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By B Nielsen, H Lehto, B Musuku

"The demand for fine and ultra-fine grinding associated with the processing of more challenging, finer grained orebodies and the global driver of minimising energy consumption has been an increased focus in our industry. Outotec’s stirred milling technology, the high intensity grinding mill (HIGmill™), was launched in 2012 in response to this industry need. First Quantum Minerals Ltd selected HIGmill™ technology for its Kevitsa mine in Northern Finland. The 700 kW mill is grinding copper rougher concentrate to improve copper/nickel separation and copper recovery. Selection of the HIGmill™ followed mineralogy analysis and laboratory and pilot testing for HIG milling in parallel with flotation tests to determine optimum grind size and energy input.The paper discusses the challenges and successes of the test work, manufacture, installation, commissioning and subsequent operation of the mill. Grinding performance is presented and a comparison between predicted and operating energy efficiency is made. In addition, the various steps to optimise wear rate and minimise maintenance and downtime are made, with particular reference to internal geometry of the mill.Citation:Nielsen, B, Lehto, H and Musuku, B, 2016. Design, Installation, Commissioning and Operation of Fine Grinding Technology at the Kevitsa Mine, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 59–66 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By M I. Pownceby, M A. Rhamdhani, D M. Fellicia, S Palanisamy, R Z. Mukhlis

The trend of global copper production has prospectively increased over time. Based on typical mined ore grades, 1 t of copper ore generates approximately 6–10 kg of copper, which requires much energy, usually in the form of metallurgical coke. Copper production using carbon as a fuel and reductant contributes up to 0.3 per cent to global greenhouse gas (GHG) emissions. As a result, research into decarbonisation processes applicable to reducing low-grade copper sulfide ores, copper oxides, electronic wastes and other alternative complex Cu-rich materials has increased. Alternative fuels for reducing carbon-rich emissions in pyrometallurgical copper processing include methane, ammonia, biomass, solar and wind power, but in recent times increased focus has been on hydrogen as a potential fuel and reducing agent for materials such as oxidised copper scrap, Cu2O/CuO and Cu-rich slags/e-wastes. From a thermodynamic perspective, hydrogen exhibits a significantly more negative standard Gibbs free energy (ΔG°) than copper oxide making it a suitable reductant and the exothermic thermal effect from reaction between hydrogen and Cu2O/CuO may be used to control process parameters. These characteristics renders hydrogen an ideal gas for reducing copper oxides and copper-containing slags/e-wastes. This review article assesses previous research on utilising hydrogen for producing and refining copper from primary and secondary feed materials.

Jun 19, 2024

By Thirumalai K, Peluso R. G

The United States has more than 45 billion tons of economic coal reserves in seams above 10 feet thick and current underground production from thick seams represent less than three per cent of the total production. A tripling of underground production from thick seams is necessary within the next 10 years to meet U.S. coal production demands. An analysis of underground accident and production data is presented in the paper. A study of accident and injury distribution in different coal seam heights in the eastern and western part of the United States in seams ranging in thicknesses from 5 to 15 feet indicates that the seam thicknesses do not produce adverse impact on underground injury incidence. Accidents associated with roof falls and haulage account for about 70 per cent of underground mining injuries.

Jan 1, 1976

By Mankosa MJ, Yoon R-H

A reliable scale-up procedure for column flotation must address three important areas of column design, ie column geometry, sparging system and wash water distribution network. The column geometry is dictated by the maximum froth carrying capacity (which determines column diameter) and the bubble-particle attachment rate and particle retention time (which determines column length). The most important factor in the scale-up of an air sparging system is the ability to produce small bubbles in both laboratory and full-scale columns. Other factors, such as energy consumption and maintenance requirements, should also be considered in the scale-up of bubble generators. It is also important to design a wash water distribution system that can properly control the froth stability and maximise the column throughput. Based on these criteria, a successful scale-up example is given.

Jan 1, 1993

By L Lorenzen, H Muller, L Bernard

Australian companies and consultants are becoming ever more involved in projects in African, South American, East European and Middle Eastern countries. However, significant differences in culture and approach to projects sometimes make these projects challenging for reasons that are not purely technical. Often the challenges are rather related to how the project owner and local authorities perceive the reality. These perceptions and sometimes unrealistic expectations regarding project costs and potential outcomes need to be addressed by the æWesternÆ project developer and consultant.This paper will discuss the specific experience of Snowden in studies commissioned by companies from such countries for the development of very large, low-grade gold deposits in some of the most inhospitable areas in the world. The paper will further review similar projects undertaken in other ænew worldÆ countries and compare these to the initial Snowden experience.As the process operating costs of operations in many of these countries are extremely competitive when compared to the typical Australian operating costs, the paper will review the operating costs and the factors which may be pertinent to a large project of this nature, both in the Australian and the ænew worldÆ context. Will Australian-based operations be able to compete in the global gold market when the gold price softens again, as it will do at some stage in the possibly not-so-distant future?CITATION:Muller, H, Lorenzen, L and Bernard, L, 2013. Challenges of developing low-grade deposits in ænew worldÆ countries from a mining consultantÆs perspective, in Proceedings World Gold 2013 , pp 307-314 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 26, 2013

A review of the most widely used global extraction sequences in sublevel is undertaken. The review includes techniques used to extract massive as well as single or multiple steeply dipping tabular orebodies. The paper also deals with thick flat lying orebodies suitable for open stoping. Techniques used to minimise the effect of stress redistributions on a global scale are discussed for all the extraction sequences analysed.

Jan 1, 2003

Coal mining legislation makes frequent reference to æSafety Management SystemsÆ but there is a chronic shortage of useful guidance material as to how these might be applied to hazardous exposures. Several studies have indicated that for each death that is reported as a result of an industrial æaccidentÆ, there are five deaths that caused by occupational exposures. Because the deaths from occupational exposures do not occur on site and often well after employment has ceased, they are generally unreported. Improved access to mortality data from coroners, the Australian Institute of Health and Welfare and superannuation service providers (early claims from death and total permanent disability), has given rise to some analysis of death and disability data that provides evidence that there are emerging opportunities to develop and improve safety management systems for hazardous occupational exposures. Issues explored include how safety management systems might be developed in relation to dusts and chemicals and other hazardous exposures to ensure the risk of disorders with long latency periods are reliably assessed and the exposures effectively managed. The current standards and guidelines which refer to safety management systems in general or to management of exposure related hazards are examined. Many standards are based on dose-response studies that provide for an acceptable percentage of workers to suffer adverse health outcomes. An alternative management system might be to apply dose-response relations to health surveillance to identify æat riskÆ individuals and effectively manage health and related safety risk at an early stage.

Jan 1, 2005

By P Warner

Mines are often located in remote areas that are not well served by æstiffÆ power grids. Radial transmission networks, high lightning incidence (eg in South Africa the Witwatersrand experiences seven to ten strikes/km2 per year), low short circuit strengths and diesel generation are not uncommon. All these factors result in the electric power supply to many mines being unusually prone to dips and disturbances. æLegacyÆ winder drives û cyclo converters and dc drives û convert power directly from the supply to the motor, with no intermediate energy storage element. Further, they rely on the supply network for commutation and are therefore sensitive to supply voltage disturbances. There is a high probability that a dc or cyclo mine winder will trip during a supply disturbance, often resulting in lost production time and call-outs for technical staff to reset or even repair equipment. In contrast, a voltage source inverter (VSI) ac drive stores a large quantity of energy (in the dc link capacitors) and is fully self-commutating. Hence, this topology is inherently more immune to supply voltage disturbances. Indeed, vendors of ac VSI mine winders make general statements about the superior performance of their drives during supply disturbances. However, the advantages have apparently not been previously quantified. This paper compares different winder drive topologies and their sensitivity to supply disturbances, considers categories of supply disturbances and quantifies the cost of the effects on the different drive types.

Jan 1, 2005

The addition of a thallous salt to the cyanide leach of a calcined pyritic concentrate causes a marked increase in the"rate of extraction of gold. This probably is due to the activation of passive gold by.th,e. thallous ions'.''Lea'd, bismuth, and mercury salts, which should produce ' a, similai effect, fail to do so. It is postulated that'this latter result, together with'the reprecipitation of silver at low cyanide levels, is due to the presence of soluble sulphide. The use of thallous salts to reduce leaching time is discussed briefly.

Jan 1, 1964

By Nagai K, Moriyama K

Toyo smelter has been making s veral efforts to reduce and diversify energy for dealing successfully with such :n:;rgy problems as the first and second oil crises. ::,specially it is one of th:; most important subjects to substitute oil by alternative: energy source, because oil is expensive and unstable with respect to its supply. t _'hercfore i was decided to propel tnC ezhstitution of coal *jr oil. in the first place, the supple- mental fuel oil in the reaction shaft was replaced by oil to coal in 1981, and then th, fuel substitution of pulverized coal was achieved in the steam superheater in 1984. 3y these fuel substitutions about 7u,' of the total fuel energy at 2oyo smelter has been replaced by coal. in this paper the fuel substitu- tions at loyo smelter are described in detail.

Jan 1, 1987

By C Itotoh, K O’Halloran, L Karlson

Global methods used to explore for minerals have progressed relatively slowly since the development of the first diamond core drill in 1863. Since then, key developments such as wireline geophysics (1920s), the tricone drill bit (1930s) and aeromagnetic surveys (1940s) all occurred in response to global events. In this project, BHP’s WAIO Geoscience operations team hypothesise that a global movement towards a greener future as well as an increasing intolerance for safety events will drive another step change in exploration methods. We have leveraged our relationships with exploration contractor partners and industry leaders to develop a realistic vision for 2033 and beyond, where drill rigs, earthworks and geophysical units are operated and maintained remotely; emissions of dust and waste are eliminated; hazardous energy sources are controlled; procurement is based on sustainability rather than cost and carbon emissions are tracked with the same rigour as production metrics. We have combined these visions into a series of graphical illustrations with the aim of inspiring ourselves, our vendors and our peers to collaborate further on producing a step change in our industry.

Sep 18, 2023

By B Darlington, L Sandberg, O Vallati

The D47 and D39 Mechanical Dynamic Extra bolts (D47 MDX and D39 MDX) have been developed in response to the ever-increasing demand from the mining industry for rock bolts with high dynamic capacity. To prove such capacity, Sandvik has performed numerous in situ dynamic testing with the unique Dynamic Test Rig (DTR) (Darlington, Rataj and Roach, 2019; Roach, Rataj and Darlington, 2019). To complement the collection of testing data, Sandvik, in collaboration with the Swedish Research Institute for Mining, Metallurgy and Materials (Swerim) have performed additional experiments in laboratory condition using Swerim’s new drop test rig. This rig utilises a momentum transfer method to apply a dynamic load to the bolt. The sample falls together with the mass until the support beam impacts stationary dampers and the momentum energy is transferred to the bolt. Part of the charged energy is released by the dumpers while the remaining portion is absorbed by plastic deformation and/or displacement of the ground support element. The D47 and D39 MDX bolts have been tested at Swerim’s test facility with different levels of input energy. Six tests were performed at the specification energy of 36 kJ and six tests were carried out with the maximum allowable energy from the facility, ie 44 kJ. The bolts confirmed their dynamic performance absorbing the input energy without failure. The D47 MDX bolt absorbed up to 33 kJ with 150 mm displacement while the D39 MDX bolt absorbed up to 35 kJ with 162 mm displacement. This work will present an overview of the drop test rig at Swerim’s facility and a collection of results of the test performed on the D47 and D39 MDX bolts. The test method and results will be analysed and compared to the tests carried out with the in situ DTR.

Nov 29, 2022

By Kurzeme M, Willoughby D. R

Current research at the CSIRO, Division of Applied Geomechanics, into the mode of response of fill as a structural component has been based on model tests for prediction of behaviour and field observation of critical parameters. The procedure is summarised in four stages: (a) define the specific fill function (b) postulate the mode of failure (c) use models to quantify the conditions (d) monitor critical parameters to check or update the analysis in (c). The above procedure is used to postulate the failure modes of each of the possible func- tions performed by fill materials. Analytical techniques, or lines of investigation, are described for each of these modes and specific reference is made, where, possible, to an exis- ting mine environment.

Jan 1, 1973

Studying the ore textures in a discrete orebody is a novel approach to estimating liberation potential of the ore minerals present. As part of a PhD thesis, this project aims at classifying and quantifying the textures of the Hilton North orebodies, and at estimating their liberation characteristics.

Jan 1, 1993

By D Baas, D Bennett

This paper describes how Brisbane-based PanAust Limited develops process control strategies that are implemented at all operations and are used in functional descriptions for plant upgrades and new projects.The process control strategies are determined by operating management philosophies designed to maximise returns from the company’s assets.The approach is endorsed in the project planning and design phases to ensure facilities and equipment that form the major production assets are fit for purpose and capable of enabling the production managers and operators of the projects to maximise shareholder returns.PanAust’s process control approach has been to develop sets of process control standards which focus on two key areas. The first area covers hardware requirements and architecture, software objectives, control models and individual loop tuning methods. The second area defines control room layout, graphic standards and the alarm philosophy. The application of these standards in a new plant or upgrade decreases the time required to achieve design capacity and optimal performance.The PanAust process control strategy changes the operator’s role from one that controls a number of individual loops to one that sets the control objectives of the processing plant. To achieve optimal performance, all the process areas of the plant are analysed to identify opportunities to improve throughput, recovery and stability. Once a key opportunity is identified, a process control strategy is developed which defines the objective of the control, its functionality and how an operator will interact with it. After development of the control model the operators assist engineers to test and debug it. Once the model is robust, it can then be duplicated throughout the group and developed as a group process control standard.CITATION:Baas, D, Bennett, D and Walker, P, 2014. Developing process control standards for optimal plant performance at PanAust Limited, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 325–334 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

By A Fowler

The unpredictability of the location, grade and width of narrow-vein deposits presents difficulties for mine geologists and engineers attempting to estimate, schedule, forecast and mine their deposit profitably. This unpredictability stems not only from the grade distribution within a vein, but also the irregularity of vein geometry in three-dimensional (3D) space. Traditional deterministic methods of modelling vein geometry do not account for the inherent variability of the veins, resulting in significant errors when using limited drill hole information. This paper presents a probabilistic method of modelling narrow-vein deposits using sequential gaussian simulation (SGS), which can quantify this variability and improve production forecasts. Vein geometry, thickness and grade are simulated to provide a number of different equi-probable realisations that each honour the drill hole and face sample input statistics. An example is presented from the Augusta narrow-vein Au-Sb mine in central Victoria, where the simulation results are validated against the input data and survey pick-ups of the veins along ore drives.

Aug 22, 2011

By K Dagdelen

A vehicle proximity warning system is being developed using GPS and wireless local area networks to improve safety of off-highway trucks in open pit mines. After two an a half years of research, software development, and laboratory testing, field tests were carried out at operating limestone quarries and open pit mining operations to evaluate GPS accuracy and overall system effectiveness under rugged operating conditions. This article describes the progress made on this NIOSH funded project and discusses the GPS accuracy tests and overall system tests that were carried out during 2001 at the Morenci open pit copper mine in Arizona.

Jan 1, 2003

By A Golsby

Gunite was invented in 1907 by Carl Akeley to repair a crumbling facade of the Field Columbian Museum in Chicago. The method used was to blow dry material out of a hose with compressed air and inject water at the nozzle as it was released. In 1911, he was granted a patent for his invention, the ‘cement gun’; the equipment used; and ‘gunite’, the material that was produced.The advantages of using the dry mix process is that the water content can be adjusted instantaneously, allowing more effective placement in overhead and vertical applications without using accelerators. The dry mix process is useful in repair applications when it is necessary to stop frequently as the dry material is easily discharged from the hose.This paper describes the applications and principles of the gunite pump system in underground coal mining and discusses why it is the preferred spraying system for both cement and plaster products.It also addresses improving productivity and examines dust, respirable crystalline silica (RCS) and health issues around gunite pump systems. The solutions include development of the latest componentry for current gunite pumps to improve their efficiency and allow their operation to be dustless.In particular, this paper addresses:why and where RCS is a problem in underground coal mininghow RCS hazards and its propagation can be managedhow the gunite pump system has become dustlesshow the gunite system has become more productivegunite occupational health and safety issues and how they have been solveda case study of gunite dry spraying.CITATION:Golsby, A, 2015. The development of a dustless dry gunite pump system in underground coal mining – a case study, in Proceedings The Australian Mine Ventilation Conference, pp 41–48 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 31, 2015

In practice a sampling solution is a compromise of many requirements: the sample should be representative; the sampling system should also be reliable, less than 95 per cent availability restricts the use of the assayed sample for process control purposes; no sample is the worst sample, and investment costs and installation space/layout are frequently a restriction. For instance, online X-ray analysers for process control introduce a delimitation error by the nature of X-ray physics. Thus only in special cases a relative accuracy better than three per cent relative, as one standard deviation, is achieved. A sampling system for process control needs not to be, as representative, for so many sample properties, as one for composite laboratory analysis samples. Sampling system maintenance is also an important issue. There are many sampling systems in the industry which have been difficult to maintain and are in disuse for lack of resources or incentives to keep them running. Pierre Gy developed the most generally accepted sampling theory. One of the main principles is that all particles in a one-dimensional process stream should have equal chances of being included into the sample. A correctly designed and operated transversing cutter comes close to this goal but has limitations in temporal representativity. For slurries an acceptable solution in many cases is to use a fixed vertical cutter(s) in a position where the slurry is well-mixed by turbulence and other means. For online analysis, reliability problems are mostly related to faulty design or installation of the piping system to the analyser. Properties of material processed, process flow sheet and piping details before and after the sampler have to be taken into account when deciding on which sampling arrangement is appropriate. Guidelines and some solutions to these issues are presented in this paper.

Mar 1, 2010

HoistEM is a helicopter-towed time domain electromagnetic system. This paper presents details of the towed array structure (the Hoist) as well as a description of the instrumentation. A comparison between HoistEM and ground TDEM (from which HoistEM was derived) is given. Over 50 000 line kilometres of HoistEM have been completed to date and datasets for structural mapping, nickel, base metals, manganese, ground water and bathymetry are presented and discussed.

Jan 1, 2004