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By R Belissont, C Veloso, L Senez, F Vasconcelos, E Kleiderer, J Mesquita, Y Basselin

Mont-Wright mining complex is an important asset of ArcelorMittal located in the province of Quebec, Canada. It is composed by Mont-Wright and Fire Lake mines, operating 365 days per annum, and producing 25 Mtpa of iron ore concentrate with 66 per cent Fe. Mont-Wright concentration plant is composed by seven lines with a flow sheet encompassing AG/SAG milling, primary and secondary classification stages, spiral concentrators (rougher, cleaner and recleaner stages) and dewatering unit operations. In this context, an equation called ‘Wrec’ was developed in 1971 with the objective of estimating the mass recovery of the different blocks in the beneficiation plant and support the mining planning works of Mont-Wright complex. This equation was based on the correlation between the results of heavy liquid tests performed with drill core samples and spiral concentrators pilot scale tests, returning an estimative of concentrator yield. However, since its first development, no updates have been done in the equation, which lead to some deviations from expected recoveries in the last years. This is probably due to the changes in the process and in the ore fed into the concentrator during the period. In this way, the study presented here corresponds to the execution of heavy liquid/spirals pilot scale tests with 26 composite samples collected at Mont-Wright deposit aiming at revising and updating ‘Wrec’ equation. Based on test work results, an updated formula was established to estimate the plant recovery and a comparison performed using industrial data showed that the old formula overestimated the real yield by 5.40 per cent, on average. At the end of the study the new equation was incorporated into the mining planning process.

Sep 18, 2023

By R Pinksen

The Iron Ore Company (IOC) of Canada Mining and Operations Departments expressed an interest in reducing the amount of oversize material (>1 m × 1 m × 1 m) being produced and its subsequent downstream effects including in-pit sorting and reduction, damage to mobile equipment, and significant delays in the loading pockets and the primary crushers. To achieve this goal an oversize reduction project was undertaken by the mine and to date has significantly improved upon baseline measures.One key approach used to reduce the amount of oversize was the implementation of thicker emulsion. The introduction of a thicker emulsion into the blastholes provided more resistance to the forces created by dynamic water and reduced the infi ltration of the emulsion into the cracks and fissures of the rock mass. Blast results showed reduced amounts of oversize and more consistent fragmentation throughout the muck piles. Additionally, a significant reduction in nitrates leached into the mine water discharge has been realised.To determine the effectiveness of the oversize reduction project, IOC used shovel based camera technology to assess fragmentation presented to the shovel at the digging face. A digital vision system (DVS) was installed on one of the shovels to capture images that were stamped with global positioning system (GPS) locations. A large population of digital images was analysed to produce a robust fragmentation distribution baseline that was used as one of the mine key performance indicators (KPI). Changes to blasting practice were subsequently measured against the baseline KPI to assess effectiveness.

Jul 11, 2011

Spectroelectrochemical Investigation of Hydroxamate Reagents on Copper Oxide Minerals

Sep 13, 2010

By J S. Laskowski

Froth flotation process requires the use of frothers. These important flotation agents are commonly characterised as either æselectiveÆ or æpowerfulÆ and are chosen following general guidelines and verification by laboratory and/or pilot plant tests. Fundamental properties of the flotation frothers have been extensively studied over the last few years. These studies have led to the development of standardised procedures to characterise frothers in terms of their ability to reduce bubble size and to increase foam stability. In this research project, the performance of five frothers in flotation of coal is evaluated and related to the fundamental properties of these agents. Since the recovery of water in the concentrate is closely related to the non-selective transport of solid particles by entrainment, the tested frothers are also assessed in terms of their ability to promote the transport of water towards the froth collection zone, both in absence and in presence of solids.

Jan 1, 2005

By L Barrere, J P. Sykes, A Trench, R S. Davies

Western Australia (WA), alongside Brazil, has remained at the forefront of the global seaborne traded iron ore market for over 40 years. Despite this apparent stability and strong market position, WA continues to face strong external international supply-side competition, mainly from Brazil, but also periodically from often marginal, non-traditional sources of iron ore. Additionally, WA iron ore supply has undergone significant decadal change internally, both of an evolutionary (brownfields expansion) and revolutionary nature (major new greenfields projects). Since 2006, a new generation of WA-focused iron ore explorers, developers and producers have emerged.The majors, BHP Billiton and Rio Tinto, have expanded mine production to record levels and the Roy Hill project is now approaching nameplate capacity. Fortescue Metals Group (FMG) is, however, the largest new market entrant of the last decade, delivering upon their vision of becoming the ‘new force in iron ore’. Unlike most of the other new WA market entrants, FMG’s operations are substantive. Most of the other smaller, new WA iron ore miners have struggled during the period of falling prices, though it is worth noting that collectively they have made a material supply-side impact during the price boom – typical of marginal supply. Finally there have been some contributions from new magnetite projects, however, the delivery and economics of these projects have not met expectations.In this paper, we touch briefly upon the key global market changes of the last decade, namely China-driven demand growth and the changes to the pricing mechanisms for iron ores – before reviewing the rise in WA iron ore supply in response to these markets. We finish by focusing on the most significant WA-focused supply-side development of the last decade, the rise of FMG as a major new supplier and the strategic situation that facilitated its rise. The unprecedented China-led rise in iron ore prices felled many traditional barriers to market entry into an oligopolistic industry, allowing many new market entrants (in WA and around the world). However, the downturn in iron ore prices resurrected these barriers to entry, with only FMG (thus far) breaking the entry barrier with significant scale. Difficult corporate decisions have been forced upon the smaller WA iron ore miners who, in some cases, will now struggle to further expand, or indeed continue to operate in the longer run.The changes that have taken place over the last decade of WA iron ore production hold insights for other emergent mineral commodity exports from the state. Successful market entry, even when industry barriers are high, does not always require an immediate low-cost production assumption alongside a strong balance sheet. FMG could see a new market, within an established commodity market, target an appropriate and new product at it, overcome temporarily-felled barriers to entry in infrastructure and finance, then innovate and aggressively cut costs ensuring it was behind the barriers to entry when they rose again after the price boom.CITATION:Barrere, L, Trench, A, Sykes, J P and Davies, R S, 2017. New generation Western Australian iron ore – strategic insights far beyond the Pilbara?, in Proceedings Iron Ore 2017, pp 375–386 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 24, 2017

By C E. Gawith

The Waihi underground mining operation currently mines epithermal veins ranging from two metres up to ten metres in width using a ‘Modified Avoca’ stoping method. This method consists of longhole bench stope mining at 15m to 18m sublevel spacing. The bulk of production drilling and blasting is top down with the extraction length of a typical stope panel nominally being 18m to 20m along strike. A stope panel is usually taken in two blasting cycles followed by the remote bogging of the stope ore. The panel is backfilled in-cycle using unconsolidated waste rock material which is tipped into the void from the upper level using a Caterpillar R2900 or R1700 sized underground loader. The underground mine first commenced production in 2008 and up until 2016, as was typical of many open stope mining operations at the time, an underground loader was used to place a waste rock bund at the top brow of the open stope. This rock bund was the principal means of protecting people and equipment from this hazard. In 2016 there was a fatality at the mine when a loader that had been tasked with building this rock bund fell into the stope void. Immediately post incident all mining and processing operations were suspended for a week to allow colleagues to grieve, to observe cultural protocols and to begin the investigation into this event. During this period senior operators, supervisory and technical staff developed an innovative system which used steel bollards to protect this open edge. With development over the following months this bollard system has eliminated this hazard from the Waihi underground mine.

Mar 15, 2021

By G McCullough, J Bassan, d P. Knights, C T. Farrelly

By 2045, carbon-neutral mines will be economically producing products that are vital for the world’s transition to renewable energy. After overcoming significant technical challenges (and the investment of significant capital), leaders have successfully eliminated the use of diesel and other fossil fuels by introducing a wide range of new decarbonisation technologies. These leaders will be reaping the benefits of lower production costs (resulting from elimination of diesel), stable and predictable operations, and easier access to capital for their future projects. This paper describes a future scenario of how a net zero carbon and zero-entry mine could operate by taking maximum advantage of technologies in development or already proven in other industries. Some miners have been unsuccessful in their efforts to reach decarbonisation targets. Instead, they have been forced to close or offload their assets to be acquired by operators with better sustainability credentials, or, in some cases, to indigenous or community-based enterprises with vested interest in making operations viable and sustainable. Regardless of ownership structure, all successful mining operations will have fostered strong and positive community relations that bring education, health, security and economic development opportunities to the communities while respecting their traditions, land-uses and culture. As shallow, easy to mine deposits have become scarce, the majority of new mines are underground. Advancements in electric underground technology and the feasibility of ‘zero entry mining’ (with no personnel in active mining zones) has made it increasingly possible to economically operate underground mines, even at shallow depths. The newest mines have a near zero footprint on the surface, produce no harmful by-products, and are employing in-place or in situ methods of extraction that are efficient and low impact. Surface land-uses, such as agriculture and renewable energy generation, continue in the immediate vicinity of the mine, with no significant ground disturbance, community impact or environmental footprint.

Sep 1, 2024

By W B. Edgar, S C. Dominy

High-nugget effect vein-gold systems are generally considered to be one of the most challenging of deposit types to evaluate and exploit. To potential investors and mining companies, they are viewed as high risk because of the associated uncertainties in the grade estimate and general paucity of Ore Reserves at production start-up. However, despite the well-known risks, these deposits often have a grade upside that makes them potentially attractive. The reporting of resource grade is of importance and perhaps even more so is the reporting of the associated uncertainty attached to the grade estimate. The use of the grade estimate supported by a grade range is recommended to achieve more complete and useful disclosure. The definition of the grade range can be somewhat subjective, ranging from opinion based estimates through to data-based estimates and geostatistical conditional simulation. Whichever method used, the over-riding issue must be the provision of enough data of appropriate quality and full disclosure to the public of relevant uncertainties.CITATION:Dominy, S C and Edgar, W B, 2012. Approaches to reporting grade uncertainty in high-nugget gold vein projects, in Proceedings Project Evaluation 2012 , pp 95-108 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 24, 2012

Coal Preparation Research at Turkish Coal Enterprises (TKI)

Sep 13, 2010

By X Hill

Throughout the 2016/2017 financial year, the NSW Resources Regulator conducted an assessment of each underground metalliferous operation across the state to assess how each operation managed the principal mining hazard of ground and strata control. The assessment considered all aspects of the mining process, including all aspects of managing geotechnical risk within drawpoints. This assessment is ongoing and, therefore, this paper is limited to the first six mines assessed in the program.In 2015 there were three fatalities in and around underground drawpoints in Australian metalliferous mines. Whilst many of the systems of work around underground development are consistent across the industry, there are large discrepancies around how each underground mining operation manage the risks associated with drawpoints.For drawpoints to be effectively managed, their management needs to be considered at the earliest stages of the mine planning process. By using downholes and adopting remote systems of work – systems that are continuing to improve with technology – the risks drawpoints posed can be greatly reduced.The assessment by the NSW Resources Regulator revealed a number of common failings across the state in the management of the risks that drawpoints pose. The assessment also observed a number of innovative practices that particular operations have adopted in the wake of serious incidents occurring within drawpoints at their operation; however, these practices have not been communicated to other operations.It is hoped the learnings from the assessment can be considered by industry and reduce the risks drawpoints pose in underground metalliferous mines.CITATION:Hill, X, 2017. Learnings from review of drawpoint management across New South Wales mines, in Proceedings 13th AusIMM Underground Operators’ Conference 2017, pp 143–150 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Oct 16, 2017

Mineral Changes that Occur During Coal Gasification

Sep 13, 2010

By Nilmani M, Malone J, Taylor RN, Floyd JM, Gray NB, Fountain CR

CSIRO staff and University of Melbourne staff and students collaborated in an intense programme of investigation on the CSIRO 50 kg Sirosmelt pilot plant.In two days of operation copper matte converting and zinc slag fuming trials were performed, whilst investigation of the process dynamics and process chemistry was carried out. This exercise is an example of the techniques available for process evaluation, which can rapidly advance the understanding of pyrometallurgical operations by use of a team approach covering a wide range of experiments.

Jan 1, 1985

By K Guilfoyle

AngloGold Ashanti Australia Ltd operates an underground mine below a large open pit at the Sunrise Dam Gold Mine near Laverton in Western Australia. Operations are based on an extensive mineralised zone which has very complex geometry, has a high ‘nugget effect’, and is difficult to interpret and model. Initial underground ore was produced from relatively narrow orebodies dipping from 15º - 70º. Open stopes aimed to selectively extract high-grade ore, using methods including jumbo stripping and longhole drilling and blasting. The complex geology makes it difficult to accurately locate development and stopes in the positions required for profitable production. In narrow stopes, rock mass damage and overbreak dilute ore grades and increase the cost per ounce of gold poured. In flat orebodies, several different techniques have been used to recover blasted ore but overall productivity is low. Thus selective mining can also be slow, costly and recovers only a portion of the available mineral resources. Large longhole open stopes with cemented paste backfill are used to extract multiple zones of mineralisation from the Cosmo and GQ orebodies. Bulk emulsion explosives and electronic detonators are used in all large stope blasts to reduce the risk of misfires and to accurately control blasthole initiation sequences and delay timing. Larger stopes improve productivity and significantly reduce direct mining costs, enabling the use of lower economic cut-off grades which increase the overall recovery of mineral resources. This paper reviews the evolution of open stoping at Sunrise Dam, the various mining methods and drilling and blasting practices used, the results achieved, and the lessons learned.

Nov 8, 2011

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 M Haest, O Dominguez, D Mittrup

With the current focus in the mining industry on reducing costs, while simultaneously improving ore quality, infrared spectroscopy is a tool that can potentially assist companies to meet both challenges. Changes in the nature of infrared spectra are strongly influenced by changes in mineralogy, which is a key input variable for exploration (geology and orebody modelling and ore characterisation) and mining (pit design, mine scheduling and processing plant design/management).Infrared spectroscopic logging of drill holes has been embedded as a standard tool in BHP Billiton Iron Ore exploration, with a process set up to automatically deliver mineralogy and associated imagery to the end users (typically exploration geologists). The availability of consistent and automated mineralogy drill hole logs across a project is improving the output quality and reducing re-work.BHP Billiton Iron Ore is now looking into using the same infrared spectroscopic data for other applications, including improving predictions of geometallurgical and geotechnical parameters. Trials show that addition of infrared spectroscopic data to conventional data sets (element analysis and depth information) is significantly improving the accuracy of regression models to predict the lump-fine ratio.Further initiatives around infrared spectroscopic data in BHP Billiton Iron Ore include the installation of infrared spectroscopic sensors over conveyor belts, infrared spectroscopic mine face scanning and infrared spectroscopic blasthole logging. The ultimate vision is to have consistent, seamless mineralogical data from infrared spectroscopic sensing available throughout the mineral value chain (exploration/mining/processing). This seamless infrared spectroscopic data ‘bridge’ will allow the transfer of knowledge between the different sections of the value chain (exploration, mining and processing). For example, ore handle-ability could be predicted on exploration samples using regression models built from processing plant observations. In the opposite direction, information gathered about the buried stratigraphy by infrared spectroscopy utilised during exploration, could be used to predict the stratigraphy encountered during mining. This collaboration across BHP Billiton Iron Ore is expected to deliver significant savings, while improving the quality of the final product, thus helping to drive efficiency over the next decade.CITATION:Haest, M, Mittrup, D and Dominguez, O, 2015. Reaping the first fruits – infrared spectroscopy: the new standard tool in BHP Billiton Iron Ore Exploration, in Proceedings Iron Ore 2015, pp 277–284 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

By P A. Jenkins, I W. O Jones

WMC has mined the Perseverance disseminated orebody exclusively by SLC (sublevel cave) methods. Deteriorating ground conditions in the vicinity of an orebody inflection forced a re-evaluation of future mining at Perseverance and a strategy to drop down below the inflection zone and recommence the cave was implemented. This strategy has led to increased production at higher grades, resulting in lower costs and better mill recoveries. This paper describes the evolution of mine planning, development, support and production strategies through the successful process of implementing the ædrop-downÆ and re-establishing the SLC.

Jan 1, 2000

By J Berg, M Hahn, R Winkel

Imaging sensor systems designed for the mining and minerals industry incorporate different physical measurement technologies that can be used to detect the machine environment, such as laser, ultrasonic/sonar, video and RF-sensors. The underlying physical measurement principles cannot be employed in most applications near the face without regular maintenance due to the harsh environmental conditions like dust, dirt or moisture. However, that is the area, where imaging sensors are most valuable to the machine operator. In the domain of 2D radar sensors these have been either restricted by the angular coverage area or by limited adaptability of signal processing algorithms. The unique full digital solid state design will establish a generation step in mining applications.In order to fill this gap of terrain imaging sensors, the Institute for Mining and Metallurgy Machinery (IMR) of the RWTH Aachen University, in cooperation with the radar company indurad, developed an imaging sensor based on radar technology employing the digital beam forming (DBF) concept. Through multiple transmitting and receiving antennas the sensor delivers high accuracy range and angular information. Using adaptive digital signal processing with multiple imaging algorithms and target detection routines, data of the surrounding environment can be used to enable automation functions in mining.A comprehensive range of radar scans in different environments have been evaluated and benchmarked by using laser scanners. Accuracy measurements in range and angular direction have shown minimal differences. Experimental measurements have been performed at slopes, on conveyor belts and hot cement clinker silos. The experimental system uses a frequency modulated continuous wave (FMCW) front-end combined with a processing unit for signal analysis and target detection.

Sep 26, 2011

By S Hancock, B H. Brady, H Muhlhaus

The aims of this paper are to present the governing science, verify the performance and demonstrate the potential engineering applications of a computational simulator for in situ leach mining of non-ferrous minerals. Assuming that the target mineral is deposited either uniformly within rock matrixes (matrix-hosted) or on fracture walls (fracture-hosted), in situ leaching can be treated as reactive flow and transport in geological media (porous media for matrix-hosted ore deposits and fractured media for fracture-hosted ore deposits). Under this treatment, the processes of in situ leach mining for non-ferrous minerals can be quantified through several sets of equations and these coupled equations have been numerically solved. The computational simulator has been applied to the simulations of one-, two-, and three-dimensional in situ leaching cases. The computational simulator, together with laboratory and in situ leaching tests, can be used to:optimise the leaching chemistry; optimise the in situ scale mining operations; scale up the in situ scale test operation to a full-scale mining operation; and evaluate the post-mining environmental restoration plan.

Jan 1, 2000

By L Dubron

This study details a mineralogical and textural characterisation of West African iron ores with an emphasis on their behaviour during mineral processing. By means of both qualitative and quantitative characterisation, a simulation of the beneficiation process applied to these iron ores is performed. A series of different analytical tools are used, including:X-Ray Diffraction (XRD) for qualitative mineralogical analysis;• qualitative optical microscopy (phase identifi cation, description of micro-textures) and (semi)• quantitative optical microscopy (counting of particles, phases and textural types); and• chemical analysis.All the information provided by these analytical methods are combined into a quantitative mineralogical and textural analysis, here called ‘modal analysis’, which enables us to simulate the capability of West African iron ores to be benefi ciated by magnetic and gravimetric separation techniques.On one hand, both qualitative XRD and optical microscopy have revealed the presence of the following mineralogical phases: magnetite, haematite, goethite and quartz. On the other hand, the chemical analyses provide us with quantitative inputs expressed as oxides. We have converted the oxides into mineralogical contents expressed as magnetite, haematite, goethite and quartz. In this way, we build a simple quantitative mineralogical analysis.Beside this, the semi-quantitative approach of the characterisation by optical microscopy also provides us with a liberation study, enabling us to split the gangue-bearing content between two types of particles:1. liberated gangue-bearing particles, and2. composite particles composed by both iron (oxhydr) oxides and gangue-bearing minerals.We have assumed that we could anticipate the behaviour of these two kinds of particles through a mineral process, by simulating the removal of at least the liberated particles of gangue. Optical microscopy also revealed a trend in the weathering profi le of the Tokadeh ore horizon with a decrease from bottom to top of magnetite and an increase of both goethite and martite showing a higher level of oxidation and hydration in the upper ore horizon.We have applied this removal extent upon the quartz content of the mineralogical quantitative analysis and we have re-calculated the quantitative mineralogical analysis considering the expected decrease in the quartz content. Finally, by converting the re-calculated (oxhydr) oxides contents into iron grades and summing them, we do obtain a fi nal simulated iron grade for the upgraded products.

Jul 11, 2011

By D J. Williams

The approach to the disposal and storage of mine tailings is slowly evolving. Tailings disposal has been based on minimising short-term capital and operating costs, with rehabilitation costs discounted by the application of a high discount factor in a net present value approach to accounting. This has led to the widespread adoption of surface tailings storage facilities (TSFs) to store slurried tailings delivered by robust and cheap centrifugal pumps and pipelines. Depending on the site climate, rate of rise of the tailings, nature of the tailings and the extent to which supernatant water is removed from the surface TSF, the tailings may or may not dewater, densify and gain strength. High rates of rise of dilute tailings to a facility used to store both tailings and supernatant water results in a wet, low-density, soft tailings deposit that not only occupies a large storage volume but also presents rehabilitation difficulties. A low tailings density results in high containment wall costs, very high rehabilitation costs and a low potential for future land use or ecological function. Overall, the cost of slurried tailings disposal, thought to be low, is actually high. However, low rates of rise, even of dilute tailings, in a dry climate with efficient supernatant water removal can produce a dewatered, high-density, stiff tailings deposit that may occupy a large footprint but to shallow depth that is relatively easy to rehabilitate. There are advantages in dewatering tailings in the processing plant to recover process water and chemicals, facilitate tailings disposal in a more solid form and facilitate rehabilitation. However, the cost of dewatering in-plant can be high, and the process water may not lend itself to reuse. There are also advantages in removing supernatant water to facilitate solar and wind drying of exposed tailings, although water is lost to evaporation and the dried tailings may best be harvested prior to inundation by fresh tailings or rainfall run-off. This paper discusses the background and trends towards the elimination of conventional surface slurried TSFs, with examples presented of the management of black coal and other tailings, including those that are clay mineral-rich.CITATION:Williams, D J, 2015. Towards the elimination of conventional surface slurried tailings storage facilities, in Proceedings Tailings and Mine Waste Management for the 21st Century , pp 11–24 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 27, 2015