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By S Nowosad, A Binder, O Langefeld, M Bothe-Fiekert, F Apollo

The mining industry faces complex and urgent challenges driven by an increasing demand for raw materials, and a socially demanding globalised world. The extraction of primary raw materials is today more important than ever as one of the cornerstones towards a sustainable future since the increasing demand for the raw materials required for the energy transition. In the last three years, leading countries as USA, China, Canada, Australia, and the European Union (EU) have developed and adopted strategies to enhance domestic extraction capabilities, diversifying sources, fostering innovation in recycling, and promoting international collaboration related to critical raw materials. On 2022, the Inflation Reduction Act was signed into law in the USA, in June 2023, the Australian Critical Minerals Strategy 2023–2030 was published and in March 2024, the Council of the EU adopted the European Critical Raw Materials Act. On the other hand, raw materials extraction is facing higher environmental and safety standards and regulations, as well as scrutiny from the broader public. Regrettable environmental accidents as tailing dam failures or acid mine drainage occurrences have led to a general distrust of mining activities leaving mining companies with the dual imperative of increasing output while implementing sustainability, decarbonisation, and circularity as a core value in their production processes. This challenging environment offers the opportunity to enhance ‘blue mining’ (BM) as a sustainable holistic approach that integrates the principles needed to plan sustainable, reliable, and responsible mines for today’s and future generations by implementing the principles of circular economy (CE). This requires a fundamental shift from the traditional linear economy approach to a sustainable, circular economy strategy. At its essence, BM encapsulates four crucial aspects – energy, ergonomics, water, and circularity and integrates these four aspects into integrative mine planning, defining clear goals and objectives from the ‘blueprint’ of a mine towards a beneficial post-mining activity. Its implementation can lead to maximisation of resources beyond the life of the extractive mine and sustainable use of materials by integrating the principles of circular economy and multiuse mine, see Figure 1. These concepts complement and recognise the need to minimise environmental and social impacts while advancing economic development. Finally, this contribution explains the requirements and challenges of moving from linear to dynamic planning approaches under the BM concept. This way, BM stands as an approach that can contribute to the mining industry receiving necessary approvals and support from society leading to a long-term transformation of the industry’s image.

Sep 1, 2024

By D A. Cuello, G B. Sharrock

The Prince Lyell orebody at Mount Lyell Mine has a rich mining history commencing with the open pit in 1935, which transitioned underground in 1972. Between 1972 and 2014 a total of 64 Mt was mined underground as the mine extended from 210 m to 1100 m below surface. As the depth increased, three separate transitions in the mining method occurred to meet the changing geotechnical conditions, ore grade, mining costs and metal prices. The first was open stoping with pillar recovery in 1972, followed by front caving and longitudinal sublevel caving (1995), and finally transverse sublevel caving (2004 to 2014). This paper provides an overview of key geotechnical and planning milestones relating to the evolution of the mining method including underground stability, gravity flow, cavability and subsidence. Key aspects of the mine design, geotechnical parameters and rock mass response are described and critiqued with reference to observational, numerical and empirical methods.CITATION:Sharrock, G B and Cuello, D A, 2016. Geotechnical milestones at Mount Lyell Mine, in Proceedings Seventh International Conference and Exhibition on Mass Mining (MassMin 2016), pp 427–438 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2016

By J Wall

The use of electronic detonators in civil tunnelling applications, to reduce vibration in small firings has been successfully utilised for a number of years. As part of the mining industry’s commitment to reducing blast damage during the development cycle in underground mining applications, a series of development blasts using e-Dev™ electronic detonators in a typical mining application was conducted at Resolute’s Mt Wright operations in North Queensland in 2010. Results were based on direct comparisons to the current industry standard of non-electric firings as a baseline, with as many parameters as possible being captured during the trial. Development costs are typically high in most underground mines, especially in capital development headings, which are in waste and therefore of no direct economic value, so by being able to accurately fire to design, costs relating to both ground support requirements and volume of material removed, (and therefore haulage required) can be minimised. A direct comparison of overbreak (ground blasted outside of design) and cast (distance rock thrown from blast) was also made during the trial, as well as close monitoring of the drilling accuracy.

Mar 21, 2011

By Moorrees C, Everson P

A detailed examination of carbonic acid leaching of crude iron-containing magnesia derived from Savage River magnesite shows that the rate and extent of magnesium and iron dissolution are affected by the slake time, leaching temperature, carbon dioxide pressure, pulp density and rate of agitation. In order to produce high-purity magnesia from the leachate by precipitation and calcination, the optimum leaching conditions, which are those that yield maximum magnesium and minimum iron dissolution, have to be a compromise in terms of the above parameters. For example, iron dissolution can be limited by leaching at an elevated temperature (-45°C), but because the maximum concentration of magnesium biearbonate decreases rapidly with an increase in temperature, it is necessary to use a low pulp density (-2 per cent solids) in order to achieve an acceptable degree of magnesium dissolution.Evidence is obtained that iron dissolution involves the formation of a soluble ferric bicarbonate complex that decomposes at elevated temperatures. The extent of iron dissolution is much higher than might be expected and it is probably because the original magnesite contains siderite in solid solution with the magnesite; on calcination, the hematite whieh is formed is in a very finely divided condition and hence more reactive.

Jan 1, 1983

East Otago gold deposits are hosted in Otago Schist that is the metamorphosed equivalent of Permian-Triassic Torlesse terrane greywackes. Relatively undeformed Torlesse sequences in Canterbury have <l m - 50 m bedding, with c. 500 m - l km and c. three kilometre scale units, typically either: 1) thick-bedded, massive, sandstones; 2) thin-bedded sandstone-argillite flysch; or 3) siltstone- or argillite-dominated units. Such lithological layering in Otago was intensely folded, deformed, and overprinted by metamorphic fabrics during Jurassic-Cretaceous regional metamorphism. Although primary sedimentary structures can no longer be recognised, a æghostÆ lithological variation is still present in Otago represented by psammitic (sand-derived), interlayered (sandstone-siltstone derived) and pelitic (siltstone-mudstone derived) schist. Lithological æunitsÆ in the schist are typically either 20 100 m or c.1 - 2 km thick, and are oblique to faults and shears hosting gold mineralisation at Macraes, Barewood, Nenthom, and Oturehua. Lithological variations and folds in lithological units are important in the along-strike distribution of gold in these deposits, and in the development of relatively high-grade pods and shoots at l00 m - 1.5 km scales. Ramps, flats and step-overs (known to be locally important for controlling mineralisation) are commonly located at lithological boundaries, presumably by local refraction of faults or shear zones as they propagated through folded stratigraphy. The various lithologies have also responded differently to deformation, causing variations in permeability that affected the penetration of mineralising fluids. Mapping lithological variations in barren host-rocks, either directly+ by fieldwork or indirectly by aerial geophysics, is a key to understanding and predicting the distribution of gold at mine and deposit scales.

Jan 1, 2001

By S Thomson, M Lovitt, T Purvis, C te Kloot, T Nguyen, Z Liu

Ernest Henry Mine (EHM), located in north-western Queensland, is an underground copper/gold sublevel caving operation currently producing over 6 Mt/a of ore. The mass mining method of sublevel caving (SLC) used at EHM involves systematically blasting a series of uphole rings in parallel ore drives and drawing the broken ore using a top-down approach. Each ore drive contains multiple precharged rings to prevent having to charge in close proximity to the brow of the previously fired ring; however, the current initiation system still involves ‘hooking up’ all detonator lead cords of the first precharged ring. The unstable nature of a rill and working close to a brow presents hazards to personnel completing the hook-up process. There is also a business risk of ore loss when damaged ground support completely prevents access to the next precharged ring. If the hook-up step could be eliminated, the risk to personnel and the business would be significantly reduced.EHM engaged Orica Mining Services in 2016 to trial their WebGenTM 100 – wireless electronic blasting system (WEBSTM) for the first time in an underground mining environment. Having successfully signal-tested the equipment, two test holes were initiated, followed by a single production ring and then multiple production rings. In total, 30 production rings were successfully fired underground at EHM in 2017. To do this, WEBSTM was successfully integrated into EHM’s current charging and firing process, resulting in no business delays or loss to production. None of the 30 rings required hooking up and all were initiated from the surface with no personnel underground. A high level of ownership from all personnel involved ensured the trial was a success, and provided scope for wireless detonators to be used successfully on a large scale – both at EHM and other sublevel caving operations. WEBSTM is now a proven example of technology that can be used to improve safety in the mining industry, through eliminating the need for personnel to work in hazardous areas.CITATION:te Kloot, C, Liu, Z, Purvis, T, Thomson, S, Lovitt, M and Nguyen, T, 2017. Improving safety through technology – Orica wireless electronic blasting system trials at Ernest Henry Mine, in Proceedings 13th AusIMM Underground Operators’ Conference 2017, pp 39–50 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Oct 16, 2017

By D J. Williams, C Zhang, F E. Herrera Cabrera

Farming on bauxite residue using screw propelled equipment (SPE) has been commonly practised to accelerate dewatering and as it promotes consolidation and enhances storage capacity. However, it is unclear when and how often farming should be conducted during the transition of bauxite residue from slurry to dry solids and how deep each slurry deposition should be. To address this issue, three desiccation tanks were established in the laboratory to investigate how much farming could enhance the desiccation and consolidation of tailings. The cuboid tanks, of 350 mm in height and 300 mm in width and length and with an opening on the top, were placed on load cells to monitor the water loss during desiccation and were instrumented with moisture and suction sensors designed and developed at the University of Queensland to measure the water content profile of the residue. The bauxite residue, composed of silt-size particles with low plasticity, was hydraulically deposited in the tanks as a slurry at 27% solid content, resulting in 100 mm depth of solid material settling. Evaporation was enhanced by placing two identical electrical fans above the tanks. Two phases were conducted. In the first phase, the two tanks were left untouched for evaluating non farmed conditions and for calibrating sensors, while in the second phase, three tanks were subjected to atemporal farming using purpose-built screw propelled equipment. The experiment was terminated when the residue was completely desiccated. This paper reports on the instrumented tank set-up and the results obtained to date.

Jul 1, 2021

By G van Niekerk, M Wortley

Screening is a critical part of many mineral processing circuits and keeping the aperture of the screening media within specification is vital to ensure efficient performance of the processing plant. Typical ways of estimating and/or measuring the wear of the screening media vary from very subjective methods (for instance, using the human eye) to manually checking the width of a few of the more severely worn gaps with a measurement device. Subjective methods can be flawed by human error while manual checking can distort the polyurethane or rubber materials that are used in several types of screening media. All of these errors can cause either premature replacement of panels or, even worse, poor screening of the material.Metso Process Technology and Innovation (PTI) and Metso Screening Media Solutions (SMS) have developed an innovative method that measures screen aperture using advanced image processing techniques. Field trials of the device are presented in this paper, which shows the comparison between the different methods of measuring apertures. Case studies demonstrate how the system, when combined with ScreenTrack, MetsoÆs industry leading maintenance system, and screening media, is providing users with the best possible screening solutions.

Sep 26, 2011

Of late there have been various papers published on this subject by various authorities, in which certain definite factors influencing slime settlement have been brought forward. As the principles set forth by these writers are of great interest, and have, in most cases, been generally accepted, the author will review them in the hope that by discussion some more knowledge may be brought to bear on many points connected with the subject.The definition of slime at the present time is not a standard one, and varies according to different authorities, some defining slime as ore crushed to such a fineness that it will pass through a screen of standard size, say 150 or 200-mesh, in water (1, 2);others as that part of the finely-crushed material which is in the physical condition which causes it to remain in. suspension in water, and possesses pr?perties which render it almost unleachable (3). Authorities seem divided on this point, but of late American writers seem to prefer the former definition. On the contrary, B L Gardiner describes slime as a mixture of small particles of crushed ore of varying sizes which, when mixed with water, tend...

Jan 1, 1912

By A Späth

Active explosion barriers are used to contain and suppress a methane gas and/or coal dust explosion propagation, including localised mine fires. Early research indicated that these active explosion barriers could be used on a mechanised cutting machine, making it the only technology that could suppress an explosion during its propagation phase at the cutting face. Thereby not only adding protection during mining operations but also reducing the development of toxic gases, fatal temperature increase and fatal overpressure build-up. During their evolution over the last two decades, further advantages of Active explosion barriers were proven in mine operations in countries such as South Africa and China. Characteristics such as effectivity, efficiency, mobility and space restrictions allow these systems to be used in various locations within a mine operation, including highwall operations. This improved technology contribution to safer coal mining was recognised by mine operators, workers and regulators. The Queensland’s Recognised Standard 21 (Resources Safety and Health Queensland (RSHQ), 2021) stipulated active explosion barriers as a technology to ensure the safety within their underground coalmines. The mobility and flexible implementation of the active explosion barriers allow a feasible and practical solution for all critical locations for explosion and fire management in an underground coalmine. The conformance to the Recognised Standard can be achieved all underground coal mining operations such as Bord and Pillar, and Longwall mining. This paper describes the conformance, implementation and use of Active explosion barriers for Longwall mining and development as well as Bord and Pillar mining in Queensland’s underground coalmines.

Oct 12, 2022

Modelling Channel Scale Flow in Heap Leaching Using Smooth Particle Hydrodynamics (SPH)

Sep 13, 2010

By S Adamson

Morphological analysis of alluvial gold recovered from the same segment of a placer by four common commercial methods indicates that gold shape and the presence of quartz intergrowths or sulphide overgrowths substantially influence the recovery efficiency of each method. The amount and types of gold saved by each method varies according to the different hydrodynamic conditions under which each of the methods operates. Reverse circulation drilling has the lowest efficiency and preferentially loses moderate-high flatness gold and intergrown or overgrown gold particles with relatively low density. Gravity riffle, hydraulic riffle, and jigcentrifugal concentrator systems respectively save progressively more of these problematic gold morphotypes, but still lose significant and sometimes substantial amounts (of profit) to the tailings. Because of the differences in recovery efficiency, reverse circulation drilling probably underestimates the grade of most placers and may have resulted in bypassing several economic deposits. Losses to tailings by commercial recovery plants arise from inadequacies in fundamental plant design features. These inadequacies compromise plant efficiency by limiting the ability of plants to simulate the wide range of hydrodynamic conditions necessary to operate effectively throughout placer systems. Incorporation of sand pumps and multiple recovery methods into the more sophisticated plants only partly overcomes these inadequacies. At best, efficiency will be maximised in a few segments of the placer determined by individual plant design, and will decrease progressively upstream and downstream of those segments. Without prior knowledge of the morphological characteristics of the gold to be mined, it is difficult to choose the most appropriate plant design, or to estimate what proportion of the gold will be recoverable by any given plant. If the relevant relationships are not considered beforehand, the recovery plant is likely to lose a significant proportion of the gold, and sacrifice maximum profit.

Jan 1, 2001

By A Hatt

This paper presents a case study of characterisation work undertaken at a greenfield exploration project to provide engineering and OH&S inputs for the design of a ventilation system. The paper discusses how comprehensive early characterisation of the ambient surface and underground environment including aspects related to heat, dusts, strata gas, and geologic/mineralogical factors enables incorporation of the right ventilation and non-ventilation controls at a study level to mitigate the risks identified.

Oct 12, 2022

By N J. Beukes, S T. Netshio, M O. de Kock

The Thabazimbi iron ore deposit comprises a series of stratabound orebodies, on average 18 - 25 m thick that are aligned along the faulted basal contact between the Penge Iron Formation and dolostones of the Malmani Subgroup, Transvaal Supergroup. Field geological relationships and petrographic observations suggest that the formation of high-grade iron ores took place after contact metamorphism related to the intrusion of the Bushveld Complex (2.06 Ga) but before the deposition of red beds of the Waterberg Group at ca 1.9 Ga. Hard, high-grade iron ores are predominantly composed of martite and microplaty hematite. Goethite is restricted to supergene-modified ores close to the Late Cretaceous û Early Cenozoic Old African land surface. At depth, the high-grade hematite ores interfinger with low-grade dolomite-hematite and calcite-hematite ores. Iron oxides (martite, microplaty hematite) present in these low-grade ores are texturally indistinguishable from those in the associated high-grade ores, ie ore formation is genetically associated with carbonate metasomatism. Microthermometric studies of fluid inclusions in sparitic carbonates and rare megaquartz reveal their hydrothermal origin. Two compositionally distinct aqueous fluids of shallow crustal origin are identified, namely a Ca-Na-rich high-salinity brine (26 wt per cent NaClequivalent, TH ~160¦C), and an aqueous Mg-K-bearing fluid of intermediate salinity (8.3 - 12.6 wt per cent NaClequivalent, TH~120 - 150¦C). The results confirm that high-grade hematite orebodies at the Thabazimbi deposit owe their origin to an event of extensive oxidative carbonate metasomatism (calcification), similar to that recognised at other important high-grade iron ore deposits in the world. Hydrothermal ore formation is both structurally and lithologically controlled. Size and quality of the orebodies was improved by Late Mesozoic-Cenozoic deep lateritic weathering as carbonate-hematite ores were enriched to friable high-grade ores, but this supergene modification is second in importance compared to the primary event of hydrothermal ore formation.

Jan 1, 2005

By Holly J

The period following World War II has seen many changes in stoping techniques at The Great Boulder Gold Mine. The new methods resulted in improved unit production figures, and have given some relief from the rising worldwide cost spiral in the post war years.Significant production figures are shown graphically in...

Jan 1, 1956

Selective Removal of Arsenic from Acid Mine Drainage Containing Ferrous Ion Using Sulfide Precipitation Method

Sep 13, 2010

By A Kurniawan, A Sjadat and M Akhasyah

PT Freeport Indonesia’s Deep Ore Zone (DOZ) is a block cave mining operation that has been in production for 15 years. DOZ is located approximately 900 m below surface and has an average production rate of more than 5000 t/d. The footprint of the extraction level will ultimately be 900 m long and average more than 200 m wide. The undercut level is located 20 m above the extraction level.While developing Panel 1K on the northern portion of the extraction level, a major geotechnical problem was encountered when there was a change in lithology and an associated fault intersection. A large collapse of the hanging wall of the extraction level drifts occurred in the area of the fault intersection between February and March 2011. This was followed by a collapse of one of the undercut level drifts directly above the extraction level in May 2011.It was suggested that the best approach to mitigate risk during rehabilitation was to systematically open up the failed area under the protection of a steel set support system. To achieve this, approximately 60 t of grout was injected from the undercut level to fill the voids created when the rock mass between the two levels failed. A ground penetrating radar system was used to survey the condition of the rock mass between the two levels before and after the injection of grout. After the grout injection phase was completed to a satisfactory level of confidence, rehabilitation activities started on the extraction level by taking out the now consolidated material from inside the drift in 2 m advances from under steel sets initially constructed in secured ground.Controlled blasting was the key aspect to the success of the initiative to open up just enough of the drift to systematically support the rock mass before the next set was installed. The systematic support consisted of in-cycle shotcrete sprayed over mesh pinned to the exposed rock, as effectively as possible, with splitsets before spiling the next advance’s protection canopy with rebar. Once secure, a combination of steel set and pumped concrete was installed as the final support. This final support provided a safe platform to repeat the process until the failed zone was safely traversed.CITATION:Kurniawan, A, Sjadat, A and Akhasyah, M, 2016. Rehabilitation of the collapsed panel 1K north in the Deep Ore Zone block cave mine, in Proceedings Seventh International Conference and Exhibition on Mass Mining (MassMin 2016), pp 763–768 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2016

By M Morey

Ok Tedi Mine is located eighteen kilometers from the Irian Jaya border in the Star Mountains, Western Province, Papua New Guinea. Sequential flotation concentrators produce a copper / gold concentrate for market, and a pyrite concentrate for environmental containment, with low sulphur tailings from the pyrite flotation sequence being discharged to river. Strict sulphur assay targets are set for the riverine discharge. Current porphyry and skarn ore blends from open pit operations at Mt. Fubilan will cease by 2017. However, drill cores indicate an economic ore body in the skarn ores surrounding and below the current pit limits. With proposed mining from a western pit wall ‘cut back’ and an eastern pit wall underground operation, potential for ore ageing in sub level cave underground stockpiles is apparent. With little information in the literature, Ore Ageing test work at prefeasibility level consisted of multiple one tonne stockpiles of -50 mm crushed rock. For the bankable feasibility study, a successful test work program was implemented utilizing 40 tonne ROM ore stockpiles composed of exposed pit extensions of future ores. Realistic ageing profiles of Skarn ores were obtained from one tonne monthly samples subjected to laboratory testing. Test work outcomes included:• Similar ore ageing profiles from both the pre feasibility study (PFS) and feasibility study (FS) programs, suggesting ore susceptibility to oxidation has greater effect in ore ageing than rock size for Ok Tedi skarns. • Laboratory rougher flotation of pyrite showed significant variation in sulphur recovery rate, suggesting three classes of pyrite floatability.• Laboratory rougher flotation of both copper and pyrite for up to 19 months ore ageing from 11 stockpiles, suggested three stages in the ore ageing process.

Aug 8, 2011

By I Gray

This paper examines the effects of the changes in stress that a coal may undergo as part of the drainage process. As a consequence of this, some coal seams will come to the situation that they have zero horizontal stress existing within them at the time of mining. The hypothesis of this paper is that this lack of horizontal confining stress means that on mining, the vertical stresses may be easily raised to a level where failure occurs. This failure may be accompanied by significant energy release from energy stored within the coal as well as that coming from the roof and floor. To determine the state of stress within the coal seam, the concept of the effective stress path that the coal passes through is examined and is found to be very dependent on the shrinkage of the coal with degassing, the Young’s modulus of the coal and its Poisson’s ratio. The Young’s modulus of the coal is important and has been found to be highly dependent on the state of stress within the coal. It may change by more than an order of magnitude.CITATION:Gray, I, 2014. The consequences for pillar stability of zero confining stress brought about by forced or natural drainage, in Proceedings AusRock 2014: Third Australasian Ground Control in Mining Conference , pp 331–336 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 5, 2014

By A Querzoli, B Williams

In late 2014 the Flinders Power Management Team was executing business improvement plans to ensure continued electricity generation until 2028 and beyond. Six months later, in June 2015, the Board announced the closure of the Flinders Power South Australian business, including the Leigh Creek Coal Mine, the Northern and Playford Power Stations located at Port Augusta and the 250km railway line. The announcement was preceded by a brief period of internal planning. A date was soon set for ceasing coal mining operations, being November 2015. The mine is unique in many ways. Located approximately 550km north of Adelaide the site has over 100 years of history and was formerly operated by the South Australian Government. Privatisation in 2000 saw the mine continue operation under Perpetual Leases from the South Australian Government. The leases included exemptions from multiple sections of the Mining Act 1971, obliging primary regulation under the Mines and Works Inspection Act 1920. The coal, being a low rank sub-bituminous brown coal, is prone to self-heating and spontaneous combustion. The mine and company town Leigh Creek were the economic and cultural heartbeat of the community. Facilities at the mine were shared by the community and vice versa. While many mines across Australia and the world enter periods of care and maintenance, few have been actively closed to the point of relinquishment (Bennett and Lacy, 2016). A swift decision to close, followed by a short mining operations shutdown period, presented significant technical and regulatory challenges for both the mine operator and for Regulators. The subsequent joint risk mapping process employed by Flinders Power and South Australian Mining Regulators was a unique real-world example of collaborative mine closure planning and execution. Lessons learnt are valuable for all mines, production facilities and for Regulators, even for those who may wrongly assume that closure is many years away. CITATION:Williams, B and Querzoli, A, 2018. Risk management for minesite closure planning and execution – start now! Lessons from the closure of the Leigh Creek Coalfield, South Australia, in Proceedings Life-of-Mine 2018, pp 68–72 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 25, 2018