number of potentially important analyte elements in coal, and the wide diversity of coals occurring in the West Coast region, this project has required a substantial amount of work to be spent on sample collection, sample preparation, development of analytical methods, and actual analysis. Considerable problems must be faced at the sampling stage: Can sufficient information be obtained from whole-seam composites, or should seams be sampled in plies. Ply analysis is preferable, but results of proximate analyses are usually available for composites only. Where multi-seam drillhole samples become available (eg Greymouth Coalfield, where some holes yielded more than six sampled seams), the ply option involves a dramatic increase in the number of samples. I have attempted to strike a workable compromise between geographical coverage of coalfields, and detailed sampling of individual seams at each locality. In many cases, sample material has been used jointly with Jane Newman who has carried out petrographic studies.

Jan 1, 1985

By Okura T, Hino J

Coal utilization for copper flash smelting in Japan was initiated due to the sudden upheaval in the price of oil in the last ten years. A major portion of the heavy fuel oil has already been replaced by coal resulting in a corresponding decrease in energy costs. In addition to energy cost savings, an interesting metallurgical phenomenon was observed in flash smelting operations. Unlike oil combustion, coal is not burned completely in the shaft. A considerable fraction of coal particles remain on the surface of slag and are burned at the settler. Chemical investigation has shown that oxygen potentials at the settler have consequently decreased, bringing the slag and matte phases into reducing conditions, thus oxidation and reduction can coexist in one flash smelting unit. As a result, a decrease in magnetite and copper contents in the slag, elimination of furnace hearth build-up and dissolution of intermediate layer between matte and slag have been observed. In general, these led to improvements of furnace operations. However, thermodynamic investigations have shown that some minor elements such as As, Sb, Bi and Pb concentrate from slag to matte. Results evaluated on the basis of thermodynamic data relatively agree with practical observa- tions. Consequently, for coal utilization in flash smelting operations it will be necessary to control oxygen potentials from the stand- points of copper loss in slag and minor element Distributions.

Jan 1, 1987

Consideration was given to the.applicab on of a solvent extraction circuit to be'included in the process'for the-recovery of a high grade product from.:-the Rum Jungle Creek.South uranium ore body.The economics of two alternative processes, firstly the Eluex process which uses an ion exchange process followed by solvent extraction.-of a.high grade sulphuric acid eluate, and secondly a process using direct solvent' extractioh of pregnant leach liquor, were studied. There was a small cost advantage favouring the Eluex process but when other factors were considered, the installation of a direct solvent extraction process appeared the better long term investment. A solvent extraction plant was installed at Rum Jungle in 1962.

Jan 1, 1963

Tyre cost at Mount Morgan Limited had been 24% of the truck operating cost. Comprehensive tyre testing resulted in a reduction in tyre costs of about one third. A record of the evaluation techniques may enable the selection of tyres that are most suited to particular conditions. Rubber characteristics, rubber quantity, tyre design, road conditions, dump conditions and inflation pressure were found to be sig- nificant variables. Measurements of tyre temperatures at the breaker strip were used to select the tyre design and inflation pressure required for Mount Morgan Limited's conditions. Relugging of tyres was discontinued as a result of tyre testing.

Jan 1, 1974

The application of new and currently practised mining techniques in new areas and at greater depths necessitates considerable and immediate research effort. This effort is aimed at identifying the factors which make a particular method suitable and economically viable in a given geological, structural and operational environment. These factors, together with greatly enhanced knowledge of a deposit at the exploration and planning stage, allow selection of the most appropriate and efficient mining method in a new area such that coal resource recovery is maximised in a cost effective manner. Current research and future requirements for research into mining methods and associated equipment and mine services are reviewed.

Jan 1, 1981

Synthetic and commercial activated carbons are characterised for several chemical and physical properties. A range of techniques is used to establish correlations between physicochemical parameters and gold- adsorption activities. The most important parameter in the carbon activation process for a product with a high gold-adsorption activity is the activation temperature. High activation temperatures yield products with large micropore volumes which provides sites that are ideal in size for adsorption. The surface area of an activated carbon is not necessarily a good measure of its adsorption activity. Surface oxygen-containing functional groups are identified by Fourier transform infrared spectrophotometry to be comprised mainly of ethers and hydroxyls. These functional groups line the edges of the micropores imparting a polar character to the pore and aid in the solvation of the adsorbate. Oxidants such as nitric acid result in a proliferation of surface carboxyl groups. resulting in a negatively- charged surface that is not conducive to the adsorption of gold.

Jan 1, 1993

An efficient filtration plant can be designed only from an adequate knowledge of the filtration characteristics of the material to be handled; if these characteristics can be expressed in the form of an equation the work of design is simplified immensely. The literature of the subject contains numerous equations which have been developed by various workers to express their results, usually obtained from a 'Very limited class of material, and from moderately thick pulps. Such expressions have been found quite unsuited for use in the case of thin, very free filtering pulps.In 1926, Underwood put forward an equation having a general for m, and which, he was able to show, provided a satisfactory expression of the data obtained and published by a large number of earlier workers. This equation has been found a very satisfactory and useful tool for the study of a variety of filtration problems. As thel basis of the equation is of assistance to the understanding of subsequent discussion, a brief account of Underwood's derivation is given here.UNDERWOOD's FILTRATION FORMULAEThe following symbols are used:

Jan 1, 1932