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Kambalda Nickel Mines (KNM) currently have eight operating underground mines, three on care and maintenance and other orebodies at various stages of development. Each operation differs greatly in scale, ore grade, milling characteristics and cost structure. The optimum number of mines operating at any one time and their level of production, within the constraints of mill blending requirements and overall mill capacity, is the key to maximising profit in a climate of fluctuating nickel price. Cost models are developed for each mining operation which relate ore tonnes mined to total cost per pound of nickel produced from that mine. Aggregating the mine cost models provides a composite cost model for the entire operation. The cost models provide the operating levels necessary for each of the mines and hence Kambalda as a whole, to operate at the lowest cost per pound of nickel produced. However, lowest operating cost does not necessarily lead to maximum profit. The level of nickel price above operating cost can dictate maximum profit positions which are contrary to the lowest cost position. In addition, the decision to temporarily shutdown mines or reopen mines in response to nickel price movements comes at a cost. In considering the optimum operating position, the price of production capacity flexibility needs to be taken into account. This paper describes the process used to assess all these factors in arriving at the optimum operating position for Kambalda Nickel Mines for varying nickel prices. The same methodology can be used by corporate management in managing multiple mine sites as well as mine management managing multiple orebodies or stoping blocks for maximum profit.

Jan 1, 1995

IT is very difficult for a founder engaged in jobbing work, comprising all sizes and classes of castings, to appreciate that the analysis of the iron he is using cannot entirely fill the situation he desires for his varied classes of work. Neither is there any panacea in the shape of an iron mixture that will suit the whole of his floor for the day.From his own experience he generally alters his cupola charges during the cast, endeavouring to meet at the same time the requisite metal composition for the castings he is about to pour.The founder on repetition work is in a much better position to stabilise his methods, arrive at a certain pig-iron' analysis, regulate...

Jan 1, 1926

The Jacobs Sliding Floor (Floor) is experiencing a surprisingly long competitive life. The first Floor was used on the Camino Tunnel in California in 1960. At that time the Robbins Company had built only seven TBMs, and the future for such machines was considered doubtful by many, as compared to drill and blast methods. This was then, and still is, commonly called the "conventional" method. Robbins' TBM No. 8 was for the Hydro Electricity Commission of Tasmania (HEC) for their Poatina Hydro Project in 1961. In this writer's view, the Poatina experience was the start of successful hard rock boring machines. But, by coincidence, the HEC is using the newest Floor for their King River Hydro project, where driving with the Floor started in July 1986 on the King Tunnel. This paper examines the history and developments in both Floor design and other "conventional" tunnelling equipment, and the site specific conditions that have allowed this old concept to still be competitive in certain select situations. Parametric costing data and some actual progress records are included.

Jan 1, 1987

By McLaughlin R. G, Brammer R. A J

King Island Scheelite had been using dealer modified front end loaders for two years when in 1974 it started to increase production. Suppliers were then quoting long deliveries for underground diesel trackless mining equip- ment, and the Company was forced to modify surface machines which had become redundant as production from the open cut phased out. The results were generally successful and encouraged further adaptations. Drill jumbos excepted, the Company now uses only converted surface machines in areas worked by diesel engined equipment and for all support and auxiliary functions.

Jan 1, 1977

By N Nosaka

Sinter plants currently have to use many types of ores with different properties due to the great demand for iron ores, which was driven by the massive growth in Chinese iron and steel industry. On the other hand, the development of iron ore mines is limited and the quality of iron ores is in a tendency of deterioration. Therefore, the quick evaluation of iron ores has become more important for a stable sintering operation. In addition to such a background, the CO2 gas emission should be decreased from sinter plants according to the Kyoto Protocol on reduction in greenhouse gases. The present paper first describes the methods for testing the metallurgical properties of iron ores, which use a small volume of sample mainly focusing on magnetite ore that is effective for reducing CO2 and NOx emissions from sinter plants. The sintering properties of ores are evaluated separately according to each stage in sintering process, that is: heating stage before melt formation, primary melt formation in adhering fines layer of pseudo-particles, and assimilation of nucleus ore particle with calcium-ferrite system melts.Next, the application of the tests to the blending ores is introduced showing examples of the studies on the effective usage of the magnetite ores with Marra Mamba type ores.

Jan 1, 2005

As the worldÆs population and global standard of living increase, the role of metals in the economy will not diminish in the 21st century, despite substitution and dematerialisation trends. Industrial Ecology is an emerging science that attempts to bring together physical, biological and social scientists and develop the tools for good management of the planet in the long run. In engineering terms, Industrial Ecology is defined as the reconfiguring of industrial activities with full knowledge of their environmental consequences. Production and use of materials must take into account the needs of both market and environment. Dispersive uses of metals will be phased out, as is being done with lead in gasoline, and post-use recovery of materials and energy will increase. This will result in an advantage for metallurgical processes that can use as feed materials concentrates as well as metal scrap and waste streams, such as bath smelting processes and slag resistance electric furnaces. The paper also discusses how metal extraction technologies, developed in the 20th century to provide essential materials to humanity, can be applied for the benefit of both mankind and environment in the 21st century.

Jan 1, 2000

By Prosser AP

The large body of knowledge about the relation between chemical process efficiency and mineralogical features is of only limited use. The profession ought to try to improve the methods of using information as well as adding to the knowledge. One attempt isòdescribed. Correlations between process efficiency factors and the mineralogical features of low- grade concentrates have been developed from both a theoretical analysis and experimental measurements. The ultimate recovery of a reactive phase in an inert matrix can be calcu- lated from simple measurements of the particle size, porosity and pore size of the concentrate, and the grain size of the reactive mineral., The rate of recovery, up to 98% recovery, can be calculated from simple measurements of particle size, porosity, proportion of reactive mineral and tortuosity. Some details are given. The correlations are of potential use in process selection and preliminary design. Satisfactory predictions have been made for near-ideal systems. Improvements in the measurement of pore size and tests on more realistic materials are required. The ultimate benefit of the correlations will be determined by the magnitude and frequency of the effects of mineralogical features other than those specified above.

Jan 1, 1975

By T J. Beardsmore, N Wyche, D Flint, T J. Griffin

Western Australia (WA) is currently the world’s largest iron ore producer, and mining of its huge reserves and resources of iron ore has become a critical part of the state’s economy and regional development. Iron ore exports from WA have reached 760 Mt/a, corresponding to shipping more than one Mt per turn-of-the-tide from the state’s ports. The iron ore sector dominates all commodities produced in WA, and in 2016 accounted for 77 per cent of the state’s royalty receipts, 56 per cent of mineral and petroleum exports (by value) and 50 per cent of mining industry employment. Expenditure on exploration for iron ore (including that for resource estimation and conversion to ore reserves) has declined markedly, from its record peak of $1100 M in 2012 to $280 M in 2016, placing it second after gold. Foreign investment has been a key element underpinning development of the iron ore industry from the 1960s until today, and will likely continue to be so into the future.CITATION:Flint, D, Wyche, N, Beardsmore, T J and Griffin, T J, 2017. The importance of iron ore to Western Australia’s economy, in Proceedings Iron Ore 2017, pp 7–12 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 24, 2017

By B Arthur, K Sexsmith, D Hockley, S D

At the proposed Crandon Project, mill tailings would be depyritised for upland disposal. The resulting pyrite concentrate would be disposed of in the underground workings as a cement-amended paste backfill. In the long term, the underground workings would be flooded and the potential for the paste backfill to generate acid would be limited. However, while the mine is operational, there is potential for oxygen ingress to the backfill that may lead to sulfide mineral oxidation and acid generation. A series of humidity cell tests were completed to assess the potential for groundwater contamination. To assess effects of surface area on oxidation, the humidity cell tests were conducted on moulded cubes of paste backfill. The tests were terminated at different intervals, and the cubes were dissected and examined mineralogically. Various leach extraction procedures were also used to assess the progress of oxidation and secondary mineralisation within the paste backfill. The test results showed that: the cement amendment significantly contributes to acid neutralisation and results in a lag in excess of one year before the onset of acidic conditions (in comparison to less than three weeks for the pyrite concentrate); the depth of oxidation in the paste backfill is restricted to about 1 mm after 107 weeks of testing; and secondary minerals form a distinct ærindÆ at the surface of the paste backfill. The results indicate that acid generation in the backfilled stopes would be minimal. The importance of including the surface area effect in the testing (ie using moulded cubes) is clearly demonstrated.

Jan 1, 2003

This paper considers two particular empi- rical models for the processes of the generati- on of hydrochemical zoning and epithermal near- surface mineralization of mercury-antimony-arse- nic formation in the discharge area of the Uzon Caldera ore generating hydrothermal system in Kamchatka. Vertical and horizontal hydrochemical zo- ning is caused by mixture of infiltration waters of the surface formation with fluid of chloride- sodium composition which are supplied up the-zo- ne of deep fault. Ore formation is caused by simultaneous existence of two geochemical barriers, namely oxidizing and reductive. The first barrier is determined by the-level of ground waters. The second one forms under the clay-opal screen un- der the influence of two factors, namely the inflow of deep reduction sulphur compounds (which are transported together with arsenic, antimony and mercury) and the generation of hyd- rogen sulphide as a result of sulphur- and sul- phate reduction. X-ray-amorphous phase of orpi- ment composition and realgar phase are formed, respectively, on the oxidizing and reductive Barriers.

Jan 1, 1987

By Plamer D. J, Newman O. M G

The Effluent Treatment System at Pasminco Metals - EZ (PMEZ) was commissioned in December, 1991 and has operated satisfactorily, ensuring that aqueous discharges from PMEZ comply with the Tasmanian Environment Protection Act. The system treats both spills and run-off from the Zinc Plant, and acidic liquor generated in the gas cleaning section of the Sulphuric Acid Plant. The spills and run-off from the Zinc Plant are collected in a large catchment pond. The pond liquor, after partial neutralisation with sodium hydroxide to pH 4, and removal of suspended solids, is preferentially recycled to the Zinc Plant, for example, for washing of residues. Liquor which cannot be recycled, is treated in the Lime Neutralisation Section. The other input to the Lime Neutralisation Section is the acidic liquor from the Sulphuric Acid Plant from which mercury has been removed by contact with aluminium pellets in a fluidised column. In the Lime Neutralisation Section, the liquors are blended and neutralised to pH 10 by the addition of slaked lime. The heavy metals and most of the fluorine are precipitated. The precipitated solids are removed in a thickener with part of the thickener underflow being filtered. Most of the thickener underflow is recycled to generate solids that settle rapidly and filter well. The filter cake is returned to the Zinc Plant for the recovery of contained heavy metals while the thickener overflow is discharged to the Derwent River.

Jan 1, 1993

I am honoured and very pleased to have been given the opportunity this evening to say a few words of thanks not only on behalf of all the guests but especially for the delegates and accompanying persons attending the 13th Congress of the Council of Mining and Metallurgical Institutions. Firstly, I would like to congratulate Sir Hamilton Whyte,KCMG for his most interesting address. In his far ranging talk, when he showed knowledge of widely diverse subjects, I had a brief fear that he was going to be talking about the details of support methods in deep level mines, or how to avoid flotation problems in multi-metal mines. Although he did not go that far, he touched on subjects which have arisen this week - long term planning and secure supply of minerals at acceptable prices. The dire predictions of the Club of Rome have been debunked with a far more elastic supply of minerals having been proved. Combined with the importance of a falling birthrate in some parts of the world, this will lead to many changes in the future, when hopefully governments will take the long term view rather than look at the next budget or the next election. Maybe some of them are not too lazy to do this for all of us. However as a fellow Ukranian, I feel that he might have been called something different if he had been in Australia. Sir Hamilton, thank you for your talk. Once upon a time - and this is not a fairy story - there was a cobbler who had two sons; one very bright who became a professor of mathematics; the other, dim, who became a millionaire shoemaker. Asked for the secret of his success, the millionaire attributed it to a vital piece of economics which his father had imparted, "Be content with small margins on a large turnover." "So", said the millionaire, "I make my shoes for $2 a pair and sell them for $5. I am very happy with the three per cent profit."

Jan 1, 1986

This paper concerns a pragmatic approach to a problem that is common to many operations in the mining industry: how, over the short-term, to grasp the extent and distribution of long-term financial risk from environmental causes and reduce these risks strategically, in order to maintain stability and flexibility in the operations. Surprisingly, many companies operate without an environmental master plan or tools that can help managers measure and reduce financial risks. Such companies may be subject to unknown unacceptable financial risks from environmental causes. While many companies have some kind of internal system of environmental standards, it is often the case that such systems have uneven or limited effect, and offer no opportunities for visualising, measuring or managing aggregate financial risks from environmental causes. `Aggregate risks' are defined here as the calculated total expected financial costs to a company, or a subdivision of a company, from environmental causes at nominated operations over a defined time period. Aggregate risks take into account the type and magnitude of an environmental problem set, the likelihood of occurrence, and the time frame during which the problems will develop or solutions are required. For the large corporation, the 'amount of' aggregate environmental risk is a statistic that can be managed, along with other financial parameters, at the corporate level to improve the stability and predictability of operations, and protect the interests of shareholders. This paper concerns development of a management framework and a tool for the large corporation that responds to the need for managing aggregate environmental financial risks. The logical framework proposed to overcome the need for strategic vision is the Environmental Master Plan, and this is described in the next section. The analytical tool proposed to measure aggregate risks and provide relevant data and insights to managers, is called an Environmental Risk Management Information System, and its mechanics are described in a subsequent section.

Jan 1, 1994

By T Laurencont, C Unger

The Mount Morgan minesite, located approximately 40 km SW of Rockhampton in Central Queensland, comprises 270 ha of unrehabilitated land which is the currently the major source of acid mine drainage run-off and seepage to the adjacent Dee River. Additionally, the minesite hosts an Open Cut Pit which contains 9000 ML of acidic and metal-rich water. In the absence of active management of water in the pit, there is a 50 per cent probability of an uncontrolled spill occurring in future years. The development of a contingency plan for management of overflow from the pit in the short term, has incorporated findings from numerous studies relevant to the Open Cut Pit including, but not limited to, water balance, contaminant source identification, toxicity testing, water quality profiling and limnological modelling, and estimates of probability of overflow. Extensive stakeholder consultation and peer review were also undertaken during the formulation of the contingency plan. The medium-term goal of lowering the water level in the pit to reduce the current high probability (50 per cent) of uncontrolled overflow to acceptable levels of risk is proposed to be achieved by a campaign of chemical water treatment. The treated water will be discharged to the Dee River, and sludge returned to the pit. The methodologies used for the selection and development of the water treatment process, that is proposed to involve treatment with lime, are described. Water treatment is the short- to medium-term component of a long range rehabilitation plan for achieving a negative pit water balance, and sustainable management of acidic water across the whole site. Achieving this ultimate goal will involve: reducing the inputs of water to the Open Cut Pit such that the annual water balance is zero or net negative, thus removing the need for water treatment in perpetuity; maximising, by surface rehabilitation works, the quality of run-off reporting to the Dee River; and minimising the volume of acidic seepage reporting to the seepage interception system. Possible strategies for achieving this long range goal consistent with overall site rehabilitation objectives are currently being developed and costed.

Jan 1, 2003

Environmental management of minesites in general, and management of water discharges in particular, is receiving ever-increasing attention. One key component in the successful design and operation of water management systems is to address the presence of sediment in the water being conveyed. Sediment erosion in the mining environment is often greatly exacerbated by disturbing the ground surface of vast areas of catchment. If sediment avoidance, transport, deposition or release are not adequately addressed, the impact on water management facilities can include loss of storage and hydraulic capacity, more frequent equipment replacement, increased operational costs and potentially environmentally unacceptable sediment discharges to receiving waters. An overview of sediment management within water facilities is presented here, and design of one particular approach, the use of settling basins for sediment removal, is discussed in detail. Examples are used to illustrate lessons learnt where particular approaches to sediment management have been found to be lacking. The common themes in the lessons learnt include the need to characterise hydrodynamic conditions and sediment properties in the water source, to set performance targets for sediment management, and to develop operating procedures to meet these targets under a realistic range of scenarios. The examples show how analysis of expected performance of sediment management can help with planning of operation and maintenance strategies. For settling basins, use of a simulation model that includes the effects of turbulence on settling can provide considerable benefits in optimising basin design and evaluating performance. Even in the most basic approach to sediment settling, establishing performance targets based on design flow and sediment characteristics is critical.

Jan 1, 2003

By Hossaini SMF

After reviewing the various approach es,namely, empirical,analytical.observational and numerical, a logical systematic approach is proposed for the estimation of compressive strength of coal pillars. In this approach first,uniaxial compressive strength of coal in pillars is estimated,taking into account the size effect and the effect of discontinuities. Next,the compressive strength of coal pillars is estimated by determining the stress distribution in the pillar and the Bieniawski strength criterion. The results appear to be compatible to the ones obtained by Wilson's method. The traditional pillar design equations give improper answers for deep workings.

Jan 1, 1991

The design of mine ventilation systems for the BHP Steel Division Collieries is based on the acquisition of ventilation survey data for the establishment of a realistic computer net- work model. The branches which form the net- work for the computer models are calculated from a range of resistance factors incorporat- ing both a frictional and shock loss component. Since shock losses can account for up to 30 per cent of the total energy losses in mine airways the use of friction factors alone without accounting for shock losses will result in the choosing of an insufficiently performing fan. Published tables of friction factors have in- variably been taken from metalliferous or single entry studies and consequently are not reliable for Australia's mining conditions where multiple entries with regularly spaced cut-throughs are the normal practice. Typical resistance factors for roadways of rectangular cross-section 5.5 m x 2.0 m, with coal sides, have been found to vary from 0.11 Ns2/m8/km where no timber supports are used, to 0.98 Ns2/m8/km where double centre legging together with wooden chocks is used. In addition to the range of resistance factors due to varying support methods, the nature of use for a roadway is very significant because of the condition of repair and upkeep maintained.

Jan 1, 1983

By Weller K. R, Stewart P. S B, Restarick C. J

The performance of the Renison tin concentrator was assessed in detail for two arrangements of the three available ball mills. With two mills used for primary grinding and the third for regrinding table tailing, the concentrator recovered 65.3 per cent of tin in the three tin concentrates produced by tabling, vanning and flotation at a calculated overall grade of 37.5 per cent tin prior to batch dressing. In the second arrangement one mill was used for primary grinding and two mills for separate regrinding of table tailing and sulphide concentrate. The metallurgical effective- ness of the change was somewhat obscured by unintended changes,i.e. an increase in the assay of the fresh feed from 1.38 per cent to 1.1+6 per cent tin and unresolved changes in the sulphide rougher flotation and tabling. However, using the results from a detailed size by size analysis of the behaviour of ore components in appropriate parts of the plant, it proved possible to show that, had the two unintended changes not occurred, up to 5 per cent

Jan 1, 1977

With mining development on hold and other underground works in a slowdown, the develop- ment of nuclear waste repositories takes center stage on the American rock engineering scene. Three repositories for commercial spent fuel -- in salt, tuff, and basalt -- are in the phase of site characterization and conceptual design, and one pilot project for defense high-level waste in salt is under construction. A repository design for crystal line rock has recently been postponed. Because of strict quality assurance requirements throughout design and construc- tion, and because of the need to predict and ascertain in advance the satisfactory perfor- mance of the underground openings, much intellectual energy has been expended to analyze underground openings in the unusual circumstances of the repository environment. In the long term, these efforts will lead to an improved understanding of rock behavior and improved methods of underground analysis and design. For the shorter term, a formalized ground control plan was developed, the princi- ples of which may be applied to other types of projects. This paper summarizes the status of underground design and construction for nuclear waste repositories and presents some details of the ground control plan and its individual elements.

Jan 1, 1987

By McGill RA

The Ranger Uranium Mine is surrounded by a World Heritage National Park. The strict environmental controls under which the mine operates are based on scientific and social requirements. Release of non-process storm runoff water to the Magela Creek during flood discharge and under controlled conditions has been identified as Best Practicable Technology for the operation of the water management system. Social and political factors have limited this release to a wet season with an Annual Exceedance Probability of one in ten. The first-generation trigger mechanism was based on a percentile analysis of monthly rainfall. The second-generation trigger is based on cumulative monthly volume increase in the retention ponds and is considered to be more applicable to the operation of the mine water management system.

Jan 1, 1988