Search Documents

By C T. Dunbar, P A. Walker, G E. LeJuge

A programme of blast improvement was initiated at the Mt Whaleback iron ore mine by BHPIO management in early-1998. One component of that work was the need to improve wall control blasting practices to better achieve the designed pit slope elements. This paper describes the geological conditions in which pit walls are developed, the mine operating equipment, the blast design concepts applied to minimise blast damage, the techniques applied in an assessment of the blast performance and the operational procedures developed to ensure that the blast concepts are effectively implemented in the production environment. Substantial changes have been implemented in both technical and operational aspects of the mining operation in order to achieve the improvements in pit wall condition, in particular recognising the need for a more flexible approach to limits blasting in response to highly variable and complex geology. The benefits to the mine are not only an improved wall condition, but increased confidence on the part of mine management that mine plans may be implemented on design and on schedule.

Jan 1, 2001

By N Gupta, R Trivedi, S Bhandari

Managing blasting operations in four mines surrounded by villages is a challenging task. This study aims to compare the blast-induced flyrock as observed in opencast mines by predicting flyrock distance using a soft computing approach known as an adaptive neuro-fuzzy inference system (ANFIS) and Flyrock Predictor software based on empirical studies. Blast design and geotechnical variables such as linear charge concentration, burden, stemming length, specific charge, unconfined compressive strength and rock quality designation were selected as independent variables, while flyrock distance was used as a dependent variable. Out of 120 blasts, data from 100 blasts was used to train and test the ANFIS model. Flyrock distance for the remaining 20 blasts was used to evaluate the model. Flyrock distance has also been predicted using Flyrock Predictor software based on an empirical approach using the same data sets as those used for ANFIS. Performance indices like root mean square error (RMSE), mean absolute error and coefficient of determination (R2) were evaluated to compare the reliability of ANFIS and Flyrock Predictor quantitatively. ANFIS was found to be a better predictive tool, with 1.75 m RMSE and 0.966 R2 compared to Flyrock Predictor, which returned RMSE and R2 values of 2.48 m and 0.932 respectively.CITATION:Trivedi, R, Singh, T N, Gupta, N and Bhandari, S, 2015. Soft computing approach to predict blast-induced flyrock, in Proceedings 11th International Symposium on Rock Fragmentation by Blasting, pp 455–462 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 24, 2015

Large deposits present computational challenges to todayÆs commercial orebody modelling systems that are based on conventional block models. We describe a system that is specifically engineered to model and visualise large deposits. Central to the system is linear octree encoding of conventional block models and real-time conversion of three-dimensional (3D) meshes to linear octrees. We provide both methodological treatment and practical experience in implementing such a system. A commercial implementation is also presented to demonstrate the validity of the approach.

Sep 26, 2011

The complexities of mining in current economic conditions, where ore extraction schedules are varied on a weekly basis so as to ensure constant supply to the process plant, can result in a number of scenarios that pose geotechnical challenges. This paper presents a case study where alterations in the mining schedule of a particular mine resulted in the necessity to mine under a large uncompacted embankment, ie integrated tailings and mine waste land form. To effectively ensure that ore recovery was maximised, a well-designed slope monitoring system to evaluate design performance and to provide timely warning of impending failures was imperative. In order for an appropriate slope monitoring strategy to be developed, a thorough understanding of the potential slope failure mechanisms, capabilities and limitations of available monitoring techniques is required. Communication of the monitoring results and response strategy to alarms generated by monitoring systems must also be carefully considered to maximise effectiveness. The results of preliminary stability modelling can be used to guide the design of a monitoring system, which in turn can then generate data which can be used to iteratively refine the geotechnical model. This paper illustrates the development and implementation of a slope monitoring system and associated communication system, using the Daydream embankment at Fortescue Metals Group's (FMG's) Cloudbreak Operations as a case study.

May 1, 2010

By D J. Logan, J Jackson

"As of 1 December 2014, the 2012 edition of the JORC Code requires Ore Reserves to be defined by studies at the pre-feasibility or feasibility level. This paper examines how the pathway for most mining developments is determined in the Pre-Feasibility Study and how a trade-off must be made between the need to make the best decision, the constraints of limited time and resources, and the level of the project’s accuracy and uncertainty in terms of value. Issues considered include framing the scope of the study, planning for robust decision-making and ensuring effective communication between the diverse disciplines within the team.An inherent conflict exists between the immediate value added to a mining business from an increase in ore reserves resulting from a ‘quick’ Pre-Feasibility Study and the long-term value of pursuing a development strategy based on proper investigation and evaluation of the options. Recognition and resolution of this conflict is necessary if a project is to progress into future development stages, both in a timely manner and with the optimal development alternative and strategy.The challenge for project developers and those conducting the Pre-Feasibility Study is to understand what the key deliverables are (ie an Ore Reserve statement, option selection, business evaluation, forward work plan or risks) and how to follow good practice to ensure that these deliver value.CITATION:Logan, D J and Jackson, J, 2016. The pre-feasibility study – big choices, little time, in Proceedings Project Evaluation 2016, pp 122–132 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Mar 8, 2016

By S Jeon, K Aikawa, M Ito, A Kusano, I Park, N Hiroyoshi

In mineral processing of complex sulfide ores containing copper (Cu), lead (Pb), and zinc (Zn), flotation has been commonly used. Typical Pb mineral in the ores is galena (PbS), while some types of the ores contain anglesite (PbSO4). This article reviews our recent studies on the effects of coexisting PbSO4 on the flotation of complex sulfide ores, and a method to suppress the floatability of sphalerite (ZnS) in the presence of PbSO4 was proposed. Comparison of flotation experiments for different types of model samples showed that PbSO4 makes the separation of Zn from Cu difficult; that is, for the model sample containing PbS without PbSO4, Zn could be separated from Cu, while when the model sample containing PbSO4, Zn was recovered together with Cu as froth. Solution analysis and thermodynamic calculation suggested that Pb2+ was released from PbSO4 and reacted with ZnS to form PbS, acting as an adsorption site for the flotation collector, xanthate. This would be the main reason for high floatability of ZnS in the presence of PbSO4. As a method to suppress ZnS floatability for the ores containing PbSO4, a pre-treatment of the ores to remove PbSO4 prior to flotation was proposed. The results of model experiments using mixture of ZnS and PbSO4 showed that ~97 per cent of PbSO4 was dissolved within 30 minutes of pretreatment using ethylenediaminetetraacetic acid (EDTA) as extractant, and thus ZnS floatability was markedly suppressed. Moreover, Pb2+ extracted from PbSO4 during the pre-treatment could be recovered as zero-valent Pb by the cementation using zero-valent Fe as a reductant. The details of ZnS flotation in the presence of PbSO4 and the effects of the pre-treatment are discussed based on the results of surface analysis like XPS.

Aug 24, 2022

By G Tranell, E Pastor-Vallés, A Vallejo-Olivares, J B. Pettersen

Metals are essential for the sustainability transition and decarbonisation of society. Yet, it will be paramount to produce them sustainably and minimise the affiliated resource and energy use and the associated emissions. In the circular economy, the metallurgical industry should recycle existing material stocks, and improve its utilisation of wastes, residues and side streams. This increases the complexity of processes, as they become both (often multi-fraction) waste treatment as well as material production processes and brings complexity to the assessment of environmental benefits. Assessing the environmental impact of technological developments frequently is supported by life cycle assessment (LCA). While the method is well documented, its implementation involves several methodological choices that deserve reasoning and analysis, such as how to define the product when former wastes are turned into new products, the selection of impact methodology when converting emissions to environmental indicators, the definition of system boundaries and co-product allocation and the interpretation of sensitivity and uncertainty in final outcomes. In this exploratory study, we investigate how the variation of LCA set-up affects the environmental burden of the system. We consider a metallurgical process where a mix of hard-to-recycle aluminium-containing streams is used to produce aluminium cast alloys in a rotary furnace. Remelting with salt-fluxes allows recovering metals from partly oxidised/contaminated streams, such as dross, bottom ash and industrial shavings, but at the expense of generating significant amounts of salt-slag/salt-cake hazardous waste. The study considers different system alternatives such as landfilling the salt-slag residues versus valourising them into salts, aluminium concentrates, ammonium sulfate and non-metallic-compounds to be used by the metallurgical, construction or chemical industries. Practical recommendations are outlined to facilitate the implementation of LCA in assessing the potential benefits of the circular economy in the metallurgical sector.

Aug 21, 2024

By D Olwagen, C Stanton, J Gerber

From December 2013 to February 2014 the Southern Middleback Ranges magnetite concentrator went through a successful optimisation process that included the installation of extra grinding power to treat a wider range of ore types. After the initial improvements, sampling surveys were conducted to identify the mineral deportment through the concentrator. Samples collected during the survey were analysed using X-ray fluorescence, quantitative X-ray diffraction and QEMSCAN™ to cross-validate the analysis. Certain streams were also put through a laboratory-scale Davis Tube Recovery washing process to produce clean concentrates for analysis. The QEMSCAN™ analysis identified various metallurgical characteristics (mineral association, particle sizes, grain sizes, particle densities, etc) and these were evaluated for each separation and comminution stage to both understand the processes involved and identify opportunities for improvement. Key findings from the investigation indicated the importance of understanding the elemental deportment of target elements throughout the various minerals. The standard practice of tracking iron deportment through assay provided misleading results on losses to tail through the plant. The investigation provided insight into both wanted and unwanted minerals and the efficiency of each separation stage. The efficiencies of separation are critical due to their impact on downstream capacity, and the investigation provided insight into where opportunities exist to extract more benefit. The findings of the geometallurgical analysis have been implemented on the concentrator, and improvements in the rejection of non-magnetic minerals have been seen.CITATION:Gerber, J, Stanton, C and Olwagen, D, 2015. Using geometallurgy during process optimisation activities at the Southern Middleback Ranges magnetite concentrator, in Proceedings Iron Ore 2015, pp 561–566 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

By K T. Mandisodza, T J. Cartledge

The principal objective of Geotechnical Engineers supporting operating mines is to provide safe working conditions and ensure that pit designs are geotechnically optimised to site conditions and pre-defined stability requirements. Pit slope designs are delivered in advance of pit excavations. Making changes to these designs is usually slow to enact and involves a layered sign-off before implementation, leading to unwanted delays in their adoption and subsequently increased production pressures. When unexpected ground conditions are encountered during the mining process, or short-term mining schedule requirements demand it, changes to these designs may not be easily feasible in certain situations. It is when these scenarios arise that Geotechnical Engineers need to be proactive and consider unconventional options to deliver safe operating conditions while satisfying short-term requirements to the mine schedule. Essentially, the geotechnical short-term strategic designs double-pronged approach supports the mine schedule while providing safe conditions and minimising geotechnical risks for people and equipment. Common short-term strategic geotechnical designs include; slope buttressing, over-steepening cut slopes to increase reserve recovery through unplanned or emergency cutbacks, and accepting risk threat and operating under unstable slopes. When implementing strategic design options, the Geotechnical Engineer must consider the broader implications for such designs. They must think of the plan’s long-term effects on the mine schedule and pit wall stability. Initiating aggressive designs to recover additional reserves to satisfy a short-term scheduling demand could result in-pit wall instability or suboptimal pit layout. Before and during the implementation phase, the Geotechnical Engineer must communicate and engage with relevant stakeholders to ensure that the plan is executed accordingly and geotechnical risks are effectively managed. Proactiveness to ground response and implementation of risk management strategies will improve safety performance and optimise mining schedules.

Jun 22, 2022

By M Bellamy

The DeGrussa copper deposit was discovered by Sandfire Resources in April 2009. Construction of the 1.6 Mt/a concentrator, open pit and underground mining operations commenced in March 2011 with first concentrate production achieved in October 2012. Over the next ten years, DeGrussa grew to include both the DeGrussa and Monty underground mines, establishing itself as one of the world’s premier copper producers with total production of 663 000 t of contained copper by the time the mine closed. Final ore was trucked from Degrussa on 5 October 2022. This paper examines the mine closure experience from both a planning and operational perspective. The paper provides an overview of the site’s mine planning process including the factors involved in determining the end of the mine life and how this was tracked and communicated in the lead up to the end of mining operations. It will also look at some of the specific operational aspects involved in maintaining steady state production all the way through to the last day while facing increasingly challenging conditions. These factors, along with the external factors faced by most of the industry such as labour shortages and COVID related disruptions, contributed to making it an interesting journey to the end of operations at DeGrussa.

Mar 29, 2023

By Blake W

Based on preliminary computer model simulations and stability analyses, both longi- tudinal and transverse, large dimension, cut- and-fill rooms were designed for the parallel dipping ore layers at Kamoto mine. Full scale testing of the designed rooms showed that the rooms are stable and that the rock behavior is predictable. Ordinary waste rock was selected as the filling material because the fill was found to carry little load.

Jan 1, 1973

By Hainsworth D, Winstanley G, Gurgenci H, Corke P

Past experience has shown that the automation of the dragline swing motion requires real time monitoring of the bucket position. A current project at the Centre for Mining Technology and Equipment (CMTE) is aiming to achieve this using machine vision. The hardware platform is a Datacube MaxVideo 200 system. The images are obtained by a fixed camera installed on the dragline boom. The field of view is large enough to include the bucket in all possible configurations. Standard chain coding and run-length coding algorithms are used to process the video image. The three-dimensional bucket position is calculated by combining the output of the machine vision system with the rope length data obtained from transducers installed on drag and hoist drums. This information is then fed into a control computer which takes corrective action to suppress bucket oscillations before they reach dangerous levels.

Jan 1, 1995

By M M. M LT Tassinari, A B. Braz, L M. SantÆAgostino, C Ulsen

Several mineral resources have been recognised to alkaline igneous rocks. In general, these mineralisations present low P grades, so a complex concentration process is required to achieve commercial grade concentrates. This process is guided not only by the ore characteristics, such as apatite grain size and liberation degree, gangue minerals and slimes content, but also by different apatite varieties, iron oxi-hydroxide surface coating and roughness. The main techniques applied to apatite and phosphate ore characterisation, such as optical microscopy, cathodoluminescence (CL) microscopy, scanning electron microscopy (SEM), X-ray diffraction (XRD), Fourier-transform infrared spectroscopy (FTIR), surface techniques and magnetic separation are discussed, aiming to evaluate distinct apatite varieties and their technological behaviour.

Jan 1, 2008

Towards Improved Hydrocyclone Models - Contributions from Computational Fluid Dynamics

Sep 13, 2010

By C Quirion

Agnico-Eagle Mines Limited, Laronde Division, operates the deepest single-lift shaft in the western hemisphere. The initial Penna hoisting plant was designed for a production rate of 1800 tonnes per day (t/d) from a 2240 m deep shaft. Exploration success, while sinking the shaft, led to a decision in 1998 to increase the production rate to 4500 t/d of ore from a loading depth of 2200 m. The new production rate was achieved by increasing the size of the rope and reducing the rope static factor from the existing 5.0 required by regulation to a static factor using the formula 25 000/(4000 + L) contained in a draft document that would eventually become SABS 0294 in South Africa. The formula permits Laronde to use a static factor as low as 4.0. The upgraded Penna hoisting system is the first hoisting plant outside of South Africa to meet the South African requirements. This paper describes the conversion of the hoisting plant to the lower rope selection factor in the year 2000 and the operating and maintenance issues experienced since then.

Jan 1, 2005

The planned extraction of deeper copper ore at Isa Mine has necessitated a review of existing equipment and methods to contain costs and improve working conditions. Mining is in progress for a crushing-conveying system to serve the deeper southern areas of the 1100 Orebody. This system will permit direct tipping of ore to the crushers and conveying of the crushed ore by cable belt conveyor to existing shaft loading facilities, a distance of about 2 km. To develop part of the conveyor drive a new machine will be used, the Robbins MM120 Mobile Miner, a joint development project between The Robbins Company and Mount Isa Mines Limited. The Mobile Miner uses a rotating cutting wheel to excavate headings 3.7 m high and from 4.7 m to 7.5 m wide. To ventilate the deep crusher complexes and associated development at high virgin rock temperatures, a refrigeration plant will be built on surface to reticulate chilled water underground. Bulk cooling of air to the 3000/3500 Orebodies and the southern crushers will be combined with the reticulation of chilled service water to the lower workings of the mine.

Jan 1, 1984

Iron ore in the Pilbara Region of Western Australia varies in composition giving iron ore a range of densities. An accurate density figure of the material leads to accurate calculations of production throughput. Density studies of two separate iron ore mines were conducted in the Pilbara. Procedures and results are reported here.The Pilbara Region of Western Australia has a number of iron ore operations. Two mines have conducted density studies of their materials. The purpose for the studies was to determine an accurate in situ bulk density that could be applied to volume and tonnage calculations of the operation. It was identified that density was one culprit causing calculation variations. Density is an important figure used to estimate ore reserves, equipment requirements, production rates and indirectly costs and sales revenue. One study was conducted at Rio TintoÆs Robe River Mine based near the town of Pannawonica. Its Mesa J orebody is currently being mined and is a low-grade deposit of goethite and hematite (Burnham, 2003). A separate study was conducted at BHP BillitonÆs Yarrie Mine situated north of Newman and east of Pardoo. Its orebody consists of high grade formed by a supergene enrichment of cherty material and a burial metamorphism to produce hematite (Richardson, 2002). The method used to determine density was by large-scale samples using the pre-mining in situ volume of the material and the weight in tonnes after mining.

Jan 1, 2003

By S P. Young, K R. Monro

Reducing metal prices have forced mining operations to become more efficient and innovate in order to do more with the existing base. Much of this effort has focused on improving the efficiency of load and haul operations. The key to this is to understand and quantify where delays and missed opportunities exist. Metrics such as utilisation of availability, efficiency utilisation and asset availability are helpful indicators of performance; however, uptime-based time usage models and performance analysis tools using productive operating time models help to identify additional improvement opportunities.Phu Kham is a copper-gold mine operated in the Lao People’s Democratic Republic (Laos) since 2008 by PanAust Limited. The mine is a single large open pit of 450 m depth, running a fleet of 51 100 t class rigid dump trucks and 300 t and 200 t shovels controlled with the aid of a fleet management system in order to achieve ex-pit material movements of 56 Mt/a.Commencing in late 2014, a range of initiatives were implemented in order to improve the efficiency of the mine haulage fleet. These include hot seating of all operator changeouts via changeout ramps, split shifting of crews to minimise queuing delays, maximising blast volumes and minimising blast event days to reduce blast exclusion delay events including opportune refuelling of equipment during blasting events, inspections of trucks during refuelling events, implementation of a dedicated haul road services team to help reduce wet weather related delays and infrastructure development for haul path efficiency improvements.These and other initiatives have allowed the mine haulage fleet utilisation of availability (UofA) to be sustainably increased from 85 per cent to 97 per cent (see Figure 1), efficiency utilisation to increase from 85 per cent to 90 per cent, and productive operating time (POT) to increase from 73 per cent to 84 per cent. The corresponding increases in efficiency of the haulage fleet has allowed an equivalent reduction of eight haul trucks from the fleet to meet continuing life-of-mine production requirements.CITATION:Monro, K R and Young, S P, 2016. Truck haulage improvements at the Phu Kham mine – the journey to 97 per cent utilisation of availability, in Proceedings International Mine Management Conference, pp 339-346 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jun 22, 2016

Average annual growth in consumption of primary energy in Australia over the past 10 years has been 5·5 per cent compared to a world average of 4·1 per cent.Over the next 10 years growth rate is expected to increase to 6 per cent per annum due largely to the rapid development in the mineral processing industry.By the end of the 19705 natural gas is expected to supply more than 9 per cent of Australia's primary energy market. Coal will supply 40 per cent and petroleum products 47 per cent. Nuclear energy will make its appearance but will make only a small contribution in the period.Australia has adequate reserves of natural gas and coal to supply its needs in the 1970s and beyond. However the newly developed reserves of crude oil, while supplying 60-70 per cent of requirements in the initialyears, will need regular and sizable additions if they are to keep pace with the expanding consumption. For Australia to become self sufficient in the period 1970-1990 it is estimated that new discoveries will need to approximate ten times the volume of recoverable reserves found in Australia to date.

Jan 1, 1971

By D Kay, M Lovitt

Mass Blasts are generally required at the completion of longhole stoping cycles to maximise the recovery of ore from a specific orebody. During the course of mining, the practice is to leave pillars of ore to support the opening left by extracted ore and to mitigate stresses from working areas of the stope. These pillars usually contain ore that has been included in the resource evaluation and is highly valuable to the mining operation. Due to their stressed nature, the removal of pillars by conventional blasting techniques, through small blasts, can result in pillars being reduced beyond their critical size and ultimately failing, rendering the ore unrecoverable. The AurionGold Kanowna Belle Gold Mine operates a Mine to Mill philosophy. This philosopy requires the fine tuning of blasting to provide the best possibe ore feed at the highest grade for mill productivity. This means that ore to the mill must be well fragmented from blasting that provides high extraction rates from draw points, with minimal dilution from overbreak or fall off, and sized to maximise SAG mill throughput. The AT04 Mass Blast contained significant ore reserves which were required to meet gold production targets. KBGB needed the AT04 Mass Blast to perform as well as if not better than conventional stope blasts to maintain mill production. This paper describes the circumstances, planning philosophy, techniques, including the use of Electronic Initiation Systems and Bulk Emulsion Explosives, and results that provided a highly successful outcome.

Jan 1, 2002