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By T J. Napier-Munn

This paper proceeds from the premise that process improvement is a key part of the mineral engineer’s role, and one in which he/she can make a significant contribution to shareholder value. It presents four tools to help with process improvement projects. Two are designed for process monitoring, to determine as soon as possible whether there has been a true change in performance: the cumulative sum (cusum) control chart plot with V-mask, and the control chart using a process model. The other two are used for process optimisation: simplex self-directing evolutionary operation (SSDEVOP), and a response surface model developed using a central composite rotatable experimental design (CCRD). These methods are robust, have a rigorous theoretical basis and are easy to implement. They also promote project continuity which increases the chances of success, particularly in fly-in/fly-out (FIFO) operations. Variants are used in other industries, but they are rarely if ever applied in mineral processing to-day for reasons which are unclear. The paper gives examples of the application of each method in concentrators which demonstrate that they have the potential to be useful additions to the mineral engineer’s professional toolbox.CITATION:Napier-Munn, T J, 2014. Cunning solutions to process improvement, in Proceedings 12th AusIMM Mill Operators’ Conference 2014, pp 5–10 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

By D J. Brake

The underground metalliferous mining industry continues to change under the influence of many factors including, to name a few, new mining techniques and equipment, new approaches to risk management, more stringent safety and health standards, new employment practices and orebodies become deeper and often lower grade. In addition, the same technological revolution and plummeting cost of technology that has brought the GPS, smart phones and digital cameras to the general population is also working its way through the mining industry impacting on communications, automation and process control as well as introducing major efficiency and productivity dividends. However, not all factors are positive including, in particular, the issues of carbon costs and electrical power. This paper explores some of the trends affecting ventilation in hard rock mines, some of the existing and likely future challenges and some of the potential future solutions to these issues.CITATION:Brake, D J, 2013. Ventilation challenges facing the metalliferous sector, in Proceedings The Australian Mine Ventilation Conference , pp 3-12 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 1, 2013

Teleseismic travel time residuals measured on 600-1000 km seismic arrays across the Rio Grande and East African rifts provide evidence for upper mantle low velocity zones beneath each rift of velocity contrast 6%-8%. Refraction studies show thinning of the crust below the rift axes. Regional uplift which extends hundreds of km either side of the axes, is isostatically compensated by negative density contrast at depth. Since the refraction argues against compensation by thickened crust, compensation in the upper mantle low velocity zones is suggested. Temperature effects alone can not explain the reduced velocities. Generation of a few percent of partial melt is the most probable source of the reduction. A passive extensional mechanism is investigated for the Rio Grande rift in which hot asthenosphere intrudes the lithosphere raising its temperature and generating moderate melting. It requires less than 1% extension to explain the melting but a prodigious 26% to raise the temperature from a pre-rifting continental geotherm to the solidus. Geological estimates find that extension is less than 10% over the uplift zone. Such a mechanism is possible only if the prerifting lower lithosphere geotherm lies closer to the solidus than that of stable continent. This is supported by the observed high heat flow in the Rio Grande rift uplift region which, given the long time constant for thermal diffusion, reflects elevated temperatures at depth well in advance of the onset of rifting.

Jan 1, 1987

By A Esfahanipour, M Osanloo

Determination of cut-off grade?strategy is one of the most important stages of open pit mine planning and design. It is the parameter directly influencing the financial, technical, economic, legal, environmental, social and political issues in relation to mining operation. Choosing the optimum cut-off grade strategy that maximises the economic outcome has been a major topic of research workers for nearly one century. Many researchers have contributed in devising methods and algorithms, such as dynamic programming, linear programming, optimal control and so on for various aspects of its determination. In this paper, a non-linear mathematical programming for cut-off grade strategy optimisation is presented, considering the three main stages of mining operation introduced by K F Lane. In this model maximisation of net present value of mining operation, under the three constraints of mining stagesÆ capacities, considered as the optimisation criteria. Due to the discrete representation of the mining resource, the proposed non-linear formulation is approximated by a non-linear signomial geometric programming. According to non-convexity and the complexity of the proposed model, an augmented Lagrangian genetic algorithm was used to find the optimum cut-off grade strategy under varying and fixed price circumstances. To validate the proposed non-linear model efficiency, the results were compared with the results obtained by the K F Lane methodology. It was found that the proposed non-linear model works efficiently in the determination of cut-off grade strategy. According to the simplicity of the structure of non-linear programming modelling in comparison with dynamic programming it is hoped that, further development of this model would certainly provide the ability of considering managerial and technical flexibilities as well as incorporating more real mining conditions in the determination of cut-off grade strategy optimisation.

Sep 26, 2011

The long-term production schedule of open pit mines that maximises the net present value (NPV) of a given project relies on the proper design of phases (pushbacks) within the ultimate pit limits. There is not a phase design algorithm applied in the mining industry today that gives yearly production schedules that are optimum.The majority of phase design algorithms currently in use by the mining industry aims at grouping the blocks that fall within the ultimate pit limits into phases such that the average value of the blocks within each phase decrease as the size of the phases increase. Current phase design methods are typically based on a pit limit optimisation algorithm, originally introduced by Lerchs and Grossmann (LG) in 1965. To obtain multiple pit shells to be used for the phase design, the LG pit limit algorithm successively applied to economic block models by changing the price of the commodity or some other factor that properly parameterises the size of the pit. These modified economic block models are developed by predetermining the destination for each block in the model based on a breakeven analysis and highest economic outcome between alternative destinations. Phase designs determined by these existing algorithms may be suboptimal if a given project utilises multiple processing facilities for metal recovery and particularly if these facilities have restrictions (constraints) that require blending of attributes in the feed. To overcome these problems in obtaining phases that optimise overall production schedules, a new algorithm is developed at the Colorado School of Mines. The algorithm determines the phases of an open pit mine by taking into account multiple process options for the blocks and period by period blending requirements. This algorithm has been implemented within a software program (the software) and is being prototyped successfully in the design of improved pushbacks at a copper mine in South America and on a gold mine in Nevada. This presentation will demonstrate the shortcomings of the traditional phase design methodologies based on comparison of results coming from the new approach versus the traditional.

Dec 6, 2010

By S H. Sie, R Seetharam, K Naito, T Takagi

Tin-polymetallic vein type deposits are one of the major source of metal producers in the Circum Pacific Belt. This type of deposit is of great importance for the modem electronics and medical industries because of their high content of rare metals (especially indium and bismuth). We have studied two representatives, Tosham of India (Cu-In-Bi-Sn-W-Ag-Au), and Mount Pleasant of Canada (Zn-Cu-In-Bi-Sn-W), using proton and electron microprobes in order to delineate the distribution of medicallhigh-tech rare metals. The electron microprobe study showed that major indium carrier in such type of deposit are roquesite (CulnS2), sphalerite, stannite and a Cu-Zn-Fe-In-Sn-S mineral; and that indium is incorporated in sulfides by coupled substitution like Cu + In = 2(Zn + Fe). The proton microprobe showed that indium at trace levels is also present in chalcopyrite and pyrite. In addition, zinc, copper, arsenic, antimony, selenium, tin, and bismuth are common in chalcopyrite and pyrite. Arsenopyrite contains nickel, copper, zinc, silver, tin, antimony and bismuth. In chalcopyrite and pyrite, zinc, arsenic, indium, bismuth and lead are higher in Mount Pleasant ore, but silver is higher at Tosham. Also thallium and gold were found only in Tosham pyrite. The Tosham deposit is genetically related to S-type magma, while the Mount Pleasant deposit is related to A-type granite. Tosham ore contains zinc-bearing biotites that coexist with chalcopyrite in ore bodies but Mount Pleasant ore lacks such biotite. We propose that the difference in elemental abundance between the two deposits are caused by the different character of source magma and different mineral associations of the ore body.

Jan 1, 1995

This paper briefly reviews the history of mine haulage trucks. It reviews producti- vity limitations with respect to size or speed. Changing haul requirements once again create the need for more flexible mechanical drive power transmission equipment. The new equip- ment however is designed to provide extended life between overhauls as compared with previous mechanical transmissions.

Jan 1, 1981

By B K. Da, S A. Balaji, G P. Roy, T K. Dutta

The raw material handling complex at the Durgapur steel plant provides iron ore, crushed coke and flux to two sinter plants. Either some facilities were not envisaged or not properly designed before the project stage which caused problems during operation of the plant. The absence of an in situ roll turning facility, used to increase maintenance activities for disassembly, transportation of rolls to central machine shop and assembly of rolls, led to decreased crusher availability and increased activities for the maintenance crew. The provision of a smaller vibro feeder/screen in place of a suitable sized screen caused jamming of the screen deck, adversely affecting screening efficiency and the crushing index of crushed coke. Some design modifications and developmental work was undertaken, such as the development and installation of an in situ roll turning facility in the existing limited space, achieving low feed (0.1 - 0.2 mm/rev), lower cutting speed of 30 - 40 m/minute for 350 BHN hard roll, which was also a difficult engineering challenge to bring within the tolerable limit of vibration. This was successfully achieved. Modifications to the screen deck, introduction of differential speed crushing and modification to the vibro screen and vibro feeder for uniform distribution of feed have been incorporated. These innovative design modifications to the in situ roll turning have led to a drastic decrease in maintenance activities and an improvement in the crushing index. Modifications to the screen have resulted in the elimination of jamming and improved screening. Modifications to the vibro screen before the primary crushers and to the vibro feeder before the secondary crushers have prevented excessive wear in the central portion of rolls, ultimately leading to increased roll life. Incorporation of differential speed crushing has resulted in an increased crushing index and decreased generation of micro fines. All the above modifications have led to distinct improvements in equipment availability, increased roll life and a decrease in maintenance activities and improvement in crushed coke granulametry, ultimately resulting in improved productivity and quality of iron ore agglomeration at the sinter plant. The innovative design modifications mentioned above are discussed in detail in this paper.

Jan 1, 2005

By D E. Thorp

The mining and concentration operations of New Zealand Steel have been carried out initially from the Waikato North Head (WNH) deposit since 1969 and subsequently from the Taharoa deposit since 1972. Over the years the WNH operation has produced about 1.2 million tonnes of concentrate which has been converted into steel, while total exports to the Japanese Steel Industry from Taharoa reached five million tonnes in February of this year. Recent expansion plans both in domestic steel production and in the ironsand concentrate export market have made it necessary for the company to look closely at, among other areas, the mineral processing of the titaniferous ironsands in both deposits. This paper deals with the recent test work carried out at WNH and Taharoa on the use of the cone concentrator unit as a primary gravity concentrating unit ahead of the magnetic separation stages and as a cleaner concentrator following the primary magnetic separation.

Jan 1, 1977

By R L. Grogan

Mining is currently undergoing a progressive expansion into novel environments (such as the deep ocean), commodities (such as tantalum, rare earths, and other ‘green economy minerals’), and new methods (such as the autonomous underwater cutting machines required to operate in the deep ocean environment, or the use of expanding grouts to deliver a blast-free mining method). The advent of novel mining, environments and commodities heralds an era that will undoubtedly start with much discomfort on the part of regulators and stakeholders, due to a feeling of overwhelming uncertainty. These proposed mining scenarios have few precedents, few examples of successful implementation, short baseline monitoring periods, and few examples of legacy sites that may assist with understanding long term risk and exposure. The evolution of the environmental and social impact assessment (ESIA) process in many regulatory environments recognises stakeholder engagement in a formal and facilitated manner. This is a positive step, and allows stakeholders to be much more meaningfully involved in the permitting process than they historically were. However, with this advance comes the challenge of identifying and communicating with stakeholders; sharing information in a meaningful way, fostering relationships with what can be an extremely large group, and delivering on commitments that inspire confidence to permit operations that have never been permitted before. In order to meet this challenge, it is suggested that changes to collection of data, communication of data, the nature of commitments, and the reporting of performance need to be made in order to effectively communicate management of new technologies, and the impacts that mining may have in new environments (such as the deep ocean). The communication challenge is necessarily greater when describing technology that has never been used, or environments that have never previously been accessed by humans on an industrial scale. CITATION:Grogan, R L, 2018. Permitting in the face of uncertainty – how to deliver confidence to regulators and investors, in Proceedings Life-of-Mine 2018, pp 46–48 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 25, 2018

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

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

Sep 1, 2024

Legislation introduced for Queensland and New South Wales Coal mines provides different levels of prescription regarding specification of mine seals û generally in relation to capacity to withstand overpressure. In Queensland, the Coal Mining Safety and Health Regulation (2001), Section 341 (d) places a further onus on the statutory ventilation officer to æensure all ventilation control devices at the mine are properly constructed and maintainedÆ and that the ventilation officer æmust ensure a ventilation control device mentioned in the regulation à and installed at the mine meets the design criteria statedÆ for the ætype of deviceÆ. Based on the experience of the author, it appears that risk management and life cycle approach to seals has not been adopted to the same extent as for other aspects of operations. Further, because of the number of disciplines and personnel involved that may influence various factors affecting seal integrity, the opportunity for oversight or unclear allocation of responsibility is considerable. While suppliers can provide explosion or design rated seals, this should only be a starting point for application of the product in a coal mine. Application is often considered by mine planning staff (taking into consideration mine environment parameters such as water, control of gas, spontaneous combustion risk, etc) in conjunction with the colliery ventilation officer, and then construction completed by contractors under supervision of operational staff. After construction, seals often are managed by operational personnel with input from the ventilation officer. Input of the geotechnical engineer into pillar design, roadway opening size, ground support specification and most stable seal location is also required. The need for a customised design approach for each seal site is proposed in order to take into account the many and variable factors that may influence a site so that improved seal performance reliability and predictability can be developed. A program of quantitative as well as qualitative monitoring of performance and triggers for rectification or maintenance action is required, and would provide support to the aforementioned proposal. Many mines rely on visual/audible inspection and periodic bag sampling as the primary means of assessment. Other significant factors such as seal material properties, rib degradation, convergence, floor heave, effects of water on both structural integrity of the seal as well as the air tightness of the seal do not generally receive the same level of attention. Based on the above observations, the author has compiled a reference checklist in regard to the above matters, including aspects of and approaches to mine and pillar design, geotechnical modelling and data collection, civil engineering design, site evaluation and practical options available.

Jan 1, 2005

By M Brady, O Salisbury, C Claassen, B Beamish, H Baxter

Monitoring for signs of elevated spontaneous combustion in the active goaf behind the longwall face is crucial for early intervention of any potential heating incidents. Typically, trigger action response plans (TARPs) are established at the start of longwall mining and often are only reviewed when triggers are activated frequently and become ‘nuisance alarms’, or in the worst case scenario after a heating event. Narrabri Mine has adopted a proactive approach of reviewing the longwall active goaf spontaneous combustion monitoring TARP at the commencement of each longwall block and prior to reaching a known ‘mylonite zone’ of crushed coal, which is associated with increased coal oxidation. The review is based on information recorded from the monitoring data of the previous longwall blocks as well as interpretation of relevant spontaneous combustion propensity results for the coal. This has resulted in the mine implementing a zoned TARP approach for each longwall block covering both the longwall retreat through normal undisturbed coal and the zone where the goaf is influenced by the increased coal oxidation associated with the mylonite coal. The consequence of this approach is that it has removed the issue of having nuisance triggers being activated during mining through a known increased oxidation zone, while maintaining a high awareness of indicators of spontaneous combustion.CITATION:Baxter, H, Claassen, C, Salisbury, O, Brady, M and Beamish, B, 2015. Implementation of a zoned trigger action response plan associated with changing mine conditions at Narrabri Mine, in Proceedings The Australian Mine Ventilation Conference, pp 113–120 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 31, 2015

By Scales PJ

Fatigue is the primary cause of failure of structural and mechanical components subject to dynamic loading. Recognition of this basic fact and the development of appropriate techniques and details are important in the design and repair of off highway trucks (OHTs). The frames and appendages of OHTs and other mobile plant used in the Pilbara are subject to tough operating conditions. Any fatigue-prone details quickly show up and become a maintenance liability of considerable concern. Much of this equipment is approaching the limit of its fatigue life and maintenance managers face decisions on whether to repair or replace. Even new equipment often contains some poor details which suffer distress soon after commissioning. In those cases a repair is required which will reinstate the detail to its original intended design life. Repair details must be practical and cost effective. They must also be tailored to the capability and expertise available in the field or in local manufacturers' establishments. This is particularly important where original equipment was manufactured overseas and long delivery times are involved. Lessons are drawn from components which have failed, using the evidence constructively, to provide an upgraded part or an improved substitute. With the experience now available it is relatively easy to extrapolate to cover new problem areas. This paper describes specialised techniques of mechanical fastening and detailing for low fatigue susceptibility, built up over many years of experience with OHTs and other mining plant and equipment in the Pilbara.

Jan 1, 1982

By S R. Williams

There is a sense of geometallurgy being new; a new methodology for mining project development and improved operational strategy. One of the main challenges that any ænewÆ technology faces is a validation of the value and the need to produce case studies. However, producing case studies can often be problematic particularly given the long cycle from mineral deposit project, through feasibility and construction to stabilised operation of a mine.However, the roots of geometallurgy go back quite some time. Successful practices with geometallurgy can be seen from as early as the 1980s. Many times those practices were not called geometallurgy but something else and, in other cases, what can be seen are various components of the geometallurgical ævalue chainÆ.This paper will analyse a selection of published past practices from a geometallurgical perspective to demonstrate the value realised from the application of this methodology. The paper will then make some general comments on where this history of work in geometallurgy has lead us to and what are the challenges today for the geometallurgical effort.CITATION:S R Williams, 2013. A historical perspective of the application and success of geometallurgical methodologies, in Proceedings The Second AusIMM International Geometallurgy Conference (GeoMet) 2013 , pp 37-48 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 29, 2013

By Hayward SB

The Maragorik prospect is an example of high sulphidation, Cu/Au mineralisation occurring at a high level in the hydrothermal system. As extensive ash deposits blanket the region, controlled-source audio magneto-tellurics (CSAMT), in conjunct-ion with bulldozer trenching, have been used to delineate subsurface geology. Fluid upflow has occurred along EW structures dilated by rotation on the bounding major NW lineaments. Rising hydrothermal fluids have exploited permeable horizons in contact with the upflow structures. This lithological control is evident as ledges of silicification and peripheral clay alteration, at high levels in the system. As is typical of high sulphidation systems, a two phase fluid consists of an initial rapidly moving vapour-dominated phase, followed by a liquid-dominated phase. Much of the zoned and overprinted silica to clay alteration is developed from the vapour-dominated fluid. Mineral deposition occurs as a result of brecciation of the competent silic-ification by liquid phase fluids. Such mineralisation is of restricted volume in ledges proximal to the feeder structures.The style of alteration and mineralisation are indicative of a very low temperature and hence a high level system. Thus, although high sulphid-ation systems are inferred to develop from porphyry-related magmatic fluids, such a source at Maragorik is interpreted to be very deeply buried.

Jan 1, 1994

At Cliffs Natural Resources Ltd (CNR) crushing and shipping sample stations, precisions are estimated for the sampling, preparation and measurement stages of iron ore sampling in accordance with ISO 3085 (2002). In this Standard, gross duplicate samples are prepared at each of the three stages, yielding eight measurement assays. Appropriate calculations of the differences between assay pairs are then made to estimate precision of each stage of sampling. The International Standard for checking precision in iron ore sampling, ISO 3085 (2002) prescribes a method for identifying outliers that is ambiguous and possibly inappropriate. The procedure also makes an unnecessary implicit assumption, that the differences between assay pairs are normally distributed. The Anderson-Darling statistic is used to demonstrate that in some cases the assay pair differences have distributions significantly different from normal. When applied at CNR as specified, the Standard leads to precision estimates well below the expected values, thus overestimating the sampling method's capability and limiting the opportunity for real process improvement. This paper suggests an improved method of estimating sampling, preparation and measurement precision. A bootstrap procedure is used to estimate confidence limits for the calculated precision estimates. The proposed method would be suitable for testing blasthole precision. The discussion is supported by extensive simulation modelling of realistic data.

Mar 1, 2010

During 2009 the technical services staff at Barrick Gold Corporation's Australian Business Unit conducted a review of their five underground mines that utilise pastefill as the backfill component for these operations. Of the five mines reviewed three use dry tailings and two use wet tailings plants. The primary aim for these reviews was to determine whether pastefill was the right option to be used, and if not, what where the alternatives. The reviews undertaken focus on several areas including, paste plant operation, reticulation and barricade techniques, the geotechnical requirements for pastefill in regards to the current mining methods, the consideration of alternative methods, capital and operating cost histories compared to initial estimates, and a cost benefit analysis of pastefill against other mining methods. The main benefits from the use of pastefill is increasing the extraction of the resource, reducing or eliminating the need to leave pillars. In some mines the use of pastefill is geotechnically driven, to manage high stress environments or mining induced seismicity. A third benefit of using pastefill in some circumstances is that it reduces dilution, however it is considered that this is not a valid argument for most of the mines reviewed. At two mines no alternative to pastefill was determined, whilst differing extraction and filling strategies were potentially identified at the other three mines. The reviews developed cost benefit curves for those sites that had alternative mining methods to assist in determining whether pastefill is the right option to use for any particular stope. At the grades typically mined in each operation, pastefill was the preferred option to use. In all mines, pastefill was determined to be the best option at this time.

Nov 25, 2010

By Kazis JV

The beneficiation of fine coal has been the major problem facing the coal preparation engineer in recent years. The influence of clay slime, particle size and reagent type are but a few of the many factors that affect the recovery of fine coal. Laboratory test work has indicated that substantial increases in recovery could be achieved by improvements in technology in all these areas. Unfortunately, in most cases this technology has not carried through to the operating plants.

Jan 1, 1984

By Kleine T. H

Blast design involves many engineering constraints and objectives. Some of the more important include the implementation costs, the desired fragmentation and shape of the muckpile. A spreadsheet has been developed to allow blast design options such as burden, spacing, blast hole diameter, decking and explosive type to be varied. As any option is varied the spreadsheet recalculates and graphs the expected implementation costs, fragmentation and muckpile shape in seconds.The spreadsheet extends the philosophy of simple robust fragmentation prediction (Cunningham, 1983) to include similar models for explosive detonation (with respect to explosive type, age, blast hole diameter and density) and muckpile shape (with respect to burden, spacing, charge location and weight). The new empirical models for explosive detonation and muckpile shape prediction have been calibrated successfully for one situation and are now undergoing further field trials.

Jan 1, 1992