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By N Tyson

Throughout Australia and the world, there have been in recent years a number of incidents involving the reaction of ammonium nitrate based explosives with ground containing certain types of sulphides. This paper presents a comprehensive strategy designed to identify, assess and mitigate the risks involved with blasting in areas of reactive ground. Undertaking blasting in reactive or potentially reactive ground involves a degree of risk, the level of which is dependent upon the controls in place for specific sites; this in turn depends upon the degree of sound reasoning and judgement behind the implementation of these controls. Implementation of controls to minimise the risk of incidents also involves a measurable increase in production and blasting costs. To achieve a balanced solution to this matter, decision-makers need to understand how the risks eventuate, how they should be evaluated, and how control measures reduce the risk. Also required is an understanding of how the problem affects the economics of the operation, and the magnitude of this effect. It is the aim of this paper to provide a structured approach to gaining this knowledge, so that mine management, the workforce and explosive suppliers may jointly develop more effective economic and safe blasting systems for potentially reactive ground. Using a combination of fault/event tree risk assessment and semi-quantitative analysis, a structured approach to dealing with the issue will be illustrated.

Jan 1, 2001

By T Honeyands, L Jelenich

We are currently witnessing large fluctuations in the relative price of ironmaking raw materials brought on by changes in the dynamics of supply and demand, market conditions, environmental regulations and technical factors affecting the iron and steelmaking process. From a customer perspective, it is the behaviour of iron ores in downstream processing that give them their value; their impact on the sintering or pelletising process and subsequently blast furnace ironmaking. It is therefore important to consider this value when developing projects, making mine planning/cut-off grade decisions and in setting price differentials for differing quality.This paper describes the use of the Marx value-in-use model to quantify the downstream value of lump iron ores. The Marx model consists of heat and mass balance modules for sintering and pelletising and a rigorous two-stage heat and mass balance model of blast furnace ironmaking. Mass balance and cost models are applied for steelmaking, casting and rolling. The use of a heat and mass balance allows accurate comparison of the impact of raw material properties on blast furnace operation. The impact of minor elements, such as alumina, silica and phosphorus, and metallurgical properties on ironmaking is described, and examples are given for the calculation of a lump premium.CITATION:Honeyands, T and Jelenich, L, 2015. Lump ore properties and their impact on value-in-use in ironmaking, in Proceedings Iron Ore 2015, pp 359–362 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

By O Dominguez

Mine value chain reconciliation (MVC) is a necessary procedure to evaluate a mine’s performance against the assumptions and models used to plan mining and processing operations. Using nomenclature from Parker (2012), F2 reconciliation is the ratio between material received at the mill, compared with material sent to the mill, commonly reported in terms of tonnes, grade and metal. Measurements of material sent to the mill can be estimated in many ways, including: fleet management system (FMS) records, truck counts, or volume reduction. Most time-based reconciliations (for example, month-end reconciliation) use short-term model depletions of in situ rock measured by periodic topographic scans or surveys.

Mar 22, 2022

By J Dyt, S Lyons

In the mining industry, crusher-related incidents have led to 15 reported deaths in Australia, New Zealand, and the USA between 1998 and 2007 (NSW Government Resources Regulator, 2024). The majority of these fatalities occurred during routine crusher maintenance tasks. A survey of quarry and mine site maintenance staff was completed to ascertain what they thought of such safety device to understand if beneficial and if so reasons if unused. Overall, findings show, staff perceived risks differently, cost, familiarity, device awareness and not front of mind, influenced adoption. This underscores the importance of asking the right questions involving maintenance and safety staff to lead to more proactive risk assessment.

Apr 16, 2024

By J G Bastias

It is sometimes necessary to resort to extremes in order to call attention to something that is pertinent to safety in mining. When some of the experts in occupational safety talk about this topic, they usually refer to a 'regulation' established by the Romans which stated that, due to the health hazards, usually death, no Romans but only slaves should work in mining. Since the time of the Roman Empire, a lot of ground has been covered in the field of mine safety. Nowadays, it can be said that occupational safety is being seriously addressed, with the result that the number of mining accidents has reduced dramatically, fatalities in this industry are less frequent, and the rate of accidents compared with other activities, such as construction or fanning, is low. This achievement has been possible initially through government legislation and by procedures established by the mining companies themselves. However, the dilemma for government is whether to regulate and if so, how much. It is pleasing to observe that most companies are establishing working procedures which conform with new government legislation, placing strong emphasis on the duty of care for mine employees. There will always be some regulatory aspects of legislation, and perhaps the best example of this is in the use of mine hoists where there are no international or Australian standards, and the regulations applied are of an empirical nature that err on the side of safety.

Jan 1, 1994

By G R. Hancock

A common and cost-effective method for post-mining landscapes is to construct linear hillslopes with a break in the hillslope at appropriate distances to reduce hillslope length and resultant erosion risk (Figure 1). The break in slope occurs at a point that has been found by local experience to be appropriate for the materials and climate. Further enhancement of the linear hillslope may be assisted by surface treatment such as ripping (Saynor, Lowry and Boyden, 2019) (Figure 1). Firstly, ripping introduces surface roughness which breaks up flow paths reducing flow velocity thereby reducing erosion potential. The depression produced by the ripping acts as a trap which captures water, sediment and organic matter

Aug 2, 2023

By D I. Cliff, K Johnstone, N LaBranche

The resurgence of silicosis and coal worker’s pneumoconiosis (CWP) in mining and the recent ban of engineered stone products underscore the need to comprehensively address mineral dust exposures and the associated health hazards. Worker exposure to particulate matter, remains a pressing concern demanding nuanced exploration as all dusts are not created equal. The established link between silica and respiratory diseases necessitates a more detailed understanding of the characterisation of particulates and their health impacts. While current monitoring relies on total mass, it is increasingly evident that the size, shape, mineralogy and agglomeration of particles play a crucial role in determining health impacts. This has been evident in the engineered stone industry with workers not only facing a greater risk of silicosis, but also seeing a faster progression of the disease and a higher likelihood of dying from it. Simultaneously, the surging demand for critical minerals, integral to low-carbon economies, has seen government and industry fast tracking the exploration, mining and processing of these commodities. Critical minerals, crucial in technologies like lithium-ion batteries and high-performance alloys, are central to achieving global environmental goals. Significant funding is currently being allocated to advance the development and processing of these materials, however there remains a considerable gap in understanding potential health risks, urging comprehensive health risk assessments. To tackle these challenges, the University of Queensland has developed innovative dust characterisation methodologies, including the use of the Mineral Liberation Analyser (MLA), a scanning electron microscope, to characterise respirable and inhalable dust samples. This advanced technique, initially applied in coal and metals mining, is expanding to critical minerals mining, unravelling diverse mineralogical components and particle size distributions. This conference presentation will showcase the latest research, emphasising the use of advanced analytical techniques to deepen our understanding of the size, shape and mineralogical composition of particulate matter. By synergising insights from coalmines, metals mines, smelters, engineered stone and critical minerals assessments, we aim to proactively manage health risks, contributing to safer workplaces and responsible production practices in the mining sector.

Apr 16, 2024

By T Elkington, A Finch

The theory of constraints (TOC) is a business improvement method that focuses on exploiting a business’s bottleneck to deliver the highest possible profit. Early applications were mostly in the manufacturing industry; however, the theory in itself is completely generic and has now been applied widely in other industries such as services, retail, software and distribution, amongst others. The intent of the approach is attractive – it focuses on the ‘silver bullet’ rather than ‘death by a hundred projects’, and it focuses on growth rather than cost cutting. Application within the mining industry has been limited to date, although there are a few applications emerging. This paper discusses how TOC can be applied to maximise value during the project planning phase and how to maximise profits when the mine is operational. The paper uses two case studies to illustrate the approach. Case study 1 uses the approach to improve tactical mine planning, which delivers an increase in revenue of 58 per cent. The second case study is a strategic mine planning example that delivers an increase in value of 77 per cent.CITATION:Finch, A and Elkington, T, 2014. Application of the theory of constraints to strategic and tactical mine planning, in Proceedings Orebody Modelling and Strategic Mine Planning Symposium 2014 , pp 129–136 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 24, 2014

A hidden asset in most exploration and mining activities is data. Common practice involves the spending of large amounts of money to discover, define and prove the viability of a mining project. Some organisations have used operations research analysis and internal costing methods to allocate a value to their data and to compare the costs of data maintenance to other more tangible activities like plant and equipment maintenance. Those organisations, which do not undertake such an analysis often, have little knowledge or understanding of the extent and the worth of their data. Often the organisations lack of knowledge and understanding of the data is indicated by their failure to fully exploit or realise their opportunities. The focus of this paper is to discuss new technologies that optimise the management and security of collected and derived data. The technologies discussed are components of the software systems acQuire and MineSight.

Jan 1, 1999

The theme of the conference this year is diversification. One way to diversify is through acquisition. The principle underlying the winner's curse is that in competitive bidding situations where the value of the asset bid for is uncertain the winning bid will overstate the true value of the asset. The successful bidder is blessed with the winner's curse. What this paper will explore is to what extent this is true; how acquirers can avoid being blessed with the winners curse; and show how joint venture deal structures are used within the mining industry to avoid the winners curse.

Jan 1, 1996

By I Mason, M van de Werken, B Zhou, J Hargreaves, W Stasinowsky

A critical step in open cut coal mining is clean removal of the overburden. This is usually achieved by drilling, blasting and digging. A key part of this process being successful is to stop drilling at the correct blast ‘stand-off distance’. The stand-off distance is the distance between the base of the drilled blasthole and the top of the coal horizon to be mined. Having this correct provides a protective cap of rock above the coal horizon so that the blast will fracture all the overburden without damaging the coal horizon or mixing it with the overburden. Drilling beyond the correct stand-off distance causes the blast to continue into the coal horizon, damaging it and mixing it with the overburden, leading to significant losses of coal product. Conversely, drilling short of the correct stand-off distance results in additional work to remove the intact overburden.

Sep 1, 2024

By G M. Volkmann

Pipe umbrella systems have effectively been used as an additional support system in the working area in weak ground conditions during the last decades. Thus, a considerable number of applications accounts in urban tunnelling with shallow overburden. However, this support system is also successfully used when a tunnel alignment crosses fault zones, sediments, moraines or talus with overburdens from shallow to deep. The pipe umbrella support system itself is termed differently worldwide – synonyms are canopy tube umbrella method, umbrella arch method, or long fore-poling method.One main reason for the increase in application is that this support system closes cost-effectively the gap between reasonable, normal supported tunnels and tunnels supported with more expensive special techniques like horizontal jet-grouting or ground freezing. By using this system, many projects can be built more cost effective without decreasing the common level of safety.The pipe umbrella construction method is pretty young, so the knowledge about this system has been intensely researched in the last decade. This led to an enormous increase in understanding the interaction between support system and surrounding ground, the mode of action, and the important details for construction.Pipe umbrella support systems are applied in difficult ground conditions, so a special developed measurement arrangement was used to observe deformations ahead of the working face during tunnelling. The evaluation of collected data sets identifi ed that cased-drilling systems have clear advantages compared to predrilling systems during the installation process in weak ground conditions. This may become important depending on project requirements, so this difference must be considered in design as well as in the tender document specifications.

Mar 8, 2011

By R Cannings, J Wallace, M McCamley

The mining industry continues to have major disasters (Bingham Canyon, Pike River, Upper Big Branch, Mount Polley and Samarco), which often have a devastating effect on the enterprise, in terms of personnel deaths and injuries, environmental destruction, and financial and reputational loss. These disasters are not imposed from outside the business or organisation, they are almost always a function of loss of control of the management of the organisation’s critical assets and processes that they contain or to which they are exposed.Asset integrity is discussed as an effective response to business risks in order to mitigate, control and recover from loss scenarios that could expose a mining operation to significant property damage and business interruption, or even total loss. Vital to this process is the identification and control of risks to critical assets. Components of a critical asset assurance program are presented for discussion.Formal risk assessment has a longer history in industries other than mining, eg petrochemical, nuclear, military, aviation and space industries. Risk assessment is a structured, proactive approach to understanding and improving risks, as opposed to a reactive ‘fix-it-when-it-breaks’ mentality. Risk assessment techniques were triggered by major public disasters, such as the Flixborough chemical plant disaster (1973), Three Mile Island nuclear plant event (1979) and others.Today, most industries see risk assessment as an inherent part of their business, but do mining sites capture business risks that are related to major loss scenarios, which could have a significant impact on the operation?Does your risk assessment process:- involve a team having the right skill set so that the discussion is both stimulated and technically sound?- use generic assessment when a site-specific assessment is needed?- fail to consider all possible outcomes, including maximum foreseeable loss (MFL)?- fail to identify all hazards and controls associated with a particular activity?- fail to monitor controls effectively?This paper addresses the issues identified by these questions and provides some direction for developing a risk management process where business risk associated with critical asset integrity is integrated with other business and safety and health risk processes to provide a robust method for managing your business. Case studies and common findings from critical asset failures are used to support the need to include critical asset assessments as part of business risk management processes.CITATION:Wallace, J, McCamley, M and Cannings, R, 2016. How robust are your asset integrity management processes? In Proceedings International Mine Management Conference, pp 53-64 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jun 22, 2016

By T Napier-Munn, E Louwrens, L Keeney

Geometallurgical characterisation of ore deposits is accepted practice in some parts of the mining industry today. Its primary aim is to provide constrained inputs that reflect inherent geological variability and its impact on metallurgical performance for the deposit. Geometallurgy improves project value because it suggests more valuable alternatives for scheduling and processing through an increased knowledge and understanding of the interactions of rock properties and extractive technologies. Lower project cost (both capital and processing) and improved recoveries are the result from closer tailoring of the mining and mineral processing strategies to the characteristics of the resource (Dunham, Vann and Coward, 2011). Tailings storage facilities (TSFs) can be seen as potential resources and it is argued that fundamental geometallurgical characterisation as applied in ore deposit characterisation should also be applied to planning the retreatment of TSFs. This paper will describe a research project at Julius Kruttschnitt Mineral Resource Centre assessing if geometallurgical principles and methodologies can successfully be applied to TSFs as they have been to primary deposits. The project is establishing a new standard method of tailings evaluation which will include a 3D spatial model of the tailings resource. Initial domaining of the TSFs was done using principal component analysis followed by k-means cluster analysis based on chemical assays from drill core samples. The subsequent characterisation of the drill core samples has involved chemical, mineralogical and metallurgical profiling, with a range of metallurgical tests being conducted on the samples. This characterisation step is followed by class-based analysis, predictive modelling and process performance domaining with the ultimate objective of establishing a 3D spatial model incorporating geochemical, mineralogical and metallurgical performance data. This approach, which takes into account processing performance permits a more realistic (as compared to doing limited chemical assays and metallurgical testing) economic evaluation of the potential of reprocessing the tailings material. It is believed that the approach is generic and can be applied to other TSFs being considered for reprocessing. The present case study has also established the gold, copper, magnetite and cobalt deportment for an iron oxide copper-gold deposit tailings resource.CITATION:Louwrens, E, Napier-Munn, T and Keeney, L, 2015. Geometallurgical characterisation of a tailings storage facility – a novel approach, in Proceedings Tailings and Mine Waste Management for the 21st Century , pp 125–132 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 27, 2015

By A Karrech, A Hasan

This paper presents the numerical simulation of mine backfilling in underground stopes using three-dimensional discrete element modelling (DEM). The simulation predicts the forces exerted at the stope base and barricade with respect to time under free drained conditions. The results of the numerical simulation are validated using basic analytical solutions and advanced experimental tests involving a geotechnical centrifuge system. Overall, a good agreement between the present numerical simulations and the existing experimental and analytical results was found. The present model suggests that DEM is a promising computational tool to predict barricade pressure in underground mine stopes.CITATION:Hasan, A and Karrech, A, 2014. Simulating mine backfill in a fully drained condition using discrete element modelling, in Proceedings AusRock 2014: Third Australasian Ground Control in Mining Conference , pp 117–124 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 5, 2014

By J Morgan

Regular monitoring of surface deformation over mine sites is important for providing updated information to managers regarding geotechnical risks related to ground instabilities. This is particularly true in cases where unexpected or accelerating movement patterns are observed, as these trends may have implications related to worker safety within active mining environments, as well as continuity of ongoing operations. InSAR is an active remote sensing technique that uses radar satellite imagery to precisely measure ground movement. This technology has started to become a standard tool for monitoring surface stability in many different sectors, including underground and open pit/cut mining applications. In recent years the launch of satellites that collect radar imagery on a more frequent basis, coupled with advances in InSAR processing techniques, has improved both the extent to which movement patterns typical of mining operations can be characterized and the temporal scale on which results can be reported to geotechnical departments. As a result of these developments, InSAR monitoring can now better meet the operational needs of mine sites. An overview of the more recently launched satellites that have a particular relevance to the monitoring of mines is provided, along with an explanation of the InSAR tools that are the most valuable to mine managers and geotechnical engineers. First, broad differences between high resolution X-band imagery and low resolution (but freely available) Sentinel imagery are discussed. Second, the various InSAR tools and their particular applications for different types of mine sites and operations are covered, which include fast delivery deformation maps for short-term reporting, multi-interferometric algorithms for longer-term analyses and rapid movement tracking (RMT) for emergency monitoring or high-risk situations. The ability of the technology to resolve 2D and 3D movement is also touched upon. Practical examples of InSAR application over a variety of mine sites will be presented, as well as surrounding hazards including landslides, to illustrate how InSAR can help provide geotechnical engineers with a picture of surface stability over the full mine site and surrounding areas to help manage risk. CITATION:Morgan, J, 2018. Wide area mapping of ground instabilities from space: InSAR for geotechnical risk assessment and hazard monitoring, in Proceedings The Fourth Australasian Ground Control in Mining Conference (AusRock), pp 375–382 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 30, 2018

By R Dunne, W McCallum

Continuous improvement might be defined as seeking incremental improvement over time through improved equipment, processes, technology and the efforts of people. Most people working in ore processing facilities embrace the general principles of continuous improvement. However, given the industry-wide issues with skilled personnel and the constantly changing environment in ore processing facilities, it is often difficult to identify improvements in a facility over a given time period. The driver for these outcomes is the use of basic principles and technology to achieve best practice targets. The process involves four stages: develop standards of practice to define best practice in specific areas; write procedures to guide the organisation towards these best practices; implement the procedures and develop a review process to provide a method of measuring performance against best practice.By reviewing performance against best practice on a regular basis, the organisation measures progress towards the best practice targets and the incremental improvement between these regular reviews is a measure of continuous improvement.This paper provides the background for developing standards of practice for metal accounting, metallurgy and metallurgical management. The paper also describes how standards of practice can be used to develop continuous improvement and the skills set of the departmentÆs leadership team.CITATION:McCallum, W and Dunne, R, 2012. Metallurgical management tools for continuous improvement, in Proceedings 11th AusIMM Mill OperatorsÆ Conference, pp 225-230 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Oct 29, 2012

By J Loeb, R Ramanathan, H Ingham, P Cameron

Most mining operations, including iron ore, maintain a focus on continuous improvement and asset optimisation in their operations. As all the unit operations in the Mine-to-Mill value chain are interdependent, available technologies that address efficiencies across the value chain are once again in the spotlight as companies are driven to improve productivity and maximise mine site profits to increase return on capital invested. Core to continuous improvement is the need to understand the baseline and impact of changes to the process. In this paper, we discuss some of the critical attributes in the Mine-to-Mill process, including their influence on productivity and cost, the need for direct measurement and areas where they should be applied. Many initiatives can be considered to improve Mine-to-Mill processes. Mining operations are planned and executed based on designs and models to achieve the operation's objectives. However, there are many variables in the different parts of the value chain, such as blasting, material handling, crushing and screening. Therefore, measurement of the key attributes establishes the baseline for Mine-to-Mill (or Pit to Plant) performance, which is necessary to understand the impact of any proposed improvements to the process design and execution and monitor the outcomes on an ongoing basis sustain the improvements that have been implemented. This paper focuses on two types of measurement – blast movement and particle size of materials through the Mine-to-Mill process. Several innovative technologies and control loops are readily available to measure these attributes and assist operations to improve productivity and mine site profits. The size of the tangible benefits, which can flow from measuring and optimising fragmentation and blast movement, provide a remarkable return on the investment. Realising these benefits needs a focus outside conventional operation silos as a successful Mine-to-Mill project requires a multidiscipline approach across all the silos in the value chain. Required technologies are available; adding the necessary ingredients of communication and co-operation by all concerned across the silos will ensure the benefits are realised.

Nov 8, 2021

By P Rubie, J Russell

This paper looks at the past, present and not too distant future of grinding mill relining.Since the adoption of autogenous grinding (AG) mills and semi-autogenous grinding (SAG) mills as the primary ore reducing devices in the comminution circuit, plant shutdown frequency and duration has largely been driven by the liner maintenance requirements of these mills.The past 30 years have seen the introduction of many technologies to reduce relining times and frequencies. Advanced relining systems have been developed which include single and twin Mill Relining Machines, capable of placing large (up to 8000 kg) liners, high energy recoilless THUNDERBOLT Hammers, and high capacity Feed Chute Transporters. Despite these advances, today many of the hazards associated with mill relining remain and reline times still vary considerably between mine sites. A sophisticated discrete event simulation program, designed to analyse the mill relining process, has revealed the dominant influences on reline times of crew performance and of the need for safe access to larger segments of the mill.A new generation of advanced and semi-automated technologies is currently being tested that will address these remaining challenges. These technologies remove people from the hazardous environment inside the mill and will allow techniques used in modern advanced manufacturing to provide a near-future step change in mill relining safety and performance.CITATION:Rubie, P and Russell, J, 2018. 21st century relining – the path to greater mine site profitability, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 621–640 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

By S D. Dessureault

In large coal strip mines, there are many different processes at work: stripping, overburden removal using trucks/shovels, cast blasting, slot dozer pushing, more fragmentation and further truck/shovel benches. A key component to each of these steps is the use of machines. In modern operations, most machine costs are tracked within Enterprise systems that transact costs and repair work order management. Similarly, in contemporary mines most machines are tracked using technology that provides precise performance measures for each key process. Such technologies include productivity monitors on draglines, dozers and drills and fleet management systems for trucks and shovels. Linking these two sources of seemingly disparate data û costs and performance by machine û would allow for the precise calculation of unit costs by specific machine. This is similar to an activity-based costing system, except in this machine-based system, calculations are made at an even finer granular level. There are many uses for such an integrated information system in mine planning and performance management, both in real-time and through historical analysis.A real-time fleet costs (FLC) measurement process was developed as part of a larger blending-related, multi-million dollar project centred on a centralised remote control room developed at the University of ArizonaÆs Mining Information Systems and Operations Management Mine Control Center. The FLC component of the overall blending system would allow a mine controller to manage the equipment fleet by viewing its cost in real time and, when mixed with other revenue-related components, the exact profit. For example, a mine controller may show high utilisation while still maintaining a production surplus. This could occur, for example, if the equipment is driven long distances. This might appear in traditional performance metrics as æhigh production performanceÆ, but in reality may prove less profitable. This paper discusses the technical development of the FLC, its deployment and its impact on controller performance, and compares mine profitability before and after its application.

Sep 26, 2011