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By R Crookes

Mine to mill optimisation is not a recently developed concept. It is one which is finally gaining greater acceptance in the Australian mining industry, possibly as a consequence of the downturn in markets and certainly made possible by the development of tools and techniques to measure and predict performance of mining equipment and milling plants. Fragment size after blasting has a major bearing on the performance of all aspects of mining and a major influence on the economics of the mine and mill. The process to optimise fragmentation consists of identifying the key factors, measuring their sensitivity through a modelling and trialing program and conducting economic evaluations on the changes on both the mine and mill. Management of the Ernest Henry copper-gold mine in Northern Queensland, Australia, has espoused the mine-to-mill concept and is actively pursuing excellence in blasting to drive down the total cost of mining. Ernest Henry has extremely hard, wet and heavily jointed geological conditions, and had high powder factors and a large percentage of oversize material reporting to the crusher or ROM stockpile. A blasting improvement program was undertaken between Ernest Henry Mining, Thiess Contractors and Orica Explosives to optimise the ore size distribution, particularly the oversize component, as a step to reducing production costs. Measures of success included bringing the rock breaker back from double shifts to part-time operation and increasing direct dumping into the crusher from 70 per cent to 92 per cent. Tools and technologies to predict and measure the performance of individual blasts are needed before it is possible to optimise fragmentation or the downstream processes. These include such specialised Orica Explosives tools as SABREX, POWERSIEVE, and POWERLINE and commercially available drill monitors. As important are the more common still and video camera, borehole loggers, measuring tapes, surveying equipment such as face profilers, and a high speed camera if possible. There are many tools which can be applied however it is rarely necessary or possible to use all of them due to time constraints and a point of diminishing returns. The critical point is knowing what the true parameters of the blast were compared to design -only then can the predictive tools be effectively utilised. Stage one of the program has seen gradual improvement as the understanding grew and practices have been implemented resulting in reduced bridging in the crusher, geological mapping with respective blast designs and the oversize component under control. This paper is about a process approach which links tools and technology to understand the fragmentation drivers and then to optimising the size distribution. The continuous improvement program continues . . .

Jan 1, 1999

By Kavetsky A

A new model of flotation is presented which allows predictive calculations of total solids flows and metal grades and recoveries to be made for industrial flowsheets. A method of making these calculations is presented and illustrated with examples. The problem of determining sufficient flotability characteristics from a sample of circuit feed to predict the behaviour of that specific ground ore in the flotation circuit (ie performing flotometric analysis) is addressed, and some suggestions are made for its solution. A feature of the flotation model is its practical technological orientation, allowing determination of a small number of ore flotability parameters by fitting observed batch kinetic flotation data. The unit model explicitly includes the cell aeration as total bubble area per unit pulp volume, and pulp residence time. Although more complex unit models are feasible, it is thought that this model is sufficiently realistic to illustrate the points made. The modelling approach is illustrated by application to flotation data from a Kambalda ickel circuit. The model is parameterised and ore flotability parameters are back-calculated from batch kinetic data. These parameters are then used to fit the observed behaviour of the industrial circuit by numerically adjusting the unit aerations. Finally, it is shown how the model may be used to predict the effect of circuit and ore changes on the circuit's technological indices.

Jan 1, 1992

By G J. Butler

Since 2005 BHP Billiton Iron Ore has been working with the consulting company Runge to implement the software XPAC Advanced Destination Scheduler (ADS) in life-of-mine studies. The Mt Whaleback mine, being the single biggest open cut iron ore mine in the world, presents some special challenges in scheduling. The biggest challenge has been the slow run time and difficulty in targeting all ore and waste requirements. The high waste to ore strip ratio means that much of the cost of mining is tied up in waste dumping. It is therefore very important to schedule waste efficiently. At Mt Whaleback there is an additional challenge of managing two types of waste: inert and environmentally sensitive pyritic material. This paper shows how the XPAC destination scheduler is configured to achieve efficient and repeatable waste scheduling results at the Mt Whaleback mine. It also discusses proposed improvements to the process. The overall ore and waste schedule is configured to target mining parameters, crusher feed and grades. The schedule is run in two stages. The first stage is ore mining. The waste that needs to be mined is locked in a sequence. The second stage is the waste scheduling. The waste destination scheduler uses three inputs: source waste parcels locked in a sequence, a haul road and a waste dump block model. The process involves setting some rules for dump progression and haul path selection. These can be validated. The schedule is then run to target the shortest travel time. The results of scheduling are graphical and numeric and can be transferred into many different formats for reporting. The graphical result shows face positions in time that can be used for detailed dump design. The numeric results are used to estimate truck fleet size, fuel consumption, labour and equipment financials. The process has been successful in reducing the project time line, increasing the ability to do more scenarios and increasing schedule accuracy, transferability and repeatability.

Jan 1, 2007

The proximity of the Town of Kalgoorlie to the Mount Charlotte mine necessitates that charge weight per delay be limited in order to keep surface vibration levels within acceptable limits and to reduce damage to underground workings. The mining system requires that large mass blasts must be used to recover pillars and therefore a large number of separate delays are needed. Until recently all blasting has been done electrically, fired from mains, but with the introduction of large diameter blastholes (165mm diameter) this firing system was inadequate. Various firing systems were considered, but after extensive trials a non-electric sequential firing system was chosen. This system fulfilled all criteria of blast design, was relatively straight forward in charging technique and had a very simple primary initiation system. Although initially designed for large mass blasts, the non-electric firing system is now used for all large hole blasting and in a simpler form for small (57mn diameter) holes.

Jan 1, 1982

By Schofield N. A

The cross-sectional method of stope grade estimation at Cobar Mines has consistently had several shoneomings, me most imponant of which being mat stope grade is significantly overestimated in the high grade lenses.The use of mree-dimensional ore lens modelling improved the grade estimation and ore waste definition but significant overestimation still occurred in me high grade stopes, particularly those wim extremely variable grade distribution. The implementation of an indicalor kriging based method for mapping of me high grade copper mineralization has significantly improved the quality of copper grade estimates and provides a mineralisation geometry similar to that generated manually by me mine geologists. This paper presents the results of a test case study in the application of indicator kriging to the mapping of the copper grade in two stopes in the QTS North mineralisation. The results are encouraging in that they prov ide coofi rmation of the geometrical model developed by the geologists and much improved estimates of the grades of me stopes whencompared to me grade reponed from mining these stopes.

Jan 1, 1993

By Paley N, Cameron A, Townson P

Although blasthole deviation is a problem which can seriously affect blasting operations, there is little practical emphasis on controlling this deviation and no practical emphasis on understanding its practical behaviour. The most common way of dealing with it involves tight control over drill set up and surveying hole paths. The surveying might involve simple collar location and inclination measurement to estimate the hole's actual path. At best, some operations routinely survey hole paths after all holes in a stope have been drilled. In addition, although there is an expectation that holes will deviate, there is no planning for this behaviour in order to reduce its impact on the blast. Design decisions are invariably made with the assumption that holes are straight. If and when surveys reveal problems it is possible only to adjust charging and initiation to 'work around them'. In extreme cases the drill might be recalled to fill in gaps. The lack of planning and the lack of understanding are doubtlessly linked.A model is presented that will predict the expected path of a drill hole. By knowing how a selected few holes deviated it is possible to make a good estimate of the deviation of other holes in the same rock mass. After minimal calibration the model can be used to increase the amount of information for a given amount of surveying or the amount of surveying can be reduced while maintaining the same level of knowledge of blasthole deviation. Equally important is the ability to plan for the deviation in future drilling through altering the initial collar angles or drilling from different locations. It is the authors' hope that planning for hole deviation becomes as much a part of the design process as planning for detonator delay scatter and explosive performance variation.

Jan 1, 1992

By Haines P. W, Sweet I. P, Rawlings D. J, Page R. W, Plumb K. A

Current regional geoscientific studies across the McArthur Basin as part of the National Geoscience Mapping Accord by the Northern Territory Geological Survey and Australian Geological Survey Organisation have provided a significant amount of new data which has enabled revision of the stratigraphic and chronologic framework of the basin. This paper provides an overview of these results, with particular emphasis on new results from Arnhem Land.

Jan 1, 1994

High interest to basic-ultrabasic rocks is ex-plained by their specific, sutural, geotectonic po-sition and by deep level of generation of ultraba-sic magmas. These two factors allow us to treat this group of rocks as valuable source of informa-tion about the lower crust and upper mantle of the Earth. Basic-ultrabasic xenolith series is another source of information about the interior of the Earth. Detailed studies of the xenolith series give valuable material to geologists as to how endogenic deposits are fed and what is their source.Besides, the interest is explained by attempts to understand the relationship between basic-ultra-basic complexes and deposits of metalliferous and non-metalliferous mineral material.Absence of genetic boundaries in manifestation of metalliferous and non-metalliferous minerals, their temporal and spatial relationship allow us to treat the minerogenesis of ultrabasic complexes as a result of one ore-forming process manifested in Koryak-Kamchatsky, Sakhalin-Japanese, Ryukyu-Korean and Taiwan-Philippines island arc systems which re-present, in the opinion of the authors, one eastern Asian chain of the Pacific ore belt (Radkevich, 11)87).

Jan 1, 1990

Inefficient conveyors suffer carryback, leading to the build-up of materials on idlers, and other expensive components. They spill and leak material at loading zones and transfer points, causing accumulations that can damage the belt, wear moving components, and increase both cleanup labor and maintenance expense. They wander or mistrack, spilling material and en- dangering personnel and conveyor components, including the belt itself. And through these inefficiencies, they multiply an operation's hidden costs-the dollars lost because of missed production, of increased downtime, of the expense for the replacement of prematurely worn or damaged equipment. In this paper, the author will examine the importance of belt conveyors to mines and process plants He will trace the state-of-the-art in systems for cleaning belts, and controlling the release of fugitive material from conveyor transfer points, by exploring the roots of the problems, and demonstrating solutions that have been proven to be effective. Included in these systems to improve material handling are transfer point stabilization and sealing systems, dual belt cleaning systems, and belt training idlers.

Jan 1, 1991

By Kupper T

Firstly, electric analog models are discus- sed to show fluid streaming conditions. In these models the depth of blast at tuyere level, the height of the bath, the influ- ence of different angles of the furnace zones and the different possibilities of the root of the cohesive zone have been changed. Tests to define the influence at a large blast furnace are given. Secondly, the wear of carbon bricks in the hearth is examined under the influence of gas, slag and pig iron. Oxidation tests in a special scanning microscope with the pos- sibility of heating and gas treatment are shown. Wear mechanisms are discussed fora large blast furnace and proposals for im- provement are given. Finally, the possib- ilities and value of the temperature meas- urement in the hearth block are discussed.

Jan 1, 1981

By Mules GJ

Geotechnical investigations have played a key role in influencing decisions for development of the Porgera Gold Project in the highlands of Papua New Guinea. Porgera is located 130 km west-northwest of Mt. Hagen in steep mountainous terrain with high rainfall. Much of the site is underlain by weak mudstone of the Chim Formation and creeping colluvial soils. Landsliding is common on the steeper slopes and in the valley floors. Structures have had to be sited to avoid areas susceptible to these movements. Early stage feasibility investigations included studies of tailings dam and waste rock dump sites, processing plant sites and hydroelectriic schemes. Further studies, leading into the design stage included the Enga Highway upgrading, water supply and power supply schemes. As construction for the project proceeds geotechnical input remains at a high level, with emphasis now on maintaining viable stable sites and refining data on which designs were based.

Jan 1, 1990

By D J Rawlings

The Palaeo- to Mesoproterozoic McArthur Basin contains a thick (-10 km) intracratonic platform cover sequence of unmetamorphosed and relatively undeformed sedimentary and volcanic rocks (Pietsch et al, 1991). It covers an area exceeding 180 000 km2 of the North Australian Craton (Figure 1), overlying segments of the older deformed basement and transitional igneous units. Volcanism in the basin (including transitional domain) followed a four-phase pattern. These phases are geologically distinct and widely distributed, and are also recognised beyond the McArthur Basin in many similar-aged tectonic provinces in northern Australia. The four phases are described briefly below. Regional and structural nomenclature used refers to Figure 1. A stratigraphic correlation diagram is presented in Figure 2.

Jan 1, 1994

By A J. MacDonald, M P. Raffield

The South Deep massive orebody consists of 20 to 30 m of payable conglomerates ranging in dip from 11¦ to 20¦ and at depths of between 2400 m and 3400 m. The mine design process selected a mining method with a proven record of application that could be adapted to overcome the inherent difficulties associated with the depth, thickness and structural influences of the South Deep orebody. A modified cut and fill mining method provides a concentrated and highly flexible method of extraction. An integrated destressing cut will enable the modification of the stress environment such that it is suitable for massive mining operations. The choice of backfill type and stoping width in the destressing cut ultimately determines the characteristics of the stress modification and, as such, is critical to the success of the cut and fill operation. This paper discusses the decision process undertaken to determine the optimum backfill type and stoping width combination in terms of, conditions in the destressing cut faces and in the massive mining environment. Numerical modelling has been extensively used to analyse various scenarios to aid in the decision process.

Jan 1, 1998

By Zervoudis J

Limitations of current touch-up solders for galvanised steel include coating thickness control problems and poor corrosion and abrasion resistance as well as health and environmental concerns due to toxic constituents such as lead. This paper reports on progress in ILZRO-sponsored research to develop an improved touch-up solder. Encouraging results were achieved in torch soldering trials with experimental zinc-tin-based alloys. Mouldability and coating thickness control were achieved over a practical working temperature range in which the solders consisted of a viscous mixture of solid primary zinc phase particles in a liquid zinc-tin eutectic matrix. The mouldability was dependent on the microstructure of the solder sticks, and optimum structures could be obtained through control of casting solidification rates and by the addition of small amounts of copper. Hardness, abrasion resistance, adhesion and corrosion tests on experimental Zn- (40 - 50 per cent) Sn-I per cent Cu also showed improved performance over lead-tin-zinc solders and compared the effects of tin content within this range. Atmospheric corrosion testing and optimisation of alloy composition and methods of solder stick production are continuing.

Jan 1, 1993

A number of suggestions have been made to improve the design of cells used for electro winning and electro refining of metals. Most of these designs have been aimed at increasing the current density used in order to improve cell capacity, although the purpose of some has been to produce electro deposited metals in a continuous manner. Improvements in the electrolyte flow pattern in conventional cells have resulted in an increase in the rate of mass transport of metal ions to the electrode surface; giving rise to lower concentrat- ion polarization and an improvement in the nature of the product obtained, Other cell designs are based on a moving electrode, usually a rotating disk, and these may include provision for removal of the product in a continuous manner, The maximum current density which can be used in an electro- lytic deposition process is determined by the limiting diffusion current, the physical nature of the, product, the purity of the product required and by the increase in power costs which result from the higher cell voltages, This paper examines the properties of an agitated bed of particles as an electrode system when used for a metal deposition Process,

Jan 1, 1969

By W J. Rankin

A study of refined metallic copper and nickel production was carried out using Life Cycle Assessment methodology to estimate the life cycle emissions of greenhouse and acid rain gases for these metals using data derived from the literature. Various processing routes were investigated which included a pyrometallurgical and a hydrometallurgical route for each metal. The effect of a number of process variables, namely ore grade, fuel type for electricity generation and efficiency of generation were also examined in the study. The results of the study, expressed in terms of total (or full cycle) energy consumption, Global Warming Potential (GWP) and Acidification Potential (AP), showed that the hydrometallurgical processes involving solvent extraction and electrowinning had higher energy consumptions and GWPs than the pyrometallurgical processes for both metals. Nickel metal production was shown to be several-fold more energy intensive than copper metal production. The significant effect that falling ore grades have on attempts to meet greenhouse emission targets was also highlighted in the study.

Jan 1, 2000

By S Lowjun, I Verster, C A. Thomas, E Forbes, K Runge, G V. Franks

Fine (<20 µm) valuable mineral particles are difficult to recover in conventional flotation circuits. (Trahar and Warren, 1976; Jameson, Nguyen and Ata, 2007; Kohmuench et al, 2018). This leads to a loss of valuable fine mineral particles to tailings. Recovering these particles would be of economic benefit. Novel reagents, including temperature responsive polymers, for example, are being developed to improve recovery of fine valuable mineral particles by froth flotation (Ng et al, 2018a, 2018b). The approach involves selectively aggregating the valuable fine particles and making these aggregates hydrophobic, resulting in hydrophobic aggregates of appropriate size (in order of 100 microns) being amenable to recovery by froth flotation. The polymers developed have been produced at laboratory scale but not a full scale yet. The exact cost of producing such novel polymers is currently unknown, but they are likely to be more expensive than conventional reagents.

Aug 24, 2022

BHP is the world&apos;s largest copper concentrate producer with production from mines at Escondida (Chile), Ok Tedi (Papua New Guinea), and Island Copper (Canada). The entire concentrate production is further processed into refined copper by third-party smelters around the world. In anticipation of an expansion in the global copper concentrate production capacity and a corresponding increase in treatment and refining charges by copper smelters, BHP has continuously evaluated various opportunities for downstream copper processing. An expansion in the Escondida mine production, combined with BHP&apos;s interest in processing some of its concentrate production on-shore in Chile, ultimately resulted in the development of the Escondida Leach Process. This process was specifically developed for higher grade concentrates, such as from Escondida. An ammoniacal lixiviant and air are used under ambient conditions to leach less than one-half of the contained copper values. After solid-liquid separation, the solution is subjected to solvent extraction regenerating the ammoniacal lixiviant and the copper loaded organic phase is stripped in spent electrolyte returned from the electrowinning plant where ultra-high quality SX-EW copper is produced. The solid leach residue can, if required, be upgraded by flotation to produce a high-grade copper concentrate with improved fuel values and a pyrite tail for disposal. After an 18-month bench and pilot plant scale program and an engineering feasibility study, Minera Escondida Limitada decided to build an 80 000 tonnes of copper per year facility near Antofagasta, Chile. The installed investment cost amounted to around $160 million. The plant went into commercial production in November 1994 and better than 99.9995 per cent Cu cathodes were produced right from the start. BHP believes that the process and the commercial plant are an excellent example of a novel approach advancing the science of copper metallurgy in harmony with present demands for environmentally sound processes and high quality products.

Jan 1, 1995

An image analysis system has been built which automatically digitizes camera input of rock fragments, analyses the digitised data to determine the sizes and shapes of the rock fragments, and outputs the analysed data to a printer in the form of a histogram or a scatter chart. The high speed of such a system allows for direct collection of data from material thrown into the air by blasting, material travelling on a conveyor belt, and material free-falling on to a stock-pile or into or out of a rock-crusher. Data on the blasted, un-crushed material provides information on changes in the lithology and structure of the rock face as it is quarried or mined: flatter fragments may represent approach to a brittle, unstable shear zone, or a change from sandstone to shale; so that the informa- tion reflects the effect on the sizes and shapes of the fragments by the blasting process and/or by the rock structure. The size and shape distributions of rock fragments produced during blasting and during processing may now be continuously monitored. Such detailed analysis of the results of fragmentation is labour-intensive and expensive when the size and shape distributions are obtained manually, but is cheap and efficient when using this image analysis system. Such a system will enable the results of blasting, quarrying, mining and crushing to be cheaply analysed and correlated with current and changing indus- trial practice so leading the way to increased productivity.

Jan 1, 1988

By Moore A. J

Control of blast vibration requires that its nature and causes be understood, and that effective control procedures be implemented to ensure compliance with limits related to the probability of damage to buildings/structures and human discomfort. This paper covers measurement equipment, assessment and prediction techniques, blast vibration control procedures and applicable statutory limits. It reviews current practice, and provides information on recent developments in blast vibration measurement equipment and control techniques, using examples based on Hunter Valley mining practice.

Jan 1, 1995