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By R Stefansen, T Wisdom, A Nicholson, K Rahal

The challenges of increasingly scarce water resources and the risk of dam failures has seen the mining industry turn to sustainable tailings management solutions such as dewatering and dry stacking. Filtering tailings has been seen in the past as a cost-prohibitive process for larger throughput mines. However, as larger pressure filters are developed, the economic case for filtered tailings has gained traction.Focus has largely been placed on the correct design and operation of the filters. It is critical, however, that the material handling portion of the disposal system is also properly designed and operated. Thorough testing at laboratory and pilot scale to determine the conveying properties of the filtered material needs to be conducted. This testing will insure the material handling system meets the important availability needs of the mine even during periods of variability in the upstream processes and mine plan.The control system must also be robust and flexible in design to compensate for this upstream process variability. The control system needs to allow for different flowsheets including straight filtered tails as well as EcoTails™, a low-energy solution for co-mingling waste rock and filter cake.This paper will present case studies of different material handling solutions, the testing required for them and the lessons learned from each.CITATION:Rahal, K, Nicholson, A, Stefansen, R and Wisdom, T, 2018. Material handling testing and control system requirements for dry stack tailings, in Proceedings Mine Waste and Tailings Stewardship Conference 2018, pp 361–368 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 23, 2018

The key to the successful debt funding of a new mining project, whether in economically established or developing nations, is the submission of a comprehensive feasibility study. The feasibility study forms the basis from which the resource banker can construct financial models which govern the amount of available funds, the conditions which control the supply of such funds and the time period over which the loan may be repaid. The bank will wish to ensure that the feasibility study is the best representation and confirmation of reality possible because this model is the basis of the loan security package. Thus the study will be vigorously interrogated by independent experts in all its elements including the ore reserve, mineability, metallurgy, operating and capital cost profile, environmental factors and management.

Jan 1, 1995

By M Ozkayhan, N Arslan

"The Efemçukuru underground mine in western Turkey is an intermediate sulfidation, epithermal gold deposit. The bulk of the mineral resources and all of the mineral reserves lie within the Kestanebeleni (KB) vein system. This system comprises four spatially-distinct mineralised zones: the south ore shoot (SOS), the middle ore shoot (MOS), the north ore shoot (NOS) and the KB north-west ore shoot. Production currently occurs only in the SOS, MOS and NOS zones. The gold mineralisation is very fine grained and occurs as free grains in quartz and carbonate, and as inclusions in sulfide minerals. Gold is recovered as part of a sulfide concentrate by flotation methods. Though hosted in the KB vein, the gold mineralisation is not evenly distributed within the veins. Definition of its occurrence is totally dependent on diamond drilling.Diamond drilling at Efemçukuru is done with its own equipment and staff, all managed by the mine geology group. The process over the mine’s six year production history incorporates continual improvement with an innovative approach by focusing on the following: drill team organisation career development and training product research and effective equipment management cost reduction planning and scheduling of development for drill stations.Over 40 000 metres of mostly BQ size core are drilled annually by three drill rigs at a cost approaching US$35/m.The planning and execution of the drilling pattern depends on the configuration of the ore shoot and the planned mining method. Ore extraction is mainly by drift and fill mining augmented by about 15 per cent longhole stoping. The drilling of a specific area is scheduled to be finished 3 to 8 months prior to mining. This scheduling is sufficient for short-term grade model updates and any needed changes to the planned development or stope sequencing prior to planned production from the stope area.CITATION:Arslan, N and Ozkayhan, M, 2017. Diamond drilling at Efemçukuru gold mine, Turkey – a case study on the benefits of timely and cost-effective drilling to short-term planning, in Proceedings Tenth International Mining Geology Conference 2017, pp 285–290 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Sep 20, 2017

By S Warden, T Neville, P Leckie

At its simplest, the classification and characterisation of an orebody is a matter of Where, What and When. Where and with what spatial resolution are measurements taken, What properties are measured, and When are the data acquired, processed, and delivered to create the most value. This paper delves into how existing and near-term advances in measurement technologies, field automation, and whole-system-digitisation are combining to open new routes for mine and exploration productivity improvement. Commencing when the initial exploration hole is dug, the advancement in deployment of survey technology—from expert-operated, to driller-operated, to driller-integrated—is used to demonstrate a template for adoption of higher technology measurements. We then introduce and discuss the multi-use measurement as offering outsized returns from a single measurement run, highlighting two new technologies that acquire rock strength while drilling and downhole assay data as examples. For rock strength, we highlight a novel approach to determining Uniaxial Compressive Strength (UCS) while drilling, its relationship to and advantages over Mechanical Specific Energy (MSE), and how it offers utility to multiple downstream processes. For downhole assay, we detail how a back-tophysics approach to Pulsed Fast and Thermal Neutron Activation (PFTNA) analysis offers significant advantages over other measurement methods and earlier implementations of PFTNA, generating a rich data set that can significantly extend and improve the information on which mining decisions are made. Finally, we discuss the possibilities enabled via optimising data delivery, collection, and curation— noting a fundamental limitation of historical systems and exploring the possibilities that will be unlocked by soon-to-market solutions that better enable Orebody Characterisation data to (virtually) move in space and time with rock material post-blasting. Ultimately, the value of optimising the Where, What, and When from point of measurement to the moment it generates maximum value will create greater life-of-asset production for a lower cost and energy input.

Sep 1, 2024

By J Jasper, L Koroznikova, J Begelhole

This paper outlines a comparison of heavy liquid and heavy suspension separation methods for iron ore characterisation.As part of Arrium MiningÆs program to improve its knowledge of ore types being processed in its two hematite ore beneficiation plants (OBP), metallurgical evaluation of hematite feed for the upgrading process has become a major focus.Iron ore deposits almost always contain more than one valuable (and relatively dense) iron mineral. Iron ores are found with a range of iron contents, giving rise to density variations.At present the industry relies on heavy liquid separation techniques for the evaluation of iron ore samples arising from exploration, mining or metallurgical processes. There are only a few high-density liquids available, which are both high-cost and highly toxic.Low-toxicity solutions that can be utilised at relative densities up to 3.0 have been developed. However, highly-toxic organic liquids are required presently to achieve relative densities beyond 3.0.Bromoform which has a specific gravity (SG) of 2.89, and diiodomethane (SG 3.31) are commonly used; both present significant health and safety hazards.æClericiÆs solutionÆ (mixtures of thallium formate and thallium malonate) provide liquids having specific gravities between 4.0 and 5.0. ClericiÆs solution is highly toxic and testing is currently conducted by a limited number of laboratories worldwide.An alternative to ClericiÆs solution and organic liquids is a low-toxicity, high-SG, suspension technique, which has been demonstrated successfully for heavy mineral sands. This heavy suspension method employs mixtures of fine tungsten carbide particles in lithium heteropolytungstate (LST) solutions.Heavy liquid separation is not commonly used as part of routine iron ore feed characterisation due to the expensive, toxic and time consuming nature of the technique. Our results show that the heavy suspensions method can achieve low-cost, low-toxic separation and are outlined and results compared with results using ClericiÆs solution presented.Heavy suspension technique provides a theoretical/absolute separation of a particular sample. By placing an iron ore sample in a suspension of a particular density, it produces two products: a sink fraction and a float fraction. As iron oxides-hydroxyoxides are denser than the gangue minerals associated with the ore, particles that have high iron content will sink and the particles with gangue association will float. This process is repeated over several densities, thus also enabling separation of the constituent iron ore phases. A theoretical grade and a theoretical mass recovery can be calculated. With these calculations, a grade-mass recovery curve can be constructed for any element that is of interest.This type of characterisation can be used to either prepare OBP feed-piles of known processing characteristics, or to benchmark the performance of the process against what can be theoretically achieved on a continuous basis.CITATION:Begelhole, J, Jasper, J and Koroznikova, L, 2013. Application of the heavy suspension technique for ore beneficiation plant feed characterisation from the Southern Middleback Ranges, in Proceedings The Second AusIMM International Geometallurgy Conference (GeoMet) 2013 , pp 269-278 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 29, 2013

By Donchak PJ, Lang SC, Hammond RL, Bultitude RJ

The Hodgkinson and Broken River Provinces form the northern part of the Tasman Orogen. They are separated by a broad belt of Late Palaeozoic igneous rocks, but were probably originally continuous. They are bounded to the west by a system of major faults (Fig. 1) which separate them from the Georgetown Province. Although largely Precambrian, the Georgetown Province includes probable Siluro- Devonian granitoids, and in the south adjacent to the Broken River Province, metamorphosed Early Palaeozoic(?) volcanics and sediments of the Greenvale Subprovince. South of the Broken River Province, the Lolworth-Ravenswood Province includes probable Precambrian rocks, Cambro-Ordovician volcanics and sediments, and voluminous Ordovician to Early Devonian granitoids. The first systematic studies of the provinces were the 1:250 000 scale mapping programs by the Bureau of Mineral Resources and Geological Survey of Queensland (White, 1965; de Keyser and Lucas, 1968). These and subsequent regional studies were reviewed by Arnold and Fawckner (1980). Remapping by the Geological Survey of Queensland since 1982, and a concurrent regional study of the deformation by Hammond (1986) have provided much new data. We acknowledge the contribution of other members of the GSQ field parties - L. Cranfield, J. Domagala, B.G. Fordham, P. Green, R. Halfpenny, R. Hegarty, L. Hutton, S. Law, D. Macansh, T. McLennan and M. Scott.

Jan 1, 1987

By D R. Seaman, R P. Tooher, B A. Seaman

"Several mine scheduling tools exist for use in optimising and scheduling the reserve according to in situ value. These tools generally value the ore on a per block basis according to regressed recovery models based on ore grade and type. It is then the task of the plant metallurgist to ensure that these ore blocks are fed to the plant in a manner that satisfies the prevailing plant constraints. This task is often completed in complex Excel® spreadsheets that are modified over time with factors applied to account for plant modifications or limitations.It is the authors’ experience that this approach is difficult to audit and replicate in a consistent manner. Furthermore, operational decisions, such as primary grind size or autoclave oxidation are made on the metallurgist or managements’ perceived optimum value and does not necessarily represent a cash flow based optimum.Many processing plants contain multiple internal constraints. As ore feed grades and properties change over the life-of-mine (LOM), processing-bottlenecks shift from one unit process to another and different operating strategies need to be adopted to maximise cash generation from the process.This paper presents a unified optimisation approach to scheduling ore based on a circuit mass balance to describe the process plant with individual models for each significant unit operation. The approach allows for optimisation over multiple input variables and the inclusion of linear and non-linear constraints.This optimisation process has been applied to different complex gold operations. The end result is an automated scheduler that selects the optimum blend of ores as well as plant operating conditions that satisfy all internal plant and shutdown constraints while maximising the objective of choice (metal production or cash flow). The models are also valuable for evaluating expansion or debottlenecking opportunities of individual processing units. These models are coded in Matlab® R2016a provided by MathWorks®, and can be deployed to end users in a compiled version with significant savings in time to run different scenarios over the Excel®-based systems.Citation:Seaman, D R, Tooher, R P and Seaman, B A, 2016. Optimisation of Complex Gold Processing Plants with Multiple Unit Operation Constraints - the Newcrest Planning Scheduler, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 191–198 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By Canterford J. H, Bologiannis F, Smith A. N

The Mutooroo copper mine is one of a number of deposits that have been evaluated by Adelaide and Wallaroo Fertilizers Ltd as a source of feed for the production of high- purity copper oxide at their Burra plant. For this deposit, the technique of solution mining or in-situ leaching appeared ideal. The Mutooroo production circuit and the results of the process optimization and environmental monitoring programmes are outlined. At the end of the experimental period described here, the production liquor typically contained I g/litre copper, yield- ing in excess of 5 t/month of cement product containing about 80 per cent copper. The environmental monitoring programme provided clear evidence that there had been no un- acceptable alteration to the properties of the groundwater in the country rock surround- ing the mineralized zone. It is anticipated that the experience gained at Mutooroo will be of considerable help in the development of other solution mining operations.

Jan 1, 1983

By Y Li, D J. Williams, E Topal

A mine waste rock dump does not have any intrinsic value, yet is an inevitable structure in surface mining operations. Since the purpose of mining is to maximise profit, possible expenditure reduction in hauling waste rock to the dump, which can represent up to 50 per cent of the total operating cost, is highly desirable. Apart from cost, potential acid mine drainage (AMD), due to seepage from surface waste rock dumps containing reactive waste rock, could threaten the ecological balance, drinking water supplies and irrigation systems downstream from a mine site. In order to minimise these potential risks, selective placement of benign and reactive waste rock, and the encapsulation of reactive waste rock by benign waste rock, need to be carried out during the construction of the rock dump.In this paper, a new methodology, based on mixed integer programming (MIP) is developed to manage waste rock dumping. The model aims to minimise waste rock haulage costs by locating the optimum destination(s) for each waste rock block, while at the same time controlling the placement of reactive waste rock to minimise the potential for AMD. Tests on small-scale virtual data demonstrated that the model is capable of dealing with selective placement of different waste rock types, encapsulating reactive, potentially acid forming (PAF) waste rock, and stockpiling benign waste rock for encapsulation and rehabilitation purposes. The solution time for the MIP model is far less than the traditional manual approach, and the resulting schedule is up to 46 per cent more cost effective.CITATION:Li, Y, Topal, E and Williams, D J, 2012. Mathematical approach for better mine waste rock dumping management, in Proceedings Life-of-Mine 2012 , pp 207-214 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 10, 2012

By J Rutter, J du Plessis, er, M Scott, D Alex

It is generally acknowledged that bulk ore sorting is an attractive prospect for the mining industry. However, uncertainties relating to the operational performance of sensor technologies, the grade heterogeneity present in analysed material and the physical separation performance of the coupled system complicate the evaluation and deployment of bulk ore sorting strategies at operations. To assist in the quantification of these uncertainties, the Cooperative Research Centre for Optimising Resource Extraction (CRC ORE) and Anglo American have implemented a systematic methodology to evaluate the deployment of sensor technologies for bulk ore sorting. This methodology was implemented at a bulk ore sorting demonstration plant using penetrative prompt gamma neutron activation analysis (PGNAA) and surface x-ray fluorescence (XRF) measurements of base metals, as a proxy for precious metals, at Mogalakwena PGE Mine. The methodology comprises of three phases. The initial phase involves the preliminary investigation of sensor technologies and analysis to reduce identified risks prior to commissioning of the bulk ore sorting plant. The second phase executes a series of experiments to prove the sensing technologies in the operational environment and provide confidence the sensors can drive separation. The final phase demonstrates the production scale bulk ore sorting performance of the plant and validates its performance by campaign of the sorted products at the processing plant. Throughout the operational deployment and evaluation of bulk ore sorting at Mogalakwena, several key lessons were learned. These learnings relate to the calibration requirements of the sensor technologies, the application of surface vs penetrative sensor techniques and the preservation of grade heterogeneity delivered to the sensors. This paper presents the methodology used, and lessons learned, in the operational deployment and evaluation of PGNAA and XRF sensors for bulk ore sorting at Mogalakwena PGE Mine.

Nov 10, 2020

In recent years, the. art of electric steelmaking has received a great deal of attention, and naturally, much controversy has existed from time to time regarding the relative merits of different practices and tywes of furnaces. Nevertheless, at the present time, the basic principles of the process are reasonably well established, and by far the greatest percentage of electric steel is a product of the basic lined, direct arc type furnace. Ferro alloy manufacture has demanded the development of furnaces having very different characteristics to those used for steel. Some special alloys, however, require conditions of manufacture which are more closely approached in the steel type furnace, and thus the latter has been adapted where necessary for the production of these alloys.One such alloy, low carbon ferro-manganese, is manufactured at Whyalla, South Australia, in a basic-lined, direct arc furnace, which is used alternatively for the production of alloy steels.BRIEF HISTORY OF THE ELECTRIC FURNACEThe principle of melting by electricity was first applied to the melting of iron in 1879 by William von Siemens, whose equipment consisted of a small crucible into which were introduced two carbon electrodes. Very little practical development took place in the next 20 years, although in 1890 a Frenchman named Heroult designed a direct arc furnace for the production of ferro alloys. At the beginning of the 20th century, several types of furnaces were patented for steel melting, the most important of these being the Heroult, using a direct arc, the...

Jan 1, 1951

Since 1958 there have been 16 major coal mine explosions in the U.S. claiming 323 lives. Whilst the exact cause of a number of these incidents has not been determined, the majority has involved gas ignitions in one way or another. In addition there have been fatal gas explosions in salt mines and vapor explosions in oil mines. Furthermore, many of the oil shale mines in the U.S. have proven to be gassy giving cause for concern. Compounding these problems is the fact that frictional ignition of methane in coal mines has dramatically increased over the past several years; over 100 such ignitions were reported in 1979. While, no fatalities have been attributed to frictional ignition in the U.S. since early 1978, a recent mine explosion in Nova Scotia which resulted in 11 fatalities was attributed to a frictional face ignition. Research being conducted at the Bureau of Mines is aimed at the prevention and suppression of gas explosions. Emphasis is placed on new coal cutter bits for reducing ignition frequency, machine-mounted water sprays for preventing frictional face ignitions and automatic devices for quenching incipient ignitions and fully developed gas explosions.

Jan 1, 1981

On the 17th November, 1964, a new No., 2 lead blast furnace was blown in at Port Pirie. The furnace departed from previous designs by incorporating a centrally located continuous tapper for both lead bullion and slag. The use of a central tapper permitted a simple and effective layout for the handling of both products. Considerable development was necessary to bring the furnace to its present level of efficiency. Units vital to the continu- ous operation were developed to allow quick replacement, thus ensuring high time efficiency under varied operating and maintenance conditions. The furnace was designed with the following objectives in mind, 1. increased crucible life, 2. elimination of oxygen for slag tapping, 3. higher temperature slag for fuming operations-, 4. less operator skill needed, 5. reduced tapping tool consumption, 6. elimination of settler skull and scrap lead, 7. better control of blast air distributi.nn. And

Jan 1, 1975

The South American mining community leads the world in recognition and adoption of the latest grinding mill relining technologies. Clearly this region has recognised the benefits of improved relining performance as a defence against the Global Economic Crisis. Five of the six RUSSELL TWIN 8 Mill Relining Systems, ordered to date, are either operating or being manufactured for South American mine sites. The sixth is for Sino IronÆs Cape Preston Project in Western Australia. This paradigm shift, towards very short relining times, aims at displacing mill relining activities from the critical path of concentrator maintenance shutdown schedules. The first uses of the RUSSELL TWIN 8 Mill Relining System have seen some of the highest semi-autogenous grinding (SAG) mill new liner placement rates ever observed by Russell Mineral Equipment (RME), as would be expected with two, independent Machines working simultaneously in the one mill. The liner replacement rate, averaged over the whole reline is good (27 per cent improvement over single Machine System in the same mill) but short of full potential. This modest result can be attributed to reline crews unfamiliarity with RUSSELL TWIN 8 System operation. This paper compares a sample of conventional (single machine) RME Mill Relining System performance data with one ædouble headÆ mill liner handler by others. Early performance of EscondidaÆs new RUSSELL TWIN 8 System performance is then compared with recent single machine data from Escondida, immediately prior to RUSSELL TWIN 8 commissioning. RME and Escondida look to constantly improving RUSSELL TWIN 8 System performance as full operational familiarity is achieved. The preparation of this paper revealed a need to develop a global industry standard for mill relining data collection. A web based platform to develop data collection templates is also discussed in Appendix 1.

Jan 1, 2009

By D McCoy

Titanium feedstocks are the building blocks of the titanium value chain. They can be mined directly, as is the case for ilmenite, leucoxene and rutile, or manufactured from ilmenite by extracting various quantities of non-TiO2 components from the ore by chemical and/or thermal processes.While feedstocks can be grouped into categories of materials with similar characteristics, they are essentially unique products from very different mining locations around the world. In fact, no two feedstocks are exactly the same. As such, the variations between the available feedstocks, in combination with the permutations in processing technologies to turn the feedstocks into titanium pigment or metal, mean that choices between feedstocks are specific to the location in which they are utilised.In this paper, the authors examine the key requirements of titanium feedstocks to the TiO2 pigment and metal sectors. Apart from the well known differences between feedstock choices for the sulfate and chloride process, the more opaque considerations in feedstock sourcing are examined.

Oct 5, 2011

By P Ramsaywok

The use of saline water for mineral beneficiation in arid regions is general practice and also the case with Exxaro Namakwa Sands, situated on the west coast of South Africa. Although it is ‘cost effective’ to use sea water for mineral beneficiation, downstream process separation efficiencies may be negatively affected. This is more specific to surface dependent separation techniques such as electrostatic and high tension (HT) separation. If minimal fresh water is available then, proper washing is often neglected. Salt crystals can form on particle surfaces during the drying process before electrostatic separation.This paper describes a study that has been conducted to determine the effect of upfront salt water processing on downstream electrostatic/HT separation. The study indicated that minor quantities of salt can cause the separation efficiency to decrease substantially.

Oct 5, 2011

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 Fitzpatrick JM

The feed preparation section of the Whyalla iron ore pellet plant includes a screening and crushing plant followed by dry grinding mills. Improvements in the efficiency of the vibrating screen and cone crusher have enabled screening plant throughput to be increased and product size to be decreased. This, in turn, has enabled improvements in the grinding mills' operation.

Jan 1, 1978

By T Soares, P Esteves, C Senna, V Souto, E Dias

Steinert provides a wide portfolio of Sensor Based Sorting (SBS) technologies, including the possibility to combine different sensor data in the development of the separation applications. This multi sensor approach provides a larger applicability and extensive flexibility for the technology. This effect is emphasized for mining applications, once every ore body presents its own features that can also comprise a large material variability. In this sense, every sorting application is customized and comprises a personalized solution. This means each project development includes a test work stage that approaches from the project discussion, test definition, up to test outcomes and processing development. In relation to very complex and large projects, a sorting pilot scale plant has become a crescent tendency. By having a pilot plant stage can represent a chance to test larger amounts of material from different mining areas, different mining projects, such as to consider different processing targets and application approaches. Based on that, a better understanding about the technology application can guide a more assertive development of large and complex ore sorting projects. The aim of this paper is to provide information about the applicability of the Steinert multi sensor technology at different pilot plants in South America. It consists in a compilation of laboratory test results, plant design and operational results. For that, a chromite, an IOCG deposit and a sulphide gold ore projects are presented. Additionally, the paper discusses the application of different sensor technologies combinations such as various processing targets, thus providing a wider understanding about sorting applications and flexibility.

Nov 10, 2020

This report on the 5th International Conference on Underground Space and Earth Sheltered Structures, which was held at the University of Technology, Delft, the Netherlands, on 2 to 5 August 1992, was submitted to the members of the Australian Underground Construction and Tunnelling Association. The report describes the conference themes and outcomes and puts forward some observations about a growing world-wide interest in the promotion of appropriate uses of underground space. The report recommends the creation of an Australian centre for research to bring together a wide range of professional disciplines and to focus attention on the potential benefits of using underground space.

Jan 1, 1993