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The 115-year history of the Hall-Heroult process for production of aluminium has been characterised by a sustained technology-driven improvement in costs and productivity. In the past decade the industry has effectively transferred best practice into older technology with improvements through computer control of the process, and redesign of cell linings using computer modelling . Incremental development is now at the point where diminishing returns will apply for further technical improvement effort however, until the gap between technical limits and current best practice is addressed through major process redesign. The process remains a long way short of its technical limits in energy consumption, carbon anode consumption, cell life and product purity. Investment cost in new capacity is very high, supporting the retention of older and less efficient technology and hence limiting the application of best practice in environmental performance and occupational health exposure. The industry is a major emitter of greenhouse gases yet the process has the potential to release oxygen as the primary waste. All of the above issues will be addressed in the new century, but only through commitment to the necessary long-term research and development that is required to achieve a redesign of the process.

Jan 1, 2000

By S. Jayson Ripke, Shane Hoff

Cleveland-Cliffs’ Northshore Mining Company operates a magnetic iron ore (taconite) concentrator and pelletizer in Silver Bay, MN. These are two recent cost reduction projects: 1. Rougher Magnetic Separators were upgraded throughout the concentrator; throughput and recovery were simultaneously improved. 2. Green Ball Roll Screens on one agglomeration circuit were upgraded from 3.5-inch to 2.5-inch rolls. Throughput improved by 24% from 62 to 77 LTPH. Green ball size distribution improved as an added benefit.

Jan 1, 2005

When we are beset with the economic problems the world faces today, we are always inclined to look at the shorter term future. Today I would like to take a long-term view of our industry, project historical demands for our products into the future and discuss opportunities for our members. Perhaps we could firstly look at the long-term demand trends for our metals. If I tend to use non ferrous metals as a basis for my figures it is because this data is more readily available to me. I am sure that most other products of our industry show similar trends.

Jan 1, 1992

The underground mining of a narrow vein hard rock orebody is a capital and labour intensive method of extraction. Due to the nature of underground mining it is difficult for higher level managers to physically see the efficiencies and inefficiencies of a particular method. Extraction methods and sequencing often need to be altered from the original planned methods as a result of mine developent, providing more in depth information as it progresses. As a result of these issues contract mining of these orebodies is common practice. There are several types of contract structures for the purpose of underground contract mining with many complex permutations of them that reflect the different needs of each individual company and orebody. The different contracts are arranged dependent on the mining companyÆs desire to transfer or, alternatively, embrace risk. This presentation gives a brief overview on these different methods and their various advantages and limitations with regard to small scale and narrow vein underground mining. With respect to these different contracting methods, the presenter reviews the mutual growth benefits of emerging partnering opportunities, specifically with regard to smaller explorers exploring and developing prospective mining tenements. The specific advantages to small explorers include the resource flexibility and speed of project development that private mining contractors can provide. Given the contracting methods that are available, there is potential for small private mining companies to gain minor stakes in major projects and major stakes in medium sized projects by employing innovative contracting solutions to provide mutual benefits to the parties. Some potential scenarios to this effect are suggested in the presentation. This paper is available as a PowerPoint presentation only.

Jan 1, 2006

Thank you for this opportunity to address your conference on 'The role of coal in the New Zealand energy market'. New Zealand's energy market has, in common with much of New Zealand, undergone major change following the market reforms of the Labour Government. As far as the energy sector is concerned this change has been for the better, as it has created for the first time in a very long time a 'true economic market' for energy in New Zealand. This is in marked contrast to the previous regime where: ò Electricity was state operated, subsidised and cross subsidised. ò Oil was imported and subject to a raft of taxes and duties. ò Coal produced by state mines was priced by cabinet committee, based on other energy prices rather than on the costs of production and delivery of the energy product. Today, with the establishment of the SOE's we have a market of competitive supply, where the customer has the choice of energy with prices based on the true costs of production and delivery. This can only be good for the customer as the cost is now based on the real costs of production, not on political whim. So where does coal fit in this brave new world of free market energy supplies? Well, opportunity, they say, knocks but once.

Jan 1, 1990

Thank you for this opportunity to address your conference on The role of coal in the New Zealand energy market".New Zealand's energy market has, in common with much of New Zealand, undergone major change following the market reforms of the Labour Government.As far as the energy sector is concerned this change has been for the better, as it has created for the first time in a very long time a "true economic market" for energy in New Zealand.

Jan 1, 1990

The placer gold industry has experienced a roller-coaster history incorporating four major boom eras. The first, 'hand-methods' boom arose in the mid-19th Century from application of an old idea in new places around the globe. The subsequent hydraulic mining, bucket dredging, and 'hydraulic excavator-portable plant' booms each arose from application of new ideas in old places around the globe, ie in places where gold had been found during earlier booms. The new ideas that heralded the second, third and fourth booms were all significant advances in excavation technology. These enabled the industry to target the known deposits that were too deep, too wet, too small, or too low-grade for recovery by earlier boom methods. Relatively few new deposits or new deposit styles arose from the 'history book' exploration approach, so the number of known deposits to which each of the boom methods were applicable was limited. Consequently, the first three booms were each followed by significant periods of industry decline, and the fourth boom is currently waning inNew Zealand. Further decline is not inevitable and can be avoided by changing to a knowledge-based exploration approach similar to that adopted by the hard rock gold industry in the 1970s. Such an approach could easily herald the next placer gold boom.   Most of the relatively coarse, easily won alluvial gold in proximal and medial reaches of the active placer systems is gone. However, a substantial alluvial gold resource remains in the distal reaches of active systems, and in ancient placers formed onshore and on the continental shelf during previous sedimentary cycles. The resource in these deposits probably exceeds the total New Zealand placer production to date. Successful development of these placers requires application of robust geologic models for the formation and distribution of the placers through time, and advanced exploration technology that has not been used before in New Zealand. Nevertheless, the knowledge and technology required to explore and mine these deposits is available now. Many of these deposits contain a large proportion of problematic gold types that are difficult to recover with the commonly used gravity technology without sustaining significant losses. Despite advances in recovery technology in last few years, too much emphasis is placed on the incorrect assumption that gold size is the primary control on recovery efficiency. Other gold particle parameters, especially particle shape, exert a much greater control on whether gold will be saved or lost to the tails, and must be considered in the design of recovery technology and configuration of recovery circuits.

Jan 1, 2003

An optical computing system was used to determine spacings and frequencies in geological fabrics and engineering joint fabrics.Three-dimensional arrays of joints were plotted on an equal-area net. Directions in which true spacings are seen were determined from these plots. Photographs taken along these directions were used for optical computing.

Jan 1, 1970

Industrial and telecommunications organizations around the world are now turning to optical fibres to satisfy their growing needs for data, voice and video communications and to solve transmission problems in noisy and hazardous environments. Already, coaxial cables have been made obsolete for intermediate and long distance applications and fibres are making in-roads on other copper cable and microwave system techniques.The idea of optical fibres is not new, but techniques to manufacture the high quality cable and components required have only recently been developed. Nonetheless, the technology is now advanced, reliable and mature, and costs are plummeting with increased production and market competition.The mining industry has benefited greatly from developments in electronics and communications over the years. Optical fibres are to have a further significant impact and the time is now right for the industry to begin to exploit the many advantages of this new medium. Applications include data transmission, long distance telecommunications, measurement and control systems, surveillance, computer networks, etc.This paper briefly describes the characteristics of optical fibres, current status of the technology, applications and possibilities for future development.

Jan 1, 1984

By S Hapugoda, A Poliakov, E Donskoi, L Lu

A significant amount of metallic iron in the world is produced in blast furnaces from iron ore pellets. To control the quality of pellets and to optimise pellet production, characterisation of both green and fired pellets is required. Optical image analysis (OIA) allows identification of different minerals, binder, remaining fluxes and porosity within pellets.For proper identification of the mineralogy, porosity and texture in pellets a high magnification is required, therefore each individual image covers only a very small portion of the pellet. At the same time the characterisation of pellets requires that the whole pellet is represented as a single object, so the size of the resulting overall image at high magnification can make it difficult to handle. A solution to this problem has been implemented within the CSIRO OIA package Mineral4 by combining images at different levels. Namely, to average out local irregularities, individual frames can be stitched during imaging into larger MosaiX images. Mineral4 further combines these MosaiX images into a single panorama image of the whole pellet.The proposed procedures allow the calculation of mineral and porosity spatial distributions, local gradients and abundance graphs based on the distance from the centre of the pellet. The ‘Pellets’ module of CSIRO OIA software also allows for characterisation of large irregularly shaped particles of lump ore and sinter.CITATION:Poliakov, A, Donskoi, E, Hapugoda, S and Lu, L, 2017. Optical image analysis of iron ore pellets and lumps using CSIRO software Mineral/Recognition, in Proceedings Iron Ore 2017, pp 583–592 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 24, 2017

By J. T. McCartney

OPTICAL PROPERTIES of U.S. coals of differing rank have been investigated by the Bureau of Mines, for about 20 years. These investigations have been remade to further the development of an objective basis for petrographic analysis of coal and to add to knowledge of the structure and composition of coal and coal components by determining their optical constants in various regions of the electromagnetic spectrum. Various experimental techniques have been used in these studies, including determination of reflectance from bulk specimens and transmittance of thin and ultrathin sections, interferometry, electron microscopy, and election diffraction. Similar studies leave also been made of graphite, the end product of coal metamorphism. The bureau of Mines conducted the first U.S. investigation of reflectance properties of coal components, laying the foundation for petrographic analysis based on arbitrary reflectance classes and for automated reflectance analysis of coals. Optical constants of coals of differing rank and of graphite have been determined in the ultraviolet-visible-near infrared spectrum. Maxima in the optical constants of graphite were observed in the ultraviolet region and were interpreted to be related to transitions of electrons between the valence and conduction bands. Similar maxima for coals, especially high-rank coals, appeared to be characteristic of the presence of graphitelike layers. A special application of optical theory to absorbing, anisotropic materials like graphite and high-rank coals has been developed. Electron microscopic and electron diffraction studies of coals have revealed various ultrafine structures in coal components and have shown the evolution of an oriented, crystalline graphite structure in high-rank coals.

Jan 1, 1967

By Willy Persson

A common feature of the kinds and amounts of impurities present most pyrometallurgical, processes is injection of oxygen to, remove various in the feed. The degree of success of a specific process step relies critically on control of the instantaneous oxygen potential/oxidation stage, throughout the step as well as upon termination of the step. This will, for instance, determine the distribution of impurities between metal and slag. As long as the operation is perturbation free -detailed analysis of all additions and application of advanced models often yield satisfactory control means However, a pyrometallurgical process is seldom free from disturbances, which reduces the accuracy of the static models and leads to inconsistencies in scheduled route might be uncontrollable changes in quality and quantity of feed, operator interventions and shift changes, timing of cranes, lining wear and accretions etc. The implementation of dynamic, control to correct for disturbances and, more generally for process optimization, requires continuous on-line information on, the actual status of the process. The implementation of sensors for continuous process monitoring, e.g., as regards the instantaneously prevailing oxygen potential or oxidation stage, has been hampered by the highly aggressive environment in smelters; This is. where remote-sensing techniques based on optics and spectroscopy, have proven to form invaluable, tools towards the realization of dynamic production control. Since about 15 years Semtch has developed and industrialized a remote-sensing technology, based on ,optics and spectroscopy, for continuous on-line process monitoring and production control of various pyrometallurgical processes. The presentation will discuss applicability aspects with examples and experiences from installations and tests in ferrous and non-ferrous industry. Keywords: Applied spectroscopy, Metallurgy, Process monitoring, Production. Control

Jan 1, 2003

By Bhattacherjee A, Makesh S

Mechanised sub-level stoping is one of the most widely accepted stoping practices followed in base metal mines in India. As a general practice, blast-scheduling of rings in these stopes is done either heuristically or randomly which leads to a high fluctuation in ore grade when drawn and delivered to the mill. In this paper, dynamic programming has been investigated as an optimisation technique for optimal blast-scheduling of rings. A microcomputer based dynamic programming algorithm has been developed in C language which runs under the UNIX environment. A case study based on Indian mine data is presented to demonstrate the application of the dynamic programming concept and use of the developed software. It is concluded that dynamic programming can be used as a production planning tool in Indian mines practicing sub-level stoping and following heuristic/random approaches for blast-scheduling of rings.

Jan 1, 1995

A comparison is made between elementary block estimation techniques and the optimal methods of geostatistics using data from an Australian deposit. Considerable improvement in the estimates are obtained by using the optimal technique in this case.

Jan 1, 1975

By Jeremy Bosman, Johan de Korte

Traditionally the feed to coal preparation plants was de-slimed at 0,5 mm. The +0,5 mm size fraction was processed via dense-medium cyclones and the -0,5 mm size fraction was beneficiated with froth flotation, water-only cyclones or spirals. With the introduction of large diameter cyclones, the aperture sizes of de-sliming screens have progressively increased to about 3 mm in the belief that the larger cyclones are not able to effectively beneficiate coal which has a particle size below the ?breakaway? size. The efficiency of separation in the large dense-medium cyclones is improved by presenting a coarser feed to the units. At the same time, the capacity of the de-sliming screens is increased due to the larger screen apertures and in effect, the throughput capacity of the dense-medium section is increased. The 3 x 0,5 mm size fraction, which was previously processed in the dense-medium cyclones, is now added to the fine coal size fraction and processed by water-only methods such as Teetered Bed Separators (TBS) and spirals. Whether this practice is the most economical way to process the 3 x 0,5 mm size fraction requires further thought since the best processing route for the 3 x 0,5 mm size fraction will depend on a number of factors, amongst which are: o The washability of the coal and the amount of near-density material o Processing efficiency o Specification of the required product o The price paid by the customer for the product o The cost of processing the coal Breakaway size The ?breakaway? size is defined as the particle size below which the Epm of the smaller particles starts to decrease significantly. Bosman1 provides an approximate breakaway size versus cyclone diameter (Figure 1). It should be kept in mind though that the Epm of the small particles is a function not only of the cyclone diameter but also of feed pressure, medium density, medium viscosity, particle shape and density, top-size of particles in the feed, etc.

Jan 1, 2006

By Y. Idrogo

Electronic delay detonators have been used in most types of blasting application with great success, with the accuracy and precision being used effectively to control negative environmental impacts like vibration. They have also provided consistent repeatable fragmentation and heave results. With the very wide choice in delay period and powerful timing design software, the choice of firing times to optimise blast results is not always clear to the designer. So the improved results achievable from the use of electronic delay detonators are often not optimally achieved.

Jan 1, 2018

By M. E. Gershon

Conventional methods of drill hole site selection are reviewed briefly. Two approaches using geostatistics are then discussed, both of which have been shown to yield improved results. Finally, a branch and bound algorithm is described which will select the best locations for drilling from a user specified number of possible drill sites. Two options are discussed. First, the user can specify a maximum drilling investment or a maximum number of drill holes and the program will select the locations yielding the minimum estimation variance. This amounts to getting the most for a given investment. Alternatively, a maximum tolerable estimation variance can be specified and the program will select the number and location of the drill holes to obtain the desired information at a minimum cost. Another benefit of the approach is the quantification of the tradeoffs between investment and information obtained.

Jan 1, 1985

By B Belle

In a predrained gassy coalmine, ventilation control plays a secondary role to the longwall (LW) goaf drainage systems to safely manage panel return gas levels. Typically, the LW specific gas emission (SGE) estimation models provide anticipated goaf gas emissions and arriving at required gas drainage capacity for various coal production scenarios. A study comparing the various LW goaf gas hole spacing patterns with weekly production rates of up to 270 kt/w of an operating mine with high SGE rates (~20 m3/t) was carried out. The goaf capture efficiency of LW panels ranged from 64 per cent to 85 per cent. For the first time, gas content of upper seam data post LW retreat were used to verify the current SGE prediction models. This study has shown that an average of 50 m goaf spacing is optimal for management of high production retreat gassy LW panels in presence of multiple upper and lower seams with gas emission zone influence reaching up to 200 m above workings. Due to the horizontal stress direction related geotechnical issues, goaf hole failures just behind the LW face is a recurring challenge resulting in significant and immediate increase in LW panel return gas levels. This paper highlights the shortcomings of current SGE prediction models for goaf gas estimation, and evolution of 50 m goaf hole spacing embedded in design process in managing the LW tailgate gas levels.CITATION:Belle, B, 2017. Optimal goaf hole spacing in high production gassy Australian longwall mines – operational experiences, in Proceedings Australian Mine Vent Conference 2017, pp 15–26 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 28, 2017

An important problem in mine operations is the classification of material as waste, low-grade stockpile, and ore. This classification must often be made with blasthole data that are widely spaced and that have sampling errors. Geo-statistical simulation techniques combined with basic economic principles allows a procedure for classification that maximizes expected profit. Geostatistical simulation methods (Gaussian, indicator, or annealing-based) allow the integration of hard and soft data in the creation of alternative, equally-probable, realizations of the mineral grade(s). At each location, for each realization, we calculate the "profit" if the block were to be classified as ore or waste The optimal classification is the one that maximizes expected profit (a Maximum Profit Se-lection (MPS) procedure). We discuss the theoretical justification of the method and implementation details. The use of blasthole data from different types of mineral deposits, that is, different levels of continuity, is considered. We also show the efficacy of the procedure with different levels of sampling error. The increased revenue due to the MPS procedure and improved sampling is shown. We show the geostatistical simulation procedure and the uncertainty in block grades that result from incomplete and imperfect sampling. The optimal classification is presented. Optimal block classifications are transferred to realizable dig-limits by hand-drawing polygonal boundaries. We compare the results of the proposed method to classification based on kriging. Limitations and areas of future work are identified.

Jan 1, 1999

The authors summarise the development and recent advances in the reconstruction and visualisation of three-dimensional objects from point data and describe applications to the reconstruction of orebody shapes from drill-hole and other data. In particular, Dijkstra's algorithm is proposed and implemented as a means of optimal reconstruction of complex orebody and topographical shapes from irregularly located sample data. The surfaces of the shapes are constructed from triangular tiles and the algorithms proposed by the authors are guaranteed to find the optimal set of tiles that "best" construct the surfaces on the basis of specified objective criteria. The algorithms are illustrated by applications to a complex silver/gold/zinc/lead deposit.

Jan 1, 2002