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By J K. Claflin, S R. La Brooy, A M. Claflin

Rotary kilns have been in service in the gold industry to regenerate carbon for 65 years. At the time oxide ores with gold head grades of 8 to 10 g/t were being treated. Carbon could be regenerated adequately at 650°C and solution losses were less than 1%. Forty years ago, research indicated that heavily fouled carbon from flotation circuits had to be held at 750 to 850°C for ten to twenty minutes for full reactivation (Avraamides and La Brooy, 1987), gold head grades were typically 5 g/t and solution losses typically 0.02 ppm – still less than 1%. In 2017 it was determined (Claflin et al., 2017) that a residence time of less than 1 minute at 750°C can be adequate to reactivate carbon fouled with organics sufficiently to achieve 0.005 ppm solution losses in a flotation tailings leach plant.With the potential for discovery head grades to drop below 0.6 g/t, solution losses of 0.02 ppm represent over 3% loss. Tight operation of the whole carbon circuit is required to keep gold solution losses below 1% going forward.There are alternatives to a rotary carbon kiln, e.g. vertical kilns of which the Minfurn, Rintoul and Combustion Air kilns are examples. The alternative kilns can be heated using electrical heating elements, induction, and microwave. These kilns can operate successfully under the right conditions, however, they are almost exclusively for small carbon throughputs and are not suitable for the large carbon advance rates that are required to process low head grade ore deposits. Large throughput carbon kilns are are almost exclusively fossil fuel fired rotary kilns and the subject of this paper. In the view of the principal author, a fossil fuel fired vertical carbon kiln is preferred to a rotary kiln, however, it is not currently used in the industry.Thermal regeneration of activated carbon has a major impact on gold recovery in the carbon circuit. The carbon kiln and associated equipment constitute 3 to 5% of the capital cost for an oxide processing plant and up to 10% of the capital cost if flotation tails are leached. Despite the capital cost and impact on recovery, the carbon kiln is often poorly selected, operated and maintained.Six years ago Ausenco embarked on the Carbon Kiln Initiative to reduce solution gold losses. This body of knowledge has been published in a series of papers culminating in this paper on how to:1. Select a kiln appropriate for the flowsheet;2. Maintain the kiln to achieve design operation; and3. Operate the kiln to minimise costs and maximise reactivation.CITATION:Claflin, J K, La Brooy, S R and Claflin, A M, 2018. Carbon kiln selection, operation and maintenance, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 251–274 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

By P Toor

Due to the high energy consumption of milling, it is desirable to improve the efficiency of this process. One alternative to reduce energy and material consumption while optimising production yield in mill operation is through balanced design and selection of liners. Over-design of liners leads to increased life but at a cost to grinding performance, a relationship which to date has not been studied closely. This paper provides a description of this process of liner life cycle optimization and presents initial results from the first of two life cycles being studied for a 32 foot (ft) SAG mill. The use of commercially proven high resolution laser scanning based liner shape information provided by the MillMapper® software correlated with well controlled site surveys at various points in the liner life was used as the basis for comparison. The survey data was modelled in JKSimMet to provide direct comparisons of mill performance. This potentially provides a methodology for the design of liners that maintain a favourable shape for the majority of liner life, yielding desirable production parameters such as lower specific energy consumption and higher throughput, while at the same time maintaining practical liner life cycles.

Aug 8, 2011

Following the Moura No 2 Wardens Court of Inquiry and subsequent changes to the Queensland Mining Legislation there is a requirement in Queensland coal mines for: a person with the recognised competencies to be appointed at each underground coal mine to the position Ventilation Officer; and the person is directly responsible for the implementation of the mine ventilation system and for the establishment of effective standards of ventilation for the mine. The Regulations require that an underground mine must have principal hazard management plans that provide for at the least the following: emergency response, gas management, methane drainage, mine ventilation, spontaneous combustion, and strata control. Other than strata control all the plans require the ventilation officer to have roles and responsibilities to develop, control, monitor and undertake actions in relation to these plans.There are also another 34 Regulations that either directly or indirectly requires the Ventilation Officer to take actions.The purpose of this paper is to outline the information that the regulators look for in sealing plans and the actions the regulators will take if the sealing does not go to plan (TARPs being exceeded).

Jan 1, 2005

By R Stimpson, B Johnson, B Hesse

During a period of twelve months between FY18-19, a series of trials were conducted to compare production drilling accuracy using two different methodologies, and the subsequent impact this had on stope performance (dilution and recovery). Testing was conducted at a series of underground mines in Australia. The drill rig’s existing alignment processes were compared to a new technology system, with the following observations: • The new technology was proven to limit rig alignment error, thereby reducing average blasthole deviation, resulting in an increase in the number of holes drilled within tolerance by up to 160%. • The increased accuracy reduced stope dilution significantly by reducing over-break of subgrade ore, whilst also increasing drilled meters (faster stope-cycle time), reducing the bridged tonnes ratio, and facilitating the capture of previously uneconomical stopes. A cost-benefit analysis extrapolated from each of the trials showed the extent to which the new technology, when applied to production data, reduced average dilution, increased ore recovery as well as general drill and blast productivity. In one such trial, the new technology was proven to have reduced average dilution by net 45.4%, which if applied to a full year’s production data, would result in AUD8.2M additional ore recovered, with AUD4.5M less spent on wasted cost of haulage and processing of diluted ore. As a result, return per tonne would increase 22%, from AUD87 to AUD106. This improvement was maintained over the following 12 months – reducing average dilution from 22% in FY17 to 12.1% in FY19.

Mar 15, 2021

By J Salaya, J Kwak, L Keeney, S Dehkhoda

In addition to volatile commodity prices influencing decision making, in recent years, social and environmental performance have become important decision drivers within the mining industry. There are increased demands from stakeholders, communities, and governments to ensure that raw materials are mined, processed and refined responsibly. The industry also faces the challenge of better managing its waste, which has led to severe consequences when not done properly. The high commodity prices of the late 90s and early 2000s encouraged larger economies of scale and drove mining companies to extract large volumes of rock for separation and concentration at the downstream processes. Over time, as ore grades dropped, the cost of mining escalated and tailings volumes grew. This arduous process also caused strains on recovery cost and performance. Scarcity of water and energy resources coupled with increased production demands and higher operating costs are putting pressure on companies to find innovative ways to increase mining intensities. Hatch’s value chain optimisation methodologies, specifically Grade Engineering® and early waste rejection of the mine, have been of interest to intensify operational performance and minimise waste generation. Enabling preconcentration of the plant throughput, the methodology has significant potential to improve overall metal production and reduce water and energy intensities, whilst minimising wet tailings. Using representative data from real world mines, this paper reports on a case study that evaluates the impact of preconcentration using sensor-based ore sorting on downstream process improvements as well as energy, water and tailings reduction. Financial and economic viability of this technique is presented for both brownfield and greenfield implementation cases. The results show that business case for preconcentration is best when: the distribution of metal in the run of mine ore is negatively skewed and left tailed; mining costs are low; energy, water and tailings management costs are high; and low cost methods of recovering pay metal from low grade material are available.

Nov 10, 2020

By D J. Thobaven

Project financing challenges caused by declining commodity prices have heightened the need to improve project metrics such as minimising capital payback and maximising net present value (NPV). Khnaiguiyah Mining Company (KMC) recognised the need to improve early cash flows at their Khnaiguiyah zinc-copper project after initial studies showed the project could not provide the desired financial outcomes necessary to compete for investment dollars in the current market.A significant improvement to the project cash flow in early years was realised through simultaneous optimisation of cut-off grade, mining sequence and strategic stockpiling. This improvement was achieved by accelerating mining in the pits, stockpiling lower value material and feeding higher value material directly to the plant. The schedule required higher mining and stockpile capacities than the sequential mine plan although minimal change occurred in the definition of ore and waste as measured by tonnes and grade. The practicality of the strategic schedule was demonstrated by implementation in the production plan with excellent conformance.CITATION:Thobaven, D J, 2014. An application of simultaneous optimisation – improving the payback period of a zinc-copper open cut project, in Proceedings Orebody Modelling and Strategic Mine Planning Symposium 2014 , pp 137–144 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 24, 2014

Estimating Breakage of Fine Ore Particles by Media in a Small Ball Mill Using DEM

Sep 13, 2010

By V Shrotri L Muhmood, P Gandhre

The current work deals with the measurement of some thermophysical properties of Ca(NO3)2 based ternary nitrate molten salts as HTF (heat transfer fluid) / TES (Thermal Energy Storage) material for CSP (Concentrating solar power) plants. The density and viscosity of different compositions of the ternary salt mixture containing Ca(NO3)2, NaNO3 and KNO3 close to the liquidus has been experimentally measured. An attempt has also been made to measure the melting point of the salt using the cooling curve technique as well as Differential Scanning Calorimetry (DSC). Thermogravimetric analysis has also been performed to estimate the peak operating temperature of the salt. Compatibility of suitable pipe material (SS304) with molten salt has also been discussed. The salt mixture proves to be a viable alternative to the already existing HTFs like Therminol VP-1 (organic oil) or Solar Salt® in regards to its lower melting point, wider operating range, low cost, nontoxicity, sufficiently high density and comparable viscosity.

Jun 19, 2024

By M Badawi, Y Foucaud, C Veloso, J Laine, A C. Araujo

Iron is one of the most exchanged commodities worldwide. Its use for steelmaking explains the growing demand in the metal which remains mainly produced by the mining and the beneficiation of iron ores. Flotation is the most used mineral separation technique worldwide, processing several billion tonnes (Bt) of ore annually, including, in some cases, hematite and magnetite ores. Based on the physicalchemical properties of mineral surfaces, flotation aims to selectively adsorb molecules that render mineral surfaces either hydrophobic or hydrophilic, known as collectors and depressants, respectively. Hydrophobic particles are then recovered in the froth by the injection of gas bubbles travelling up in the cell and attaching the hydrophobic particles. However, despite the popularity and the good performances of flotation, mining industry faces new challenges of decreasing grades and increased mineralogical complexness in ores. Many flotation variables, especially when related to reagent adsorption, remain poorly understood and it becomes necessary to gain knowledge to enhance the existing processes. Molecular modelling techniques like the density functional theory or molecular dynamics simulations (ie Classical molecular dynamics or Ab initio Molecular Dynamics) currently represent powerful tools for different applications in material sciences, like catalysis or depollution purposes. They have recently been successfully applied in the flotation area, with an increasing number of publications dealing with this topic every year. These tools provide crucial information on bulk and surface properties as well as on the adsorption mechanisms of reagents on mineral surfaces, key step in the flotation process, and synergetic effect of collector mixtures. A better understanding of the adsorption mechanisms of flotation reagents, provided by molecular simulations, will help to finely choose flotation reagents, and even lead to the development of new reagents formulations. Overall, these tools enable the discovery of practical and industrial solutions to improve the flotation process, which will undoubtedly help the mining industry to face its future challenges.

Nov 8, 2021

The Energy Authority of NSW has wide powers and responsibilities conferred by its Act which are pertinent to the State's coal industry and its development into the next century. With respect to coal, the broad objective is to maximise the benefits to NSW and its people derived from the State's coal resources. The initial focus of the Authority's coal-related activities in the late 70's and early 80's was on petroleum substitutes from coal. Research was supported, especially on hydrogenation, and the Authority participated in the Joint Australia/Federal Republic of Germany coal-to-oil feasibility study. It also co-ordinated a State Government initiative to involve the private sector in examining the possible establishment of a synthetic fuels industry based on Hunter Valley coal. With a short-fall in world-wide petroleum supply now seen as less likely for some years, the Authority is looking also at ways of working towards the broad objective in the field of coal utilisation on both domestic and export markets. Areas of interest include possibilities for using washery rejects, means of making NSW coal more competitive as an energy source, use of coal-seam gas and new or special technologies for burning coal. The future is expected to see renewed interest in producing petroleum substitutes, and coal - as the State's major energy resource - is seen as a strong contender as a basis for such an industry. Developments in coal-based power generation are also expected to have an impact, with advanced technologies having a possible place here as well as Overseas.

Jan 1, 1987

L&M have been involved on the Shotover since 1980 when we joined Jack and Barney Ryan, who had started in 1972 with gold at $45 per ounce after a successful career as roading and demolition contractors in Christchurch. The first 85 tonne plant was a typical NZ trammel-riffle table plant with an armour plated hull for surviving Shotover floods, and was fed by a 53 tonne UH20 excavator. All this gear had to be carted in over the Skippers road on a small truck or sledge for the heavy loads. This operation was successful and generated the cash flow to sample the lower section of river and plan a second plant. To reduce fine gold losses this was planned to be a jig recovery plant and also included a vibrating screen which saved space and weight over a trammel. There are five flowlines of primary jigs and one secondary, followed by two Knudsen bowls for cleanup.

Jan 1, 1985

The global mining industry is perceived to be a world leader in sustainability reporting û with a 2008 Ernst & Young survey placing four mining companies in their top five performers in sustainability reporting in South Africa. There is certainly good evidence to support this finding, but there remain many ongoing issues with respect to sustainability reporting and some important areas for improvement by mining companies globally. This paper begins with a broad (but brief) review of sustainability and the technical basis for reporting against a wide range of typical indicators or measures on the environmental aspects of mining. The various protocols, frameworks or systems are then reviewed, with a particular focus on the Global Reporting Initiative (GRI) and its associated mining sector supplement (including the evolution from environmental to sustainability reporting). A wide-ranging survey of reporting by mining companies is presented, including detailed analysis of 2007 and some commodity sectors over time. Examples of reported data are synthesised and analysed, focusing on their accuracy, consistency and utility for accurate assessment of the life cycle impacts for minerals and metals. A number of areas are identified for improved reporting by all mining companies, including water resources and consumption, energy consumption, process inputs (eg acids, solvents, etc), pollutant emissions, including greenhouse emissions, mine site data (not aggregate company totals) and finally rehabilitation and land status. Given the nature of mining, and considering parallels between æpeak oilÆ and the mining sector, it is critical that the state of sustainability reporting continue to evolve and improve û both in the number of companies using the GRI but also in the level and consistency of data being reported. Overall, the paper presents an important review of the present state of the art in sustainability reporting for mining, and provides a range of insights into ways to help improve reporting in the future for all mining companies.

Jan 1, 2009

Central to any business is its Asset Management Plan which encapsulates the business context and key organisational objectives such as profitability, safety and environmental standards. Life Cycle Planning (LCP) is a key component of an overall Asset Management Plan. A comprehensive approach to Life Cycle Planning forecasts the financial expenditure required to support the performance of the asset over the business life. It incorporates capital, maintenance and operational expenditure along with an estimation of economic life. Within its body the LCP provides the detail of the maintenance plan and method of its execution. Once optimised the LCP becomes the overarching plan executed through the application of several elements of the Asset Management Plan to ensure the return on investment from the assets is optimal. Each of the elements of the LCP is bound by a set of loops that provide information based on the analysis of outcomes. These loops drive the continuous improvement of performance and cost over the life of the asset. In this way we ensure that the LCP is a dynamic plan responsive to the changing business environment. The paper being presented today will describe the process undertaken and the outcomes derived when this approach was applied to a $600 M+ coal handling and preparation plant in QueenslandÆs Bowen Basin. It will also delve into the difficulties encountered from both technical and cultural aspects; the latter proving to be the most difficult to manage. It will describe the hurdles and barriers that hampered progress including the human influences and the natural desire to revert to what has been done in the past when things became a bit difficult. In the end the results are there to show that the upfront expenditure and investment in time was time and money well spent and the outcome has the operation well placed to manage the assets in a manner designed to deliver the optimal business outcome.

Jan 1, 2007

By A Dal-Corobbo

Traditional acid and metalliferous drainage (AMD) wastewater treatment focuses on the iron co-precipitation/adsorption process as this is a very effective method of reducing heavy metals, including copper, lead, zinc, arsenic, etc, to parts per billion (ppb) levels in AMD wastewater streams. One of the drawbacks to this method however is the large volume of sludge produced and subsequent disposal costs for the mine site concerned.A proprietary metals treatment system called high density sludge (denoted HDS) which significantly reduces the quantity of waste generated is described in this paper. This process generates a dewatered sludge that contains in the order of 50 to 55 per cent solids. This sludge is denser than conventionally dewatered sludge, which typically contains only 20 to 30 per cent solids. This advanced process has a wide range of applications and can be easily retrofitted into existing AMD treatment systems. It has been successfully installed at several mine sites to treat AMD wastewaters. This paper discusses the high density sludge process, its benefits and provides data and operating results from pilot test installations.CITATION:Dal-Corobbo, A, 2013. High-density sludge process for treating metal bearing acid and metalliferous drainage wastewaters, in Proceedings Water in Mining 2013 , pp 217-220 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 26, 2013

By J M. Shekiro

In the chloride process to manufacture TiO2 pigment, feedstocks containing higher TiO2 contents (high-grade ores or HGOs) are favoured in order to minimise production of undesirable by-products. Most of today’s HGOs are produced through the smelting or reduction and leaching of ilmenite, processes which consume significant energy and/or produce large volumes of non-titanium materials that may have to be landfilled. In order to improve the economic and environmental sustainability of its TiO2 business, the DuPont Company, working with Kobe Steel Ltd, has developed an innovative process called TiRON for making HGO. Using a rotary hearth furnace, the process reduces ilmenite to a high TiO2 slag and metallic iron granules. The TiO2 slag is suitable for TiO2 pigment manufacture, and the iron is suitable for steel making. TiRON can process sand or rock ilmenite of varying compositions and particle sizes. Fossil fuel instead of electricity supplies the energy for the reduction. Dusts and off-spec materials are recycled. These process attributes, together with capital requirements estimated to be significantly lower, give TiRON substantial economic, environmental, and process flexibility advantages over conventional ilmenite upgrading processes. TiRON has been demonstrated at the semi-works scale, and preparations are being made to bring it to the pilot scale.

Oct 5, 2011

Grinding and Beneficiation Characteristics of a Low-Grade Haematite Ore

Sep 13, 2010

By N McKenzie, E Taylor, S V. L Barrett, H Lagger, A Purwodihardjo

This paper discusses the temporary support design methodology for the largest road caverns ever built in Australia—the Lutwyche Caverns—part of the Airport Link project in Brisbane, Australia. The Lutwyche Caverns with a maximum excavated span of 27 m form a key component of this major road project, allowing on and off ramps merging with the underground highway. In addition to the two large span caverns, a 15 m soft ground tunnel with 5 m cover above the caverns and two 24 m deep burial chambers for the 12.4 m tunnel boring machines (TBMs) had to be built in record time at Lutwyche.The temporary support design methodology involved the use of a range of analytical approaches, including empirical methods to provide a starting point for design development, key block models to determine the potential influence of discontinuities on excavation stability and 2/3D continuum and discontinuum models to determine the potential influence of adjacent excavations and the proposed construction staging on the design. In addition, probabilistic analysis of potential kinematic instability using a discrete fracture network (DFN) approach was also undertaken to establish the critical block loads for the temporary lining, while the continuum and discontinuum models were used to design the support for the 1.5 m diameter rock pillar at the north end of the northbound cavern.The numerical modelling was undertaken in close conjunction with the contractor to develop the optimal construction sequence, considering the available construction equipment on-site and the overall project program requirements. Part of the presentation will further show the applicability of the developed design during construction (deformations, monitoring field observations) and lessons learned for future cavern construction in Australia.CITATION:Lagger, H, Purwodihardjo, A, Barrett, S V L, McKenzie, N and Taylor, E, 2014. Temporary support design for the largest road caverns ever built in Australia – the Lutwyche Caverns, in Proceedings 15th Australasian Tunnelling Conference 2014 , pp 399–410 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 17, 2014

Within ten months of the first significant intersection on the Vera deposit, approval was given to proceed with a $28.3 M underground development of the Vera-Nancy gold mine. Contrary to what the timeframe suggests, the development of the underground mine was planned in a logical and methodical manner which enabled confirmation of the resource, evaluation of the orebody for mining and sufficient production to recommence milling operations at the Pajingo treatment plant. This paper describes the underlying factors on which the project was planned and developed. The approach has successfully enabled the mine to be in production 18 months after discovery without compromising any future production or potential expansion

Jan 1, 1998

By W J. Cowie

Several years of operating experience of over 100 gold recovery operations on the West Coast has provided a database from which the basic operating costs of these types of operations can be characterised. Using figures generated from the averaging of plant operating costs throughout the region and financial modelling using Lotus spreadsheets has been developed to analyse both existing and proposed developments. This type of modelling has several uses: 1. Identification of the impact on profitability of changes in management practices, finance costs, operating costs and revenue streams. 2. Project evaluation and planning. 3. Profitability projections for development financing. 4. Troubleshooting with existing operations. 5. Valuation of existing operations and properties.

Jan 1, 1987

By Y Durkheim, P Saunier, L Ameglio

"In the last decade Afitex developed the Draintube™ geocomposite, which provides simultaneous drainage and waterproofing functions. This new type of drain tubes planar geocomposites (DTPG) differs from other geocomposites as the drainage core is composed of multiple corrugated and perforated pipes instead of biaxial or triaxial nets. It is furthermore associated with needle-punch stitched layers of non-woven geotextiles, which act either as capillary mediums or as filters.In this paper, the structure of the Draintube™ drainage composite is presented along with its key properties and the drainage mechanism associated with its particular structure.The relevance of this kind of structure is then reviewed based on past and current laboratory bench evaluations and field installations for mining applications such as the covering of acid rock drainage (ARD) tailings for the Central Manitoba Mine (Canada) site-rehabilitation; and as a pregnant solution collection layer in heap leach pads.Some of the demonstrated critical advantages of Draintube™ in the mining industry are as follows: reduction of the thickness, hence lower volume of granular drain layers improvement of fluid and gas collection and reduction of the hydraulic load reduction of secondary collector network mechanical protection of the sealing membrane fast and economical installation of interlifts stability under extreme conditions (compression, temperature, pH) increased stability of entire covering system and reinforcement of protection of dykes filtration of the covered material customised drainage positive connection of the geocomposite to collector pipes enable leaks detection (using a conductive textile layer) with an electrical test.CITATION:Saunier, P, Ameglio, L and Durkheim, Y, 2015. Tubular drainage and lining geocomposite for mine tailings and heap leach pads, in Proceedings Tailings and Mine Waste Management for the 21st Century, pp 297–304 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Jul 27, 2015