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By W Mahoney, F Clement, E Saraiva

Prefabricated waterproofing sheet membranes are extremely complicated to install in underground sections with complex geometries and, despite being already subjected to quality tests in the factory, the installed membrane often exhibits leakages due to different reasons. Main sources of leaks are the required high amount of welding seams and damages caused during installation of reinforcement, as well as overstretching and poorly installed secondary concrete linings. Also the design of the tunnel lining is strongly influenced and limited by the use of prefabricated waterproofing sheet membranes. The use of sprayed waterproofing membranes for more than a decade has contributed to durability and serviceability, as well as to increasing sustainability of tunnel linings. The presented sprayed waterproofing membrane MasterSeal 345 is an advantageous alternative to prefabricated waterproofing sheet membranes under typical tunnelling conditions, especially in geometrically complex areas, such as in lay-by niches, cross passages and crossover caverns, where installation of conventional waterproofing membranes is inherently difficult, and locating leaks is challenging. This membrane has been successfully used in underground projects with different waterproofing design concepts and under diverse hydro-geological and environmental conditions for over a decade. It provides tunnel designers with different options and optimisation for the design of the tunnel concrete lining. Additional advantages to owners, contractors and designers from the use of the sprayed membrane include flexibility in the design, increased productivity and flexibility in working programming, as well as improved logistics, resulting in significant program and cost savings and reduced long-term maintenance costs. This paper describes the key features of this sprayed waterproofing membrane, its application range and limitations, the waterproofing concept, design options and related benefits. Further, guidance for membrane application and quality control and a summary of two recent project references in the United Kingdom and in Switzerland are provided.CITATION:Saraiva, E, Clement, F and Mahoney, W, 2014. The use of sprayable waterproofing membranes in underground structures – concept, design options, benefits and limitations, in Proceedings 15th Australasian Tunnelling Conference 2014 , pp 323–332 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 17, 2014

By H Thanasekaran, M J. Mankosa, J N. Kohmuench, G H. Luttrell

"Fluidised-bed flotation has been demonstrated over the last 16 years as an effective method for improving the flotation recovery of coarse particles. This technology has been successfully deployed into the industrial mineral sector with multiple installations within phosphate beneficiation plants and potash mills. Due to the minimal mineral surface expression required when utilising this technology, more recent studies have centred on the applicability of using this HydroFloat™ technology for the recovery of coarse sulfides and base metals. Multiple approaches have been investigated to determine the best means for implementing this novel coarse particle flotation system into both existing and new plant circuitry. These include the treatment of tailings to recover values that have been lost using conventional technologies and also the direct treatment of a coarse feed, either within the grinding circuit or by use of a separate split-feed flotation approach. Recent applications of the technology will be presented along with data generated from several test campaigns and ongoing research investigations. The benefits of properly applying this technology, such as reduced power consumption and increased mill capacity will be discussed.Citation:Kohmuench, J N, Thanasekaran, H, Mankosa, M J and Luttrell, G H, 2016. The Impact of Fluidised-bed Flotation for Treating Coarse Sulfides, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 105–112 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By M Bouare, C Holland, K N’Diaye

Two adjacent open pits in Mali hosted by deeply weathered saprolitic materials were mined consecutively over the course of approximately 12 months. During excavation, both pits experienced significant displacement and tension cracking as the result of deeper than expected depth of weathering coupled with relatively steep slope angles and significant groundwater. In response, geotechnical and operations teams overcame numerous monitoring challenges with prisms and radar to develop a simple and effective monitoring system coupled to a Trigger Action Response Plan (TARP) which enabled continued safe operations while reducing ore loss. Observations of previous slope performance of these two pits allowed for greater confidence in empirical failure runout calculations that was used to specify the standoff widths for the exclusion zones in the pit. Back analysis of the slope as-built performance after the first indications of slope distress was also conducted. The back analysis was used to confirm rock mass parameters for modelling while being utilised as a reality check for the stability analysis. The stability analysis indicated that leaving a large step-out or buttress would not prevent the displacement, resulting in some ore being sacrificed to ensure the safety of personnel. Key learnings from this experience highlight the importance of: • up-to-date geological interpretation of the depth of weathering • ensuring slope design guidance is reviewed and updated as latest information (ie geology and monitoring) is received • having multiple complementary slope monitoring methods to ensure redundancy • ensuring visual observations and as-built performance are utilised as a reality check to provide greater confidence in stability analysis and design guidance.

Jun 22, 2022

By P Velletri, N Gaylard

The management of wear surfaces in mining operations has remained largely unchanged since the inception of mining. Sacrificial wear liners are installed on the inside of chutes, hoppers and other equipment used to transfer bulk ore to protect the asset from abrasive wear caused by the flow of material. These liners are generally replaced at fixed intervals which may be determined based on historical wear rates or may be driven by other maintenance requirements for that asset. This approach does not always yield satisfactory results, especially for critical assets where the impact of downtime on production can be substantial. For such assets, a condition-based maintenance strategy has the potential to significantly increase productivity and reduce the total cost of ownership associated with the asset. However, for such a strategy to be successful, timely information on the actual condition (remaining thickness) of the wear liners is essential. This paper describes the development and implementation of a wear monitoring system that can be used to remotely and continuously report on remaining liner material thickness in real time. It details some of the challenges that were overcome when developing the system, including the design of a patented thickness measuring system that can be used in a variety of liner materials and is tolerant to the presence of ore on the wear surface. The paper also explains how a cloud-based approach enables data from the wear sensors to be integrated into external systems such as a data historian, which has been demonstrated through a collaborative project with one of the largest iron ore producers in the Pilbara. This ability to combine real time liner thickness information with other data sources, such as throughput, provides the foundation for the transition to a condition-based maintenance strategy.

Nov 8, 2021

By H Asche

The proposed Rockwater Power Project is a hydropower development on the Waitaki River in the South Island of New Zealand. The proposed development will have an installed capacity of 250 MW with a peak flow capacity of 260 m3/s. The project commences at Lake Waitaki and extends some 35 km downstream on the north bank to a surface power station at Stonewall. Flow is returned to the Waitaki River via an outfall channel.The tunnelling for the project is through Greywacke, which comprises Permian and Triassic age marine sediments that are well indurated and weakly metamorphosed. The rock mass is jointed and sheared and there are frequent faults, which range up to hundreds of metres in width. Three 12 m diameter tunnel boring machines (TBMs) are proposed to excavate the 35 km long tunnel.The paper describes the development of the tunnel alignment, rock mass classification, design of the support, rock and hydraulic loads, support installation options and construction sequencing.The alternatives of rock bolts and shotcrete and segmental lining were both investigated and are discussed. Support using rock bolts and shotcrete offers the potential of rapid construction with minimum support cost when the ground conditions are good, but delays due to support installation increases with deteriorating ground conditions. In contrast, segmentally lined tunnels offer greater certainty in cycle time with reduced program risk. Both options are described and discussed.The horizontal alignment is affected by the presence of major fault zones, which are either avoided, or pretreated by driving conventional tunnels through in advance of the TBM delivery, topographical constraints with the rugged topography and operational hydraulic constraints. Construction requirements, future power station operation and the minimisation of leakage from the tunnel have all impacted on the vertical alignment.The number and sequencing of TBMs to be used is discussed in terms of program time and risk minimisation.

Mar 8, 2011

By C Donnelly

Redpath Australia is using a unique mining method for the Australian underground coal industry at Kestrel Mine Extension in the Bowen Basin, Central Queensland.The project involves completing two separate drifts from the surface for access to the German Creek Coal Seam located approximately 230 m below the existing surface. The scope of work is primarily the construction of two drifts; the first is 1577 m at 1 in 6 gradient and the second 1874 m at 1 in 8 gradient. Each drift has been developed by a Mitsui S200 roadheader with modifications to allow for a continuous tunnelling/mining cycle operation. A shotcrete boom has been fitted to the left hand side of the machine with the operators console located at ground level. Another operators console is elevated on the right hand side of the machine to allow operation of the rotary drill boom which is mounted on a slide rail to allow flexibility of positioning depending on the stage of the cycle. In support of the roadheader activities, an integrated conveyor system mounted on a sliding floor arrangement is able to be advanced as the mining face progresses. This sliding floor consists of four 1.5 m × 6 m sections that utilise hydraulic rams to ‘walk’ inbye, allowing room for installation of precast concrete floor panels for final floor completion. This method borrows from the tunnelling and construction industries to eliminate place-change delays in the mining cycle by enabling complete ground support installation without retreat of the primary development machine from the face. The aim is to reduce the project duration with the completion of final floor and services to within 30 m of the operating face as it advances.

Mar 21, 2011

By D Blair, L Fergusson, G Barros

"The purpose of this paper is to present the findings of a waste rock remediation program conducted at a gold mine in New South Wales (NSW) over a six-year period. The treatment of waste rock dumps included the longitudinal results of one-off applications using: ViroMine Technology, including the application of a chemical reagent called Terra B, which is a benign, clay-like substance derived from processed bauxite and other sources lime and biosolids (added for nutrient value) clay capping and topsoil compared treatment outcomes from these three approaches to a control.Parameters measured in the program included leachate pH, total actual acidity (TAA) and chromium reducible sulfur (CRS), Al, Cd, Cu, Fe, Mn, Ni, Pb, Zn, and tree height and vegetative cover density with data collected at regular intervals over a six-year monitoring period. Findings over the life of the study indicated, for example, that leachate pH in the control area was 4.5 in year 1 falling to 4.0 by year 6; pH in the lime and capping treated waste rock was initially raised to about 5.5 after treatment but fell to 5.0 within 24 months and remained a low 4.7 by year 6; pH in the Terra B waste rock was 6.8 in year 1 immediately after treatment, and actually increased to 7.3 by year 6 with no further treatment. This finding is of relevance because it effectively profiles the acidity curves of waste rock control, lime, and capping applications, and shows that they decline over time, despite an initial æpH shockÆ to the solids as measured by TAA and CRS in the case of lime. Similar treatment curves were observed for heavy metal leachates. Tree height and vegetative cover density indicated that with increasing acidity in the waste rock dump, the lime and capping options did not allow healthy revegetation, but in the Terra B treated areas tree growth and density were comparable to background, undisturbed forest levels.is needed with respect to tailings management, based on a novel integrated research framework.CITATION:Fergusson, L, Blair, D and Barros, G, 2012. Sustainable waste rock remediation and revegetation - A real-world longitudinal study comparing ViroMine technology to standard applications and doing nothing, in Proceedings Life-of-Mine 2012 , pp 249-258 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Jul 10, 2012

By T Wellman, G Sternadt, R Hingston

The 335 000 oz Wilber Deposit is located within the Meekatharra-Wydgee Archaean greenstone belt in the Murchison District of Western Australia. The deposit comprises high-grade gold mineralisation hosted within a steeply west-dipping quartz lode, which lies within a broader (20–60?m) north-east striking shear zone envelope. Locally, the northerly-trending host rock geology includes greenschist facies high-Mg basalt (albite, actinolite, chlorite, biotite, calcite, zoisite, muscovite and titanate) intruded by at least two generations of felsic to intermediate porphyries (albite, actinolite, zoisite, chlorite, sericite, biotite, quartz and titanate). The Archaean rocks are cross-cut by a number of east–west striking Proterozoic dolerite dykes (biotite (50 per cent), albite, carbonate, epidote, titanate and actinolite) that are interpreted to have intruded pre-existing regional structures. The entire mine package is cross-cut by a system of shallow north-east-striking, north-west-dipping, barren quartz veins that commonly contain large (up to 30 cm), euhedral, smokey quartz megacrysts.The north-east-trending lode lies within a 3 m wide shear zone and varies from a single discrete 0.5 to 4 m wide laminated, massive or brecciated quartz-carbonate vein to multiple laminated veins up to 1 m wide within the shear. The veins exhibit strong boudinage, with cross-cutting quartz-carbonate seal veins in the boudin necks. The boudin necks often contain pink calcite. The shear zone fabric wraps closely around the boudin necks proximal to the vein, becoming more lode parallel distal to the vein. The lode is offset by a north to north-north-west trending fault.Mineralisation occurs as free gold within the quartz carbonate veins, with accessory sulfides including pyrite ± chalcopyrite, ± galena ± sphalerite. Fuchsite is observed in the veins, as laminar wall rock inclusions, with visible gold commonly associated with the wall rock laminations.Gold grades range from less than 1 g/t within the hosting shear zone, either at the margins or interstitial to the veins, to approximately 30 g/t in the single vein, and up to greater than 60 g/t in the multiple vein areas. Gold is commonly visible and disseminated throughout laminated, breccia and massive quartz veins, although laminations show the highest concentration of gold grains.CITATION:Hingston, R, Wellman, T and Sternadt, G, 2014. The geology of the Wilber Deposit, Andy Well Gold Project, Murchison District, Western Australia, in Proceedings Ninth International Mining Geology Conference 2014 , pp 55–64 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 18, 2014

By A Li, H Jinto, M Laxman

The behaviour of tailings under cyclic loading has an impact on the stability and deformation of tailings dams and a good understanding of the cyclic behaviour of the tailings under earthquakes is important for tailings engineers and tailings operators for the design and safe operation of tailings dams. This paper presents an investigation into the cyclic behaviour of tailings using both laboratory cyclic direct simple shear (DSS) testing and numerical modelling. The laboratory testing involved cyclic DSS tests on gold tailings and zinc-copper tailings under different loadings and loading frequencies. The gold tailings specimen tested at a higher loading frequency and a higher cyclic stress ratio experienced spontaneous liquefaction during cyclic shearing and the zinc-copper tailings specimen tested at a lower loading frequency and a similar cyclic stress ratio exhibited ductile behaviour and liquefied due to cyclic mobility. The liquefaction behaviour of the tailings was modelled using an advanced constitutive model (UBCSAND), which was developed specifically to model soil liquefaction and strain softening under cyclic loading. The constitutive soil model presents the nonlinear soil behaviour under dynamic loading using a hyperbolic stress-strain relation. Dynamic analyses were carried out using a finite difference program FLAC. The cyclic stress-induced excess pore water pressures measured in the laboratory were modelled using numerical simulations of the laboratory tests under different loading conditions. The results of the non-linear dynamic analyses demonstrated the capability of numerical modelling of cyclic shearing induced excess pore water pressure and the onset of the spontaneous liquefaction. The laboratory investigation and numerical modelling technique provided the key properties and parameters for the dynamic analyses to assess the stability and deformation of tailings dams under design earthquake events. More importantly, the laboratory tests and numerical modelling provided some insights into liquefaction behaviour of the tailings during earthquakes. CITATION:Li, A, Laxman, M and Jinto, H, 2018. Liquefaction behaviour of tailings under cyclic simple shear testing, in Proceedings Mine Waste and Tailings Stewardship Conference 2018, pp 250–262 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 23, 2018

By S Love, M Anderson, M Boland

"The high rate of failure of new mine developments to meet feasibility study expectations has been the subject of many fine technical papers. Yet failure rates remain stubbornly high.Similarly, the common occurrence of disastrous acquisitions resulting from failed due diligence on projects is well known. Yet such mistakes continue to be made.The authors argue that project and due diligence failure are caused at least partly by cognitive biases. These biases pervade decision-making throughout project evaluations.A wider understanding of these biases (and their effects) is necessary. Only then can mitigating actions be taken.The opportunity for this wider understanding exists. A number of best-selling books have been published on the topic in recent years. With wider understanding of key concepts and terms, cognitive biases can be recognised and discussed. They can also be challenged and mitigated.The authors believe that these concepts should be entry-level, required knowledge for anyone evaluating, developing, reviewing or financing mining projects.Perhaps the most prevalent biases in project evaluation failure are the ‘over-optimism’ biases. In particular, the planning fallacy and confirmation bias.The anchoring effect is also pervasive. This bias propagates unrealistic assumptions from scoping and prefeasibility studies through to so-called definitive feasibility studies. Unrecognised anchoring biases also undermine the validity of many ‘independent’ due diligence reviews. They are also prevalent in corporate acquisitions.The availability heuristic refers to a mental shortcut that can lead to a number of biases. One of these is the narrative fallacy. The mind constructs coherent narratives and opinions, regardless of the amount and quality of the information that support them. Narrative fallacy commonly occurs in the evaluation of social and political risk. Another is disaster neglect, which is especially common in the failure to assess risks associated with tailings management.This paper outlines the relevance of these biases to mine project evaluations. It also provides examples where the authors have observed their effects.CITATION:Love, S, Boland, M and Anderson, M, 2016. Influence of cognitive biases on project evaluation, in Proceedings Project Evaluation 2016, pp 226–235 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Mar 8, 2016

By S K. Panda, M A. Van Ende, S Chatterjee

Tata Steel Netherlands (TSN) aims to reduce its CO2 emissions by 35–40 per cent by 2030 and become CO2 neutral by 2045. A first step to reach these targets is via the utilisation of an Electric Arc Furnace (EAF), which will run on a mixture of high proportion of Direct Reduced Iron (DRI) and scrap. For an EAF operation, optimisation of slag chemistry is important to achieve the right mix of basicity (for refining especially dephosphorisation), foaming, volume (rate) and refractory life. Slag composition and rate can vary widely depending on the process variables like charge mix, charge composition, feeding rate, oxygen lancing, external carbon injection/addition, fluxing and refractory erosion/corrosion. Moreover, it is important to note that the slag composition and rate are ‘transient’ parameters and change throughout the heat. This makes all the dependent phenomena and/or outcomes transient as well. To describe all these effects simultaneously and be able to realistically simulate the EAF operations, a validated dynamic process model is important in the absence of real plant data. In this study, a validated dynamic EAF process model based on the concept of Effective Equilibrium Reaction Zone (EERZ) has been utilised to analyse the impact of high DRI industrial scale EAF operations on the transient slag characteristics – including slag volume (rate), composition, phases, solid fraction and viscosity. Simultaneously, the model is able to predict the impact on steel and offgas characteristics. Case studies were performed with 70 per cent DRI:30 per cent scrap mix considering both low and high-grade DRI. Both melting and refining aspects of the process including continuous feeding, arcing program, carbon addition, fluxing and oxy-lancing were considered.

Jun 19, 2024

By L Chaffey, M Buckland

The minerals industry has enormous potential to positively contribute to sustainable development and many leading companies have concluded that their long-term success is directly linked to their ability to leave a lasting positive legacy. While there are many examples of success, there have been failures as well and much work has been done in recent years to define the role of the minerals industry in sustainable development and identify the key elements for success. In the past, our sector could point to the taxes and royalties it paid, the exports it generated and employment it created and felt confident that its contribution would be recognised and duly acknowledged. This is no longer the case. Critics of the industry have highlighted resource-rich countries that have failed to capitalise on their resource wealth and have arguably lower standards of living than their resource-poor peers û the æresource curseÆ hypothesis. Recent research has done much to clarify the factors that contribute to a countryÆs success or failure and all stakeholders in the industry now need to include these learnings in their approaches going forward. We know that our long-term success relies on embedding a company- wide approach to sustainable development into all aspects of our business operations. In this paper we highlight BHP BillitonÆs experience in the development and implementation of policies and systems designed to enhance our contribution to sustainable development. We detail the business drivers for excellence in this area and the key external codes and initiatives that have shaped our approach. The values-based BHP Billiton Charter, Sustainable Development Policy and associated Health, Safety, Environment and Community (HSEC) Management Standards are central to our approach. Implementation is reviewed through our HSEC audit program. One area in which we have placed particular emphasis is our approach to community development. BHP Billiton has a corporate target to contribute one per cent of its pre-tax profit on a three year rolling average to voluntary community programs. As our profit stream has increased with the minerals boom this is approaching an A$100 million commitment. In our paper we detail how we are working to ensure we maximise the value of this contribution for our communities and our shareholders.

Jan 1, 2006

By S F. Rogers, K Doumis, J H. Graaf, B J. Barsanti

Advances in technology now allow geotechnical practitioners to better describe the properties and variability of a rock mass through advances in surface and underground mapping, borehole technology and geophysical imaging. Yet the way in which practitioners use this data is not being realised to its full potential and the quality and quantity of data that is collected is often superior to the conventional design approaches that are typically adopted. A discrete fracture network (DFN) approach provides the ideal basis for using this data to generate geologically-realistic rock mass models based on parameters derived from field data, which more effectively capture the variability and rock mass behaviour. However, until recently, the DFN approach has mainly been applied to cave mining and small-scale models associated with synthetic rock mass modelling or groundwater flow modelling for the nuclear waste and oil and gas industries.Ground support design for blocky rock masses in Australia is often dealt with in a rather traditional manner, adopting either an observational empirical approach through rock mass classification systems or conventional wedge stability analysis techniques. Using these methods requires several generalised assumptions about the rock mass fabric and excavation geometry. As such, the support system is often designed for a worst-case scenario based on a predetermined risk tolerance that the mine is willing to accept and a design block size that is generally determined by the proposed excavation dimension.A study by Doumis (2014) used conventional wedge stability analysis and the probabilistic key block analysis software JBlock (Esterhuizen, 1996) to estimate potential block sizes and support requirements. A DFN approach has also been adopted at Callie underground mine using FracMan™ software (Golder Associates, 2014). The methodology of the DFN wedge analysis will be compared with the key block analysis work undertaken by Doumis.CITATION:Graaf, J H, Barsanti, B J, Doumis, K and Rogers, S F, 2014. Towards the implementation of discrete fracture network modelling as a geotechnical design tool – case study of callie underground mine, in Proceedings AusRock 2014: Third Australasian Ground Control in Mining Conference , pp 399–408 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 5, 2014

By P Clark

This paper discusses the challenges, solutions and lessons learnt as tunnelling work continues on the Melbourne Main Sewer Replacement (MMSR) project.The MMSR project is a $220 million dollar project for the Melbourne Water Corporation. It involves the construction of approximately 4.2 km of new sewer from the southern fringe of the CBD through the inner metropolitan suburbs of Port Melbourne and South Melbourne.Of the 4.2 km of sewer currently in construction approximately 2.2 km will be constructed using a 2.95 m diameter Lovat EPB tunnel boring machine (TBM) with approximately 1.9 km of small diameter (300 to 600 mm) reticulation sewers constructed using trenchless techniques.These sewers are being constructed in a dense urban environment, which means that the tunnels and shafts are often in close proximity to buildings and structures. The underground constructionof the sewer is further complicated by the variable geology of the ancient Yarra River delta which includes weathered basalts, the infamous Coode island silt formation and fine loose sands.Some of the key challenges and lessons learnt so far during construction include:· steering and alignment control of the TBM through very soft silt with little residual strength,· development and refinement of a monitoring and alarm system for leaving the machine dormant on a day works only project,· control and measurement of tunnel lining defl ection during ring build and grouting,· prediction and monitoring of surface settlements during tunnel excavation,· improved understanding of the geology and hydrogeology at this previously unchartered area of Melbourne,· consolidation settlement due to dewatering at shafts required careful construction controls, and· ground support and excavation in close proximity to the existing 110 year old sewer which requiredvery detailed risk control measures.

Mar 8, 2011

By J D. Lubben

Hibbing Taconite is a Lake Superior-type granular magnetite taconite deposit occurring within the Biwabik Iron Formation along Minnesota’s central Mesabi Iron Range. The deposit is situated on the northern margin of the Proterozoic Animikie Basin. The deposit strikes northeast, dips gently southeast, and occupies 10 km of strike length. Mining focuses on 50 m of granular cherty and laminated slaty taconite within the Lower Cherty member.Ores generally consist of a quartz, magnetite, siderite, ankerite, minnesotaite, stilpnomelane, and haematite mineral assemblage. Processing is optimised by exploiting the physical and chemical variations that exist between three major ore types. Taconite ore averages 20 per cent magnetic iron (MagFe), 27 per cent weight recovery (WtRec) and produces a final concentrate with 4.5 per cent silica (SiO2). Since 1976, production has totalled approximately 237 million long tons (Mlt) of pellets (8 Mlt per year rated capacity).Ore processing uses a simple fl ow sheet of autogenous grinding (<0.044 mm) followed by two phases of wet magnetic separation, fi ltering, limestone/bentonite addition, balling, and firing to create pellets averaging 66 per cent total iron. A Liberation Index (LIS) is used as a primary guide for ore grading and metallurgical control. Grind requirements, magnetite liberation and silica grade are closely monitored to ensure plant optimisation and product quality.A recent program of benefi ciation of low-grade ores by in-pit crushing and dry magnetic cobbing has demonstrated that low-grade ores (<17 per cent MagFe, <25 per cent WtRec) can achieve a signifi cant metallurgical upgrade (up to 25 per cent MagFe and 40 per cent WtRec). This operation recovers 60 per cent of the total crushed volume, and has a calculated effi ciency factor (magnetic iron recovery) of 79 per cent. This paper discusses the benefi ts of this upgrading and its effects on ore blending and processing.

Jul 11, 2011

By P Holtham, J Meng, E Tabosa, W Xie

Turbulence and its distribution are of great importance in flotation, and have received considerable attention recently. However, there is no mature technique to measure turbulence in three-phase (liquid-solid-gas) industrial flotation cells due to the opaque, highly aggressive and abrasive nature of the slurry involved. Previous research has shown that the piezoelectric vibration sensor (PVS) is a promising tool for turbulence measurement in industrial flotation cells. The PVS is a robust device that converts mechanical vibration to electrical signal, from which turbulence information can be extracted. An improved calibration method has allowed development of a frequency model to calculate the force applied to the sensor. Experimental results and comparison with laser doppler anemometry (LDA) have shown that the PVS can measure fluid kinetic energy, which is related to turbulent kinetic energy, a parameter used in the literature to represent turbulence in flotation. Laboratory measurement in a two-phase (water and air) 60 L cell and with slurry in a 3.5 L cell gave good stable results and mostly consistent trends between the measured turbulence profile and cell operation. When applied in a 300 m3 industrial cell filled with water, the addition of air or slurry to the cell resulted in a shift in the turbulence profile. This is expected because a change in fluid density will change the force applied to the sensor. It is therefore concluded that the piezoelectric sensor is an easy-to-use and robust technique that is fully capable of measuring turbulence in industrial flotation environments.CITATION:Meng, J, Tabosa, E, Xie, W, Runge, K C and Holtham, P, 2014. Development and application of a piezoelectric sensor for turbulence measurement in industrial flotation cells, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 457–470 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

By S H. Algie, D P. Taplin, S G. Doig

"Suboptimal performance of clusters of hydrocyclones (cyclones), relative to the performance of the individual cyclones that comprise the cluster, is a common phenomenon. The primary cause is well known: uneven distribution of the slurry feed into the individual cyclones. The direct result of uneven distribution is that each cyclone in a cluster performs somewhat differently. Hence, some, if not all, of them do not work at their intended operating points, and the classification is not as sharp as intended. The impact on grade, recovery and milling efficiency will vary depending on the duty of the processing circuit, but the most immediately apparent consequence of uneven distribution is a difference in wear rates in the individual cyclones; this exacerbates the problems of unequal performance of the individual cyclones. In severe cases, and as differential wear proceeds, flows from the individual cyclones may become visibly different. Uneven distribution, once the phenomenon was identified, was seen to be a significant issue in the high-solids hydrocyclone cluster in the ball mill recycle section of Evolution Mining’s Edna May Operation (EMO, Westonia, Western Australia) gold processing plant. In 2012, a FloCEP® hydrocyclone feed distributor system was installed to alleviate the problem. Over the next four years of operation, this innovation has proven its value in the metallurgical and maintenance areas. Individual cyclones now wear at the same rate, greatly reducing the need for operator intervention, as well as increasing overall plant availability through minimising unplanned maintenance. The costs of the installation can be justified by savings in maintenance alone, though the greatest value, as is described in this paper, is in allowing the plant to produce consistently closer to its operational design limits. The FloCEP® system is a low maintenance, readily installed retrofit, based on two patented devices that are combined with complementary proprietary design methodology allowing customisation for specific flow rates and slurry particle properties. Together, these devices produce and distribute a pseudo-homogenous slurry flow without moving parts.Citation:Taplin, D P, Doig, S G and Algie, S H, 2016. Experience with FloCEP® Slurry Flow Conditioning at Evolution Mining's Edna May Operation, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 251–260 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By J B Tucker, A T. McGrath

Situated in north-west Queensland, Australia, the Ernest Henry Mine (EHM) has been producing copper and gold since 1996. Owned and operated by Glencore Xstrata, ore is currently sourced from a newly developed underground sublevel cave (SLC) mine below the old EHM open pit (the pit). Ore feed to the concentrator is supplemented by satellite open pits comprising the Mount Margaret operation.The transition from open pit to a producing underground mine involved a complex extraction sequence for the first two production sublevels on RL1650 and RL1625. Underground mining during cave initiation was further complicated when south wall instability prevented completion of the final open pit shell. The transition mining phase included mass firing of an inclined crown pillar between the initial SLC void and the pit followed by a combination of transverse and longitudinal SLC mining.The inclined crown pillar mass firing was the first significant milestone in the extraction of the transition ore block. Comprising approximately 890 000 t of in situ material; 70 000 m of drilling was charged with 351 t of emulsion and 6026 electronic detonators to initiate the single mass firing. The firing contained five direction changes over 19 seconds making it one of the largest and most complex underground blasts ever conducted in Australia.Risk management was integrated into every facet of the technical and operational planning and execution of the transition mining phase, whilst maintaining daily mine construction and production commitments. This paper provides a detailed overview of the transition objectives and constraints, mining method selection, post mass blast outcomes and the journey ahead.CITATION:McGrath, A T, Campbell, A D and Tucker, J B, 2014. Transition of the Ernest Henry Mine from open pit to an underground sublevel cave, in Proceedings 12th AusIMM Underground Operators’ Conference 2014 , pp 297–308 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Mar 24, 2014

Exploring long-term future possibilities for your business and methods for achieving them are critical functions of leadership. More than ever, strategic initiatives today have to be planned and delivered in an environment of disruptive change û driven by shifting business or regulatory imperatives, new technologies and global economic change, and diverse stakeholder interests. The notion of The Future as a single inevitable outcome is obsolete. There are many possible futures. This paper explains an innovative process û known as scenario planning û to help executives in the construction and testing of longer-term strategies to deal with uncertainty.

Jan 1, 2006

By M Spagnolo, M Ashley, D, L Reemeyer

PasmincoÆs Century Concentrator in North West Queensland commenced operations in November 1999. The nameplate production capacity of 500 000 tpa of zinc metal production in concentrate was achieved in August 2002. Completion of the production ramp up was successful due to the culmination of a number of initiatives throughout 2001 and 2002. Mine to mill interaction to understand and eliminate head grade related bottlenecks affecting Concentrator production and reduce feed variation. Grinding circuit process development û operating and process control strategies to improve stability and reduce grind size to support zinc recovery. Pumping upgrades to control spillage in ultrafine zinc flotation Low density zinc flotation strategy û to improve silica-sphalerite separation to improve zinc recovery while maintaining acceptable silica in final concentrate. Flotation circuit process development û froth crowders, froth cameras and reagent control strategies to improve primary zinc flotation performance. Review and implementation of longer campaigns between planned shutdowns to improve availability. Team reorganisation û to improve setting and implementation of metallurgical strategies. This paper describes these initiatives and their contribution in achieving the production target. It also notes the ball mill motor failures that delayed the successful achievement of the ramp up, and CenturyÆs response to minimise the production impact. The paper also outlines the capital improvement program that was implemented to improve zinc recovery to design 82.5 per cent recovery once the production rate had been achieved.

Jan 1, 2003