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By D A. Kepert, I J. Tehnas, M A. Pudovsk

BHP Billiton (BHPB) was the first company to start iron ore mining in the Pilbara at Mt Goldsworthy in 1966 through Goldsworthy Mining Limited (GML - then Consolidated Goldfields Australia, Cyprus Mines and Utah). Operations later started at Newman on Mt Whaleback in 1969 with the Mt Newman Mining Joint Venture (MNM û then comprising American Metals Climax û AMAX, Colonial Sugar Refineries û CSR and BHP). In 1986 it acquired majority ownership of MNM, and at the same time the previously 100 per cent BHPB owned but undeveloped Yandi property came on board. Purchase of Jimblebar (formerly McCameyÆs Monster) occurred in 1990 and full ownership of Goldsworthy followed in 1991. With the exception of Jimblebar (100 per cent owned), all mines are now 85 per cent BHPB and the balance with Itochu and Mitsui. This evolution of the company resulted in an eclectic mix of mines/ores, each with their varied exploration and evaluation histories. Discussion of some aspects of these histories, and reflections on changes in exploration-related activities with particular reference to discussion of advances in geological understanding since the 1960s forms the basis of this paper. BHPB presently has open cut mines at four main centres û Newman, Jimblebar, Marillana Creek (Yandi) and Yarrie û and is currently developing the former GML Area C near Yandi. With the exception of NewmanÆs Mt Whaleback mine and immediate satellites, all are contract operated. Ore is carried on BHPB railroads (696 km total) for export through the companyÆs Nelson Point or Finucane Island shipping facilities at Port Hedland. Some is directed to the BHPB Boodarie Iron hot briquetted iron plant near Finucane Island. Over 73 Mt of ore was produced by BHPB in calendar 2001, and the company has now mined over 1500 Mt in Western Australia since their operations at Yampi Sound first started in 1956.

Jan 1, 2002

By L D. Munro, S A. Jackson

This paper provides a logical approach to developing a TSF design concept through: • Identifying key properties of tailings and containment structures; • Reviewing underlying principles for effective operation; • Showing how these apply to select an appropriate TMS; and • Demonstrating how to align the TMS to site-specific constraints and TSF design. This approach follows a path of rigorous data analysis independent of discharge parameters (whether low-density slurry, paste or cake disposal) to select the most cost-effective and sustainable approach for any given material or site.

Jul 1, 2021

By M Binks

The Fosterville Gold mine is located approximately 20km to the East of Bendigo in central Victoria. The gold at Fosterville occurs as solid solution within disseminated arsenopyrite and pyrite. The Fosterville ore bodies contain various amounts of native carbon in the form of bituminous coal. This carbon (Non-Carbonate Carbon or NCC) has been the predominant mechanism for gold loss from the processing facility through”preg-robbing”.Processing of the Fosterville ore is achieved initially through crushing, grinding and flotation to extract the sulphides. The sulphide concentrate is oxidized using Bacterial Oxidation, before being leached in a conventional CIL circuit. A high portion of the native carbon (NCC) in the mine ore is naturally hydrophobic in nature, and subsequently reports to the flotation concentrate stream, and ultimately onto the CIL circuit. This NCC has a notable preg-robbing ability. Treatment of Black Shale ores, which have elevated NCC levels, has historically resulted in CIL recoveries as low as 35%, with around 60-80% of the gold loss from the leach circuit attributed to preg-robbing.Standard technologies for dealing with a carbonaceous leach feed have been trialed with limited success. The discovery of the significance of heat on leach recoveries, triggered extensive testwork on a range of leach feed and tails samples. Pilot plant testing demonstrated that “Heated Leaching” of the CIL tails was the best process with an average recovery increase of 7.5% being achieved. Following a successful pilot study, an engineering feasibility study was completed by Minerva Engineering, and the project economics determined. With strong recovery gains evident and a predicted project payback of 1-1.5 years, approval for the installation of the full scale plant was granted. Detailed design commenced in September 2008 with installation commencing in January 2009. The circuit was successfully commissioned in April 2009.Following commissioning, the Heated Leach circuit has achieved recovery gains of 4-14%, and has proven itself to be a significant contributor to the overall plant performance.

Aug 8, 2011

By R Dunne, G Lane, S Ha, D Dreisinger

The paper outlines the 17 Mt/a Telfer Project plant process design from sample selection to feasibility study design. The 366 Mt Telfer mine reserve consists of a diverse range of copper and gold mineralisation, from massive sulfide reef ores to stockwork ore, oxide copper minerals to chalcopyrite, siltstone to competent quartzite, all with relatively high levels of gravity recoverable gold. The complexity of the orebody demanded a flexible plant that could recover copper and gold values by a combination of gravity recovery, flotation and concentrate leaching. The demands of treating ore from a high grade underground mine and a variable grade open pit (that includes underground old mine workings) necessitated a dual train approach from primary crushing to concentrate production in order to minimise the requirement for campaigning of different ore types. An extensive sampling, testwork and technical evaluation program was undertaken to identify processing characteristics and the optimum process route for each ore type. The design experience included: the development of robust primary stockpiling and pebble crushing concepts; detailed review of scale-up of SAG and ball mill pilot plant data to plant scale; the selection of two 15 MW SAG mills and two 13 MW ball mills for the grinding circuit; and detailed modelling of the pyrite concentrate carbon-in-leach (CIL)/sulfidisation acidification recovery thickening (SART)/acidification volatilisation recovery (AVR) process to optimise design for copper and cyanide recovery from leach liquors. The Telfer plant design also measures the development of process design based on experiences at the Cadia Hill Cu/Au concentrator, commissioned in 1998. The differences between the two plants are compared and contrasted.

Jan 1, 2003

Rio Tinto Iron Ore (RTIO) manages eleven mines in the Pilbara region, Western Australia. Three of these mines have previously or are currently mining black shale that contains varying amounts of pyrite. Several new deposits currently being evaluated and existing mines that may progress below water table in the future, will also encounter this waste material. The black shale presents not just an acid rock drainage risk but also a spontaneous combustion risk. This paper presents the black shale management strategy and provides an overview of the relevant activities undertaken by RTIO. The strategy can be divided into two components which firstly involve defining the risk and secondly involve managing the risk. The mineral waste management plan is used to identify specific mineral waste hazards by:geochemical characterisation of waste material,undertaking mine site specific risk assessments,characterising the receiving environment,identifying sulfidic boundaries in geological and mining models,quantifying the amount of sulfidic material in medium and long-term mine plans, anddesigning and sequencing black shale waste dumps. Once a mine exposes black shale the Spontaneous Combustion and Acid Rock Drainage management plan is used and the major activities are: regular site meetings with a representative from every group that works with black shale;compliance with safe working procedures for site specific and detailed activities;regular training;the use of specific explosives to prevent premature detonation;ongoing geochemical characterisation;acid water management, monitoring and analysis;regular internal and external auditing of procedures and practices; andclosure planning assessments and preparations (ie cover trials, geochemical void modelling, geochemical waste dump modelling). The success of this holistic strategy is evident by the awareness of personnel within the business, thorough understanding of the geochemistry and by undertaking proactive management of black shale during mining. The strategy and management plans adopted by Rio Tinto Iron Ore have activities that other mine sites with potentially acid forming material may like to consider implementing.

Jan 1, 2009

By J-T Zhu, Q-Y Tu, S-L Kong, L Wang, Y-P Cheng, H-Y Liu, Q-L Yang

China is the largest coal-producing country in the world, while the geological conditions of deep coal mining are extremely complicated with high ground stress, high gas pressure and low permeability, which results in the difficulty of gas drainage and aggravation of gas explosion and coal and gas outburst disasters. Co-extraction of coal and gas is an effective method to eliminate coalmine gas disasters and realise the safe exploitation of coal and efficient gas drainage at the same time. This concept is widely accepted by the main coal-producing countries around the world, while the concrete definition of co-extraction is vague and not unified, and there is little accurate theoretical support for co-extraction of coal and gas, which makes it hard to determine efficient gas drainage methods correspondingly according to the features of coal seams in a comprehensive and systematic way. Based on theoretical analysis, laboratory test and field observations, basic thoughts and specific definition of co-extraction of coal and gas were put forward after analysing the occurrence characteristics of coal seams in China. We obtained the mechanism of mining-enhanced permeability and established the corresponding theoretical model, which is the process of fracture network formation through opening recovery of the original fractures and new fractures produced by unloading damage. Based on the core idea of ‘mining-enhanced permeability’, engineering approaches of ‘unloading by boreholes drilling’ for the single coal seam and ‘unloading by protective seam mining’ for the coal seam group were proposed to realise safe and efficient co-extraction of coal and gas. Meanwhile, combined with engineering practice, we put forward the construction principle of coal exploitation and gas drainage system in different coal seam occurrence conditions. The above methods were applied successfully in the Tunlan coalmine in Shanxi Province and the Panyi coalmine in Anhui Province, which had established the ‘underground-surface united’ spatial gas drainage modes, and could ensure safe and efficient co-extraction of coal and gas in the outburst coalmines.CITATION:Cheng, Y-P, Wang, L, Liu, H-Y, Kong, S-L, Yang, Q-L, Zhu, J-T and Tu, Q-Y, 2015. Theory of safe and efficient co-extraction of coal and gas and its applications, in Proceedings The Australian Mine Ventilation Conference, pp 79–92 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 31, 2015

By Y Peng, C Burns, Y Mu, R A. Lauten

In both laboratory flotation experiments and from analysing the composition of the lead concentrate at the Boliden Tara lead-zinc mine in Ireland, it has been found that F-250 may replace cyanide as a pyrite depressant. Replacement or reduction of the cyanide consumption is highly desirable from a safety perspective given the toxicity of cyanide. Scrutiny of results from the plant trial indicate that F-250 is less efficient as a cyanide depressant when the flotation feed contains high levels of pyrite. Statistical analysis of the results does not capture this trend, illustrating a need to collect more data at higher pyrite ore levels. A recent model proposed for biopolymer-induced pyrite depression is reviewed and discussed next to the suggested mechanism for pyrite depression via cyanide. Review of the interactions causing pyrite depression point to different manners in achieving depression. In light of the less efficient F-250 pyrite depression at high pyrite levels, it is speculated if the two depressants may act synergistically at high levels of pyrite in the feed. CITATION:Lauten, R A, Burns, C, Mu, Y and Peng, Y, 2018. Pyrite depression at Boliden Tara using F-250 – a biopolymer, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 385–392 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

Throughout the study phases (scoping, prefeasibility and feasibility) of new mining projects one is forced to work with and make predictions based upon limited date obtained from diamond and reverse circulation drill holes. These data are extrapolated to determine how much of the valuable metal is present in the ground, how it can be recovered it and the efficiency of this recovery. Mining methods to extract the ore are investigated with forecasts made regarding excavation stoping stability and performance in an attempt to optimise production. Extraction and use of rock mass data for use in characterising the mechanical behaviour of the rock mass is no exception. One often relies heavily upon the use of empirical charts developed over many years on hundreds of case histories based upon rock mass characterisation schemes. This is largely successful and indicative of what one might expect. However specific site characteristics can always play a significant role, and are not necessarily apparent in diamond drill core. Feasibility studies for the Favona orebodies indicated that the rock mass was generally poor to extremely poor, and that stoping conditions would be difficult in all of the orebodies for various reasons. A range stope performances were achieved ranging from very good to very poor and in some cases unexpected results were achieved. A comparison is made between what was actually achieved and what was expected since stoping commenced in 2007. Explanations are attempted for differences in stoping performance and, in some cases, unexpected results at the Favona underground mine are attempted.

Nov 25, 2010

By R Crosbie, K C. Runge, E Tabosa, J K. McMaster

Flotation feed density is an operating parameter which is currently not well understood. Most models of flotation only incorporate its effect on particle residence time, but it is likely to have additional effects within both the pulp and froth phases of the machine. Test work was performed in MetsoÆs 3 m3 RCS test rig to investigate the effect of flotation feed density on metallurgical performance. The rig was operated at Rio TintoÆs Northparkes operation using flotation feed and scavenger tail. For each feed, tests were performed at different feed densities, and measurements were performed to estimate the pulp and froth recovery as well as other key flotation parameters (eg bubble size, turbulence and froth stability). Results of this test work have shown that the pulp density does affect key parameters of the flotation process in both the pulp and froth phases. Pulp phase kinetic rates decrease at high density and this is attributed to a reduction in the turbulence within the cell. Froth phase recovery, however, improves presumably because of a stabilising effect due to a greater loading of solids on bubble surfaces.There is a need for more research to be done to better understand these interactions so that metallurgists can determine the optimum flotation feed density to use at a particular operation, or within a section of a flotation circuit.CITATION:Runge, K C, Tabosa, E, Crosbie, R and McMaster, J K, 2012. Effect of flotation feed density on the operation of a flotation cell, in Proceedings 11th AusIMM Mill OperatorsÆ Conference, pp 171-178 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Oct 29, 2012

By Hale C. T, Carnie W. A

Rosebery mine has had over 100 years of mining activity. The reserve has remained static for the last eight years with an expected mine life of six years. A move to rectify this was made in 1994 with the birth of the Deep Exploration Project (DEP). $45 M was committed to drill 100 km of underground exploration diamond drilling and develop 5.5 kin of decline aiming to add 9.5 Mt to the reserves and minimise lead time for development of P and K lenses discovered in the early-1990s. In 1996 this aim was expanded with the objective to build the resource base to 20 Mt by June 2000 allowing the mill to operate at 1.0 Mtpa (0.9 Mt from underground). Preliminary results of the project to-date are outlined and exploration diamond drilling techniques and strategies are described.

Jan 1, 1997

By Morley I. W

In the year 1926, Edie Creek, in the Morobe District of the Mandated Territory of New Guinea, saw the greatest gold rush of recent years. Situated 35 miles inland from the coast, and at an altitude of over 6000 feet, Edie Creek presented to the original prospectors a wet, jungle-clad uninhabited, and inhospitable region. There were no roads; and the only means of approach from the equally inhospitable coast was by an eight to ten days' tramp through coastal swamps and gorge-scarred mountains. All food supplies and equipment had to be carried on the backs of "kanakas," and in many cases through country occupied by hostile natives.Since the first discovery of payable gold at Edie Creek, mining on the Morobe Goldfield has shown remarkable progress, and in spite of the tremendous natural difficulties, the field today ranks as one of the most important in Australasia.Aeroplanes, more than any other factor, have been responsible for this rapid development. They provide the only means of transport from the coast, and at present serve the needs of over 600 Europeans and 3000 indentured native labourers engaged in the industry.

Jan 1, 1933

The reasons for and the methods of inte- gration of the gold treatment plant with the existing nickel concentrator are discussed. The integration was accomplished in three stages commencing in May 1980 and attain- ing current throughput in December 1982. The problems encountered and their solution, including the design and construction of a new tailings dam are also discussed.

Jan 1, 1984

By D Craw, P V. Angus

Gold mineralisation at Macraes occurs as late quartz-carbonate veins within a body of sheared and hydrothermally altered Otago Schist, the Intrashear Schist. The alteration is characterised by the presence of rutile and the absence of epidote and titanite, indicative of an alteration fluid containing >10 mol per cent CO2. In areas of high strain, a fabric of black microshears develops, gradational to mylonitic cataclasite in the high strain zone adjacent to the hanging wall of the duplex shear zone. The microshears contain hydrothermal graphite, inferred to have been deposited from a methane-rich fluid. The mylonitic cataclasite is characterised by abundant pyrite, the absence of albite and extreme grain size reduction. Gold recovery in the CIL processing plant at Macraes can drop to 50 per cent or lower for some unfavourable ore types. Preg-robbing by a component in the ore, possibly graphite, was suspected as the cause. Mylonitic cataclasite was identified as the lithology responsible for the poor recoveries, with the capacity to bind about 30 ppm of gold in the leach tanks. A program of detailed geochemistry and quantitative grain-size measurement using Coulter analysis was undertaken to identify specific mineralogical factors associated with preg-robbing. The results indicate that pyrite, graphite, and extreme grain-size reduction are the factors associated with highly preg-robbing ores at Macraes. The evolution of the mylonitic cataclasite is accompanied by strong potassium enrichment, as muscovite, and depletion in sodium as albite is removed. This suggests that a simple powder XRD ratio of the albite to illite peaks would suffice to distinguish the preg-robbing ore for grade-control purposes.

Jan 1, 1999

By W Curlewis, D Hake, Z Cuthbert

The South Island Line (East) will be a medium-capacity railway covering approximately 7 km from Admiralty Station to South Horizons Station on the south side of Aberdeen Harbour in Hong Kong, with intermediate stations at Ocean Park, Wong Chuk Hang and Lei Tung.South Island Line (East) Contract 904 project is located on the island of Ap Lei Chau at the southern side of Hong Kong island and requires extensive construction works to be completed in close proximity to the existing residential estates of South Horizons and Lei Tung. The project also has areas of significant cultural heritage, including 18th and 19th century temples and historical gravesites. Owing to the site access constraints and location for the project, detailed planning and methodology innovations have been required to ensure the most effective and responsible means of delivering the project works. To excavate the tunnels using drill-and-blast techniques in these restricted locations, the maximum instantaneous charge weight that could be fired while blasting was severely limited. To overcome these restrictions, the project team developed and pioneered the use of ‘deck loading’ in Hong Kong to minimise the impact of blasting operations and has successfully implemented double- and triple-deck blasting operations during the completion of tunnel excavation works.Upon completion of the drill-and-blast excavation, the tunnel lining works were completed using both in situ concrete lining with travelling forms and permanent shotcrete works.CITATION:Curlewis, W, Cuthbert, Z and Hake, D, 2014. SIL904 Hong Kong – Drill and Blast Tunnels, station blasting innovations (double- and triple-deck blasting) and lining solutions, in Proceedings 15th Australasian Tunnelling Conference 2014 , pp 21–28 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 17, 2014

By T D. H McGrath, J P. Vaughan, J Heath, J J. Eksteen

A reliable laboratory method to characterise the response of free gold particles when subjected to flash flotation conditions has been developed by AMIRA P420 researchers at Curtin University. This test has been applied to assess the flotation recovery of gravity recoverable gold from free milling ores as well as synthetic ores featuring either a gravity concentrate or gold powder. Trends in free gold flotation kinetics as well as size and milling effects were identified for gold recovery, based on the different gold types, reagent dosage and residence time.CITATION:McGrath, T D H, Eksteen, J J, Vaughan, J P and Heath, J, 2013. Laboratory flash flotation trends for a variety of gold particles, in Proceedings World Gold 2013 , pp 357-366 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 26, 2013

The Golden Cross is the first large precious metals mine to be both commissioned and closed in the æmodernÆ era in New Zealand. This paper discusses the life cycle of the Golden Cross mine, with emphasis on the closure process and post closure management.   The closure process has generally been very well managed, and successful, but in spite of that some on-going issues remain unresolved. Nearly nine years after the end of mining the mine owners are still actively managing the site, with no immediate end to that in sight.   The site has been described as atypical, due to the identification of a deep seated landslide below the tailings and waste rock storage facilities. However that should not be given too much emphasis when addressing the overall closure and post-closure management issues, which could well apply to other existing and future mine sites in New Zealand.   The Golden Cross can provide valuable lessons for other miners, and the issues arising at this site should be watched closely by the industry as a whole.

Jan 1, 2006

By M Rafty, A Markham, S Atkinson

Australia contains some of the most productive mining areas and is characterised by ancient landscapes and highly variable hydrology. Historical mining of iron ore, coal and other minerals has targeted ore deposits located above water tables, and elevated above creek lines where possible to reduce cost. The downturn in mining caused by falling ore prices over recent years has triggered a drive to reduce cost, maximise yield and delay capital expenditure associated with opening new mines. So as the ore deposits with more favorable mining conditions become depleted there is an increased focus on mining ore associated with valley floors and creek lines. This is demonstrated by a regional assessment of the extent of Channel Iron Deposits (CID) and Iron Ore (Fe) Mines and Deposits in the Pilbara Region of Western Australia (Figure 1). A large proportion of these mines are, or plan to, target high grade CID ore associated with existing creek systems. Figure 2 shows outcropping and inferred sub-cropping CID extents, which suggests there are vast quantities of CID ore deposits throughout the Pilbara Region, intersected by major creeks which could be mined at some point in the future using creek diversions (Atkinson et al., 2017). A similar picture could also be produced for coal mining in Queensland, particularly in areas such as the Bowen Basin.While creek diversions provide an opportunity to maximise the utilisation of these orebodies and extend the life of mine, creek diversions can involve substantial financial, social, environmental and regulatory risks that need to be carefully managed (Markham et al., 2017, Atkinson et al., 2017). This paper discusses the key issues and opportunities associated with diversion decision making. It highlights the importance of using a well-structured assessment methodology that allows key stakeholders to be part of the assessment process and is complementary to material presented in Atkinson et al., (2017). Design considerations for operational and closure designs are presented, as well as mine planning considerations, risks, cost saving opportunities and the benefits of an integrated approach to design. The role technology plays in diversion design and performance monitoring is discussed as are the potential opportunities for the future.CITATION:Atkinson, S, Markham, A and Rafty, M, 2018. Diversion decision making with an integrated approach to design for operations and mine closure, in Proceedings Life-of-Mine 2018, pp 74–79 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 25, 2018

By M Sandy, P Bamford

The Challenger Gold deposit was discovered in 1995 by Dominion Mining Ltd in a remote western area of the Gawler Craton in South Australia. Mine development commenced in 2002 with initial production from an open pit supplemented by ore from a very small adjacent auxiliary pit. Development of the underground mine commenced in 2004. The orebody plunge of just less than 30 degrees requires careful attention to mine design. Production from the M1 orebody, with less than 800 ounces per vertical metre (ovm) and very limited æsurgeÆ capacity, requires careful scheduling and implementation to ensure continuity of ore feed for milling. Initial production results from underground stopes included more dilution than anticipated. The narrow, high-grade zones proved to have much more complex geometry than early interpretations had indicated. Greatly improved understanding of the mineralisation controls resulted in important changes being made to the underground mine design and method. Coupled with careful control of development and drilling and blasting practices, this resulted in an immediate reduction in dilution and high recoveries of the resource. The benefits of these changes flowed through in the 2005/06 financial year, resulting in a 150 per cent increase in gold production to 108 080 oz and a sharp reduction in cash operating costs to A$280/oz. This was followed in 2006/07 with production of 108 91 oz of gold at an operating cost of $309/oz and in 2007/08 with 109 326 oz of gold at $367/oz. Production to June 2008 has been mainly from the M1 orebody, with the lowest stoping to date on the 580 m Level (615 m below surface) above development mining on the 520 Level. The rate of vertical advance of mining this orebody has averaged 150 vertical metres per year. The increased current combined JORC compliant resource and reserve position of over one million ounces, now includes the M2 and M3 orebodies with a current total average gold inventory up to 1400 - 1500 ovm. Exploration has intersected other shoots and all shoots are open at depth. The adjacent M2 and M3 orebodies are being developed for stoping. The narrow width of these zones from 1 m up to 4 m will require continued focus on ore zone definition, accurate development and careful drill and blast practice. In addition, to minimise cost increases in the current period of rapidly escalating labour, equipment, consumables and energy costs, high productivities will need to be maintained to allow the established rapid mining advance to continue at low unit costs.

Jan 1, 2008

By B L. Coulter, E Wightman, A S. Burrows

With their commitment to sustainable development in an increasingly carbon-constrained world, many resources companies are focused on reducing the energy required to create their final products. In particular, the comminution and smelting of metal-bearing ores are both highly energy-intensive processes. If resource companies can optimise the energy efficiency across these two processing stages, they can directly reduce their overall energy consumption per unit mass of metal produced and thus reduce their greenhouse gas footprint. Traditional grinding and flotation models seek to improve the efficiency of mineral processing, but they do not consider the energy used by downstream metal production, eg smelting and refining. Concentrators and smelters individually may be running efficiently, but are they optimising energy consumption of the overall system? A key step towards answering this question is to understand whether it takes less energy to remove an impurity in the concentrator or the smelter. Analysis of the complete concentrator û smelter process chain may show that there are times when the concentrator should use more energy to reduce the overall energy requirements across the mill and smelter. The new methodology discussed here will integrate downstream processing energy with mineral processing energy, to find the overall most energy efficient circuit design and operating strategy. The proposed methodology includes: determining what grade and recovery positions can be achieved in the concentrator by using different combinations and amounts of grinding and regrinding, thermodynamic calculations of the energy used to process the different concentrate grades to metal, and integrating the concentrating and smelting models to find the lowest total energy for the system. A case study which investigates the effect of increasing regrinding energy on the overall mineral processing û smelting energy consumption is presented. For the copper-nickel sulfide ore investigated the addition of regrinding results in 11 per cent less energy being used in the overall concentrator û smelter process chain per tonne of metal produced. Although regrinding is often seen as an energy-intensive process, in this case study the use of 1 kWh of energy for regrinding reduces the overall energy consumption by 12 kWh. The new mill to melt methodology will allow companies to model energy consumption from mill to smelter with a view to reducing the energy-intensity and greenhouse gas footprint of their processing and smelting operations.

Jan 1, 2009

By S S Solomons

In 1991 the uranium spot market price dropped to approximately US$7/Ib U308, a historical low in real terms and the short-term outlook for the industry in the next five years was grim. At this time the Ranger operation was producing uranium concentrate at its design capacity of approximately 3 000 tonnes/year. The loss of two major long-term contracts owing to price and reduced power utility demand due to excess inventories meant that the company could not match production to sales. Continuance at this production level would have resulted in a rapid buildup of product inventory and the tie-up of significant cash reserves. After analysing various options, an innovative operating strategy was devised such that production and sales were approximately balanced without a significant impact on the unit production cost or a long term effect on the plant or operation. A campaign mining/milling operation commenced and approximately 40 per cent of the workforce were retrenched. Multi-skilling of all employees was a critical aspect of ensuring a successful outcome. This paper examines the strategy and reports on the success of the operation two years after the restructuring exercise was effected in November 1991.

Jan 1, 1994