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By J Hunt

A critical aspect of geometallurgy is quantifying mineralogical and textural relationships that affect mineral processing (eg, liberation and recovery). However, to date, this has been an expensive and time consuming venture and only minimal amounts of this type of data are typically available to be included in the mine planning process. Our research is focused on developing methods that will produce the required mineralogical and textural data rapidly and inexpensively. New methods of characterising liberation potential from image analysis of coarse particulate material and direct small-scale flotation measurement are compared with measurement of liberation at final grind size (ie conventional tests on MLA). The new tests are designed to rank the liberation potential of samples in order to classify an ore deposit into domains of low, medium and high liberation potential. This parameter can then be used to adjust the cutoff used to differentiate ore from waste. Results to date show that all tests provide the same ranking for the samples. The measurement based on coarse particulate material compares favourably to the results from MLA analyses on the same samples. Further work is being carried out to determine which of the tests will be the most effective in terms of time, effort and cost

Sep 5, 2011

By R Wilson, S Luke, R Williams, B Freeburn

"In 2010, two McLanahan RSS14×50 scrubber screens were installed at Fortescue Metals Group’s (Fortescue) Christmas Creek site. By 2015, the trommel (screen) section had effectively reached the end of their serviceable life. This was determined by regular measurement of structural components over the previous 18 months that tracked wear life. At the same time, numerous trials and optimisations had taken place on screen panel design and material composition. During 2015, a new set of trommels were designed, manufactured and installed that incorporated many new features: increased open area to facilitate high throughput, improved wear protection for structural members, simplified trommel panels and realigned discharge ports to reduce wear on exit. Numerous other upgrades have taken place on the drive system, feed chutes, liner and weir configurations and park brake, to name a few. This paper will highlight how regular measurement drove design changes and how the site and the original equipment manufacturer (OEM) managed a replacement program that has delivered improved performance.Citation:Wilson, R, Luke, S, Freeburn, B and Williams, R, 2016. Regular Measurement Defines Upgrades on Scrubber Screens, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 285–290 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By H Bleuler

A new portal and access drift was constructed by Concrete Constructions for BHPÆs Elouera Colliery, south of Wollongong.The portal area at the base of the Illawarra Escarpment is in soft colluvium material, underlain by highly to moderately weathered sandstone. The area has a well documented history of slope movement or slope creep and one of the main criteria for the design was to minimise disturbance to the unstable slope by limiting the excavation for the portal establishment. This was achieved by incorporating a sloped headwall and gabion wingwalls to accommodate the anticipated creep and groundwater seepage.Main features of the design process also included the provision of both primary and secondary support in a single shell application and the use of canopy tubes to provide support ahead of the tunnel face.The active involvement of the designer during the construction phase and the flexibility of the design concept allowed changes to the support methodology to be carried out as excavation proceeded.This paper describes the design process undertaken for portal establishment and access drift to cater for the variability of the exposed ground conditions along the drift alignment.

Jan 1, 1999

By R deMoraes, A Bobet

The last decade has seen a resurgence of interest in lunar exploration and the emergence of countries like China and India as space fairing nations. In 2004, the US announced a new Vision for Space Exploration, whose objectives focused on human missions to the Moon and then Mars. The near future is likely to see the emergence of a worldwide drive to revisit the Moon as the first step in investigating the Solar System. To date, the Apollo missions provide our only experience of human operations on the Moon or anywhere else beyond Low Earth Orbit. Much was learned from these missions. However, their short duration means that many of the environmental effects that will be important for longer-duration missions could not be quantified. In addition, long-duration missions and infrastructure on the Moon require new technologies and capabilities, which must operate successfully and reliably in this lunar environment. Developing these technologies poses significant challenges for the exploration program. The paper discusses the risks associated with the construction of lunar surface and underground structures and the challenges to adopting the standards and rock mass classification systems developed on Earth and their applicability to the Moon. Moreover, an exchange of views to explore near-surface geologic and geotechnical profiles of the Moon is emphasized and implications of the lack of knowledge on rock mass characterisation of the Moonrock mass, the lack of theoretical/empirical experience on the use of rock mass systems outside Earth, and uncertainties.

Nov 29, 2022

By R L. Koenig

Previous papers at Metplant conferences have covered the options for crushing and grinding circuit selection. High Pressure Grinding Rolls (HPGR) may have considerable advantages over autogenous milling circuits but test work and evaluating different grinding circuits must be done to establish which circuit provides the best option. The Hawsons low grade magnetite project provides a specific example in using thorough test work, careful simulations and detail in design to allow the evaluation of grinding circuit performance. Fortunately tools are available for this evaluation and the test work for the Hawsons iron ore is detailed in this paper. The results of the test work and simulation indicates that although the Hawsons iron ore is competent in terms of autogenous milling given the medium hardness of the ore in the Drop Tests, the HPGR testing indicates that the use of HPGR is likely to use half the energy requirement. This is a characteristic of the Hawsons iron ore and is likely to be valid for other iron ores in the Braemer Iron Formation which stretches from the Hawsons lease in New South Wales to Razor Back and South Dam in South Australia. The Hawsons magnetite iron ore resource has been known from the early 1960s when CRA explored the area. However, the Pilbara region was discovered in this era and this led to development of high grade direct shipping grade hematite ores. Carpentaria Exploration (Capex) rediscovered the magnetite whilst undertaking multi-commodity exploration in the Broken Hill district during 2009. The magnetite grade was found to be low at around 16% Davis Tube mass recovery (DTR) but despite this, the project provides a positive business case as a result of the following key factors:• The mineralisation is particularly soft for crushing and grinding with a Bond Work Index of 6.3.• The mineralised rock fractures easily preferentially along grain boundaries.• The location is close to mining infrastructure and a skilled workforce in Broken Hill, 60km to the North East.• It is close to road and rail infrastructure for access to the resource.• The only contaminant in concentrate is silica.• The resource contains many billions of tonnes of magnetite mineralisation.The low Bond Work index is a key characteristic of the Hawsons iron ore and the use of autogenous milling and HPGR circuits is compared to other iron ores indicating why the plant energy requirement may be just as important as iron ore grades.

Aug 8, 2011

By S M. J Koleini, F Hedjazi

The purpose of this research was to study the calcination of lead-zinc flotation tailings from the Angouran lead and zinc flotation plant in Iran as a pre-concentration step prior to hydrometallurgical processing of the oxidised tailings. There is an abundance of these tailings in the Angouran region and making use of these tailings would help preserve national wealth and also reduce the serious problems of environmental pollution caused by the tailings. At the optimal conditions of calcining at 750 - 800¦C for 45 minutes, the sample showed a mass loss of about 19 per cent. Mineralogical analyses showed that under these conditions the carbonate minerals including smithsonite (ZnCO3), calcite (CaCO3) and dolomite (Ca Mg (CO3)2) decomposed to their respective oxides. Hemimorphite (Zn4Si2O7 (OH)2.H2O) converted into willemite (Zn2SiO4) and this transformation postponed the formation of silica gel in the leach solution. The grade of zinc increased from 22.20 per cent to 29 per cent. These mineralogical changes resulted in desirable reactions in the acid leach process.

Jan 1, 2004

By B G. Blacka, O Salisbury, K W. Mills, R G. Jeffrey

Whitehaven Coal Limited operates an underground longwall mine near Narrabri, New South Wales. The mining horizon in the Hoskissons Seam is overlain by a 16–20 m thick unit known as the Digby Conglomerate, a unit that is sufficiently massive to have potential to cause a windblast during first caving at the start of each longwall panel and periodic weighting throughout the panel. A program of hydraulic fracturing has been successfully used to precondition the conglomerate strata to increase its caveability at the start of each panel. This paper presents a system of temperature monitoring that was used successfully to measure hydraulic fractures at Whitehaven confirming their rate of growth, orientation and interaction with previously placed hydraulic fractures.CITATION:Mills, K W, Blacka, B G, Jeffrey, R G and Salisbury, O, 2014. Temperature monitoring of hydraulic fractures used for preconditioning massive conglomerate strata to reduce windblast, in Proceedings AusRock 2014: Third Australasian Ground Control in Mining Conference , pp 189–194 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 5, 2014

By A J. Clough

There has been an unprecedented rise in the fatality rate in the Australian mining industry over the last few years. The factors behind this rise are not clear; however, it is noted that the increase in fatalities has occurred during a fall in commodity prices.This paper examines prevention methods and systems to deal with hazards that have the potential to result in either single or multiple fatalities. Managing the risks associated with mine ventilation is used to illustrate the principals behind the approach.The paper also touches on the broad science of human error and proposes a multifaceted approach to controlling and preventing fatal risks.A summary of the steps involved in developing an effective principal hazard management plan is provided.CITATION:Clough, A J, 2015. Ensuring an effective principal hazard management plan, in Proceedings The Australian Mine Ventilation Conference, pp 3–8 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 31, 2015

By R C. Morris

Supergene lateritic iron ores are uncommon when compared with the vast tonnages of BIF-hosted microplaty haematite ores of the world or with the dominant supergene mimetic martite-goethite ores of the Hamersleys. In Australia and to a lesser extent in India and South America, mimetic replacement of gangue minerals by iron hydroxyoxides is a major factor in forming supergene iron ore from banded iron-formation (BIF) and results in the superb preservation of all of the original BIF features. This includes primary banding down to the finest inclusions, as a result of pseudomorphing of the BIF gangue at depth by goethite. The enrichment as a whole is an absolute accumulation of Fe at depth, dissolved from the surface BIF, and a removal of the gangue elements without loss of the original BIF mineral textures. Thus the ores grow upward to meet the downward destruction of the surface BIF by erosion. By contrast the supergene lateritic ores including the 'blue dust ores' are residual ores resulting from the relative accumulation of Fe. In the supergene lateritic ores derived from BIF, removal of the gangue is accompanied by repetitive solution and reprecipitation by secondary haematite and goethite. The final product of lateritisation of BIF and BIF-derived ores is typically complex, due to successive overprinting of earlier stages of alteration during the process, and because of the different precursors. This progressive lateritic modification tends to produce a varied surface complex including massive, vermiform, and botryoidal, or nodular aluminous/siliceous goethite and haematite, variously known as ferricrete, duricrust, canga, or 'hydrated zone hardcap'. The significant difference in these ores to the supergene mimetic martite-goethite ores is that they grow downward, with the total destruction of any of the parent BIF or BIF-ore textures.

Jan 1, 2009

By P Revell, A Jenkin

This paper presents an analysis of significant Australian-based R&D programs focussed on the minerals industry, which was commissioned by CRC ORE. The landscape analysis may assist organisations with R&D management issues including program creation, program/partner selection, portfolio management, and public policy settings. The dataset was collated early in 2020, and contains programs being conducted by or with Australian-based ‘Research Service Providers’ (RSPs), most notably Universities and CSIRO. It does not include R&D being conducted in-house by mining and METS companies, or by them with other organisations that are not RSP’s. The dataset contains 65 R&D programs, with total annual cash funding of $229m (70% from industry and 30% from government). The total funding compares unfavourably with the combined R&D expenditure of Australian universities and CSIRO of over $12b, and minerals industry export revenues of over $200b. The R&D landscape is analysed by program numbers and funding, technical domain, geography, and funding source. Areas of relative strength are noted in ‘mineral processing’, CSIRO Minerals, and the CRC program. Areas of relative weakness are noted in ‘bulk materials handling and logistics’, ‘tailings and waste management’, and ‘social and community’. The field of preconcentration is noted as a current area of R&D strength, but it is under significant threat with the impending completion of CRC ORE. The overall R&D landscape is characterised by a majority of small-scale programs, low levels of industry coordination, a low focus on step-change innovation, and total funding lower than should be expected for such a large critical industry. It is hoped that key stakeholders in the Australian minerals industry, particularly governments, and mining and METS companies, reflect on the analysis and act to address holistic weaknesses.

Nov 10, 2020

By L Ding, B Xu, C Wang

In this paper, we introduce the term ‘LJC’ to refer to the LJC Automatic Magnetic Flotation Separator, which is an advanced technology developed by Longi Magnet, integrating various techniques such as hydro separation, magnetic flocculation, and magnetic columns. This technology combines gravity, hydro separation, and magnetic separation to achieve efficient and reliable separation processes. With its low maintenance requirements and high reliability, the LJC technology has proven to be effective in magnetite processing. The LJC technology offers two primary benefits when compared to traditional magnetic drum separators. Firstly, it can enhance the quality of the targeted or improved concentrate at a coarser product size by minimising the carryover of gangue minerals into the concentrate. Secondly, it can significantly improve the concentrate quality (eg achieving >67 per cent Fe) while maintaining similar liberation size and mass yield. In China, this technology has been widely adopted in magnetite processing, replacing traditional magnetic drum separators and fines flotation in the final stage of the process. Through collaboration with a magnetite producer in Western Australia, Longi Magnet successfully implemented the next-generation LJC Automatic Magnetic Flotation Separator to replace the original stage 3 magnetic drum separators. The application of the LJC technology resulted in an increase in product P80 from 32 μm to 43.1 μm, while maintaining a final concentrate grade of 65 per cent Fe. Additionally, the power consumption, measured in kWh per tonne of concentrate, was reduced by 10 per cent. By eliminating the bottleneck caused by the requirement of a coarser liberation size to achieve the desired concentrate grade, the plant’s throughput was increased by significantly. The LJC technology has demonstrated its ability to reduce the carbon footprint, improve concentrate grade and enhance mass recovery, offering an alternative solution for magnetite processing. The high-grade magnetite produced by the LJC technology is particularly suitable as a raw material for Directed Reduction Iron and green steel production. This paper introduces the principles of the LJC Automatic Magnetic Flotation Separator and provides details of its application in a magnetite operation in Western Australia.

Sep 18, 2023

In most States of Australia it is a legislative requirement for underground mines to have a separate means of egress from the normal means of ingress to permit the safe evacuation of workers to the surface in event of an emergency. Such egress may be in the form of a ladderway equipped shaft/underlie or trafficable incline/decline. Additionally, there is a general requirement to have one or more airways, separate to the main shaft or other principal entrance of an underground mine, extending to the lowest level to permit ventilation to all parts of the mine. Fulfilling these requirement is difficult in the development phase of a mine when access underground is achievable by only a shaft or decline in the process by being sunk. What is frequently practiced in Australia is for production to then commence, sometimes in association with continuing development, in the same configuration without the establishment of this separate method of egress to the surface nor additional airway/s with reliance on refuge chambers to cater for back up in any emergency. Not only, could this jeopardise the health and safety of workers in case of an underground emergency it could be construed as a statutory breach of legislation. While recognising that refuge chambers are often used throughout underground operations nowadays their equipping and the criteria for their location needs to be bought into focus. This presentation discusses how such legislative requirement can be met alongside the use and appropriateness of refuge chambers.

Jan 1, 1998

By T Sasaoka, H Shimada

Mined-out limestone/aggregate quarries in Japan contain many high and enormous pit walls. Many precious resources are abandoned in these final pit walls. In addition, there are many mines which are located in or near populated areas in Japan. Utilisationof the potentially useful under- ground space at mined-out sites is a topic relevant to the practice of surface mining. This paper describes and discusses the concept of underground space utilisation and tunnelling systems, referring specifically to geotechnical/ tunnelling parameters.

Jan 1, 2008

By E J. Coyle, L A. Millington

Tailings storage facilities are geotechnically complicated structures that develop heterogeneous strength profiles and varied porewater conditions. The monitoring of porewater pressures is one of the only direct measurements that can be performed to monitor the performance of a facility throughout its life and is of particular importance in upstream facilities. Foundation underdrainage, continuous and staged tailings deposition, climate inputs (rain, snow, humidity, evaporation, etc), and stratified tailings permeabilities can complicate this critical measurement that introduces uncertainty to stability analyses. These difficult conditions manifest in vibrating wire piezometer measurements as very low or negative pressure readings, both of which are within the instrument’s range of accuracy. However, the data can be difficult to interpret, and a range of interpretations are adopted from optimistic low phreatic surfaces to conservative fully saturated tailings. Where tailings are potentially liquefiable, these very low readings introduce further uncertainty regarding the pore space saturation ratio and liquefaction potential above the estimated phreatic surface. This area of uncertainty is the vadose zone, and its affect on tailings behaviour is not well understood. The two facilities analysed in this paper are upstream, raised embankments with tailings classified as clayey, sandy silt that have been found to be potentially liquefiable. The vibrating wire piezometers (VWP) at both sites show very low or negative readings when they are initially installed near the surface and then go through cycles of re-saturation and de-saturation. Eventually the readings settle as the VWPs are buried deeper within the tailings. The instrumented sections within the tailings column do not show consistent readings that would be indicative of a hydrostatic phreatic surface at either site. Rather, they are highly variable and can be interpreted as either representing a high phreatic surface within the tailings or as a ‘perched’ phreatic zone within the tailings layers. How the VWP data is interpreted has a significant impact on how the facilities are raised and operated. The design outcome for Site 1, which adopts a lower phreatic surface, results in an embankment that meets factor of safety (FoS) requirements under residual strength conditions without any buttressing. Conversely, a conservative (high) phreatic surface has been adopted for Site 2 and has resulted in the facility requiring a significant buttress to meet FoS under residual strength conditions.

Jul 1, 2021

By M Akop, G Phillips, L Elliott

An estimation geologist has many tools in their kit and using the correct one for the job is vital for creating a useful model. Reconciliation is a key step to monitor the performance of a resource model and to ensure the correct tools have been selected and appropriate parameters are set. This paper presents an example of refining the estimation methodology for a Channel Iron Deposit (CID), resulting in an improved model. Rio Tinto Iron Ore (RTIO) CIDs are unique iron ore deposits located in the Pilbara region of Western Australia and contribute a significant volume to the world’s seaborne iron ore market. A problematic feature of these deposits is the irregular dispersion of clay pods that cannot be delineated with confidence within the resolution of the exploration drilling. Resource to grade control reconciliation showed an over-prediction of high-grade material in the resource model. A fresh approach was required to improve grade and tonnage predictions. Historically, clay pods were delineated using traditional wireframing techniques and estimated using ordinary kriging with hard boundaries. The new method utilised indicator kriging to estimate the probability of clay. Probabilities generated from the indicator kriging estimate were used as an additional weighting following the ordinary kriging of grades. Results showed indicator kriging improved global high-grade tonnes reconciliation, however, as expected, it did not improve the spatial prediction of clay. Based on improved reconciliation results indicator kriging has now been adopted as a suitable alternative for analogous CIDs at RTIO. These improvements benefit the mine planning process, but do not replace grade control models.

Mar 22, 2022

By S Schwarz, D Alexander

The mining industry, and in fact the world, has undergone significant changes in the past five to ten years, ranging from the metals boom, the global financial crisis and the rise and fall of national economies, to name just a few. There has been a focus on sustainable development for projects and operations in the mining industry, mainly pushed onto the industry by communities, governments and other agencies. While sustainable development and operation is a worthy priority for mining operations, discussions with mining industry personnel (with a strong slant on the mineral processing perspective) have shown other issues have surpassed the typical issues of water resources, energy availability and the environment. These include staff turnover and skills shortages, extracting metal from more complex orebodies and the uptake of new step-change technology.A number of key operating mineral processing personnel were interviewed to determine their perspective on the current issues facing the mining industry. This paper details the findings of this survey and highlights some of the topics that have been identified as the top issues from a mineral processing perspective.CITATION:Schwarz, S and Alexander, D, 2012. Current issues in the mining industry - From the operational mineral processorÆs perspective, in Proceedings 11th AusIMM Mill OperatorsÆ Conference, pp 369-372 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Oct 29, 2012

By J Player, G Sweby

The material properties and hence performance of saturated alluvial sediments slope can be incorrectly forecast if the water content is not preserved, and materials properties not correctly determined. The occurrence of saturated sediments in the Western Australia (WA) Goldfields, while not common, should be a significant investigation focus. Geotechnical engineers new to the area may be unaware of this and hence the importance of correct testing and determination of the material strength. Application of appropriate analysis to determine stable pit slopes to an acceptable level of risk, is not possible unless the appropriate strength and hydrogeological parameters have been established at the outset. A back analysis is presented of a pit that had extensive slope failures in alluvial clay-rich sediments with discussion on the approach adopted by the original design engineers to assess pit wall stability and consequent poor slope performance. Learnings from a full pit 3D back analysis are presented, with an approach to geotechnical and hydrogeological investigations and analysis for slopes in similar materials.

Jun 22, 2022

By S Ferguson, G Noble

The mining industry is facing economic pressures to treat more challenging and lower grade ore types, as well as pressure relating to environmental impact and social license to operate. Preconcentration through bulk ore sorting has the potential to benefit all these areas by enabling mining operations to divert material of low economic value prior to processing, thereby achieving higher feed grades and recovery, while reducing the processing plant and tailings dam footprint and capital required throughout the life of mine. The effectiveness of bulk ore sorting depends on the heterogeneity of material at the measurement location, as well as the accuracy and precision of the measurement. An understanding of ore heterogeneity can be assessed using drill core data, which provides metre by metre elemental assays. This paper reviews such data and assesses the grade distributions over different scales, which suggests that sufficient heterogeneity exists at mining scales to allow the potential for bulk ore sorting. Prompt Gamma Neutron Activation Analysis (PGNAA) technology has proven to be a successful measurement technique within many industries, including mining. PGNAA was first developed in the early 1980’s for the measurement of the elemental composition of bulk materials on a conveyor belt. Today, Pulsed Fast Thermal Neutron Activation (PFTNA) technology is also applied in elemental analysis of bulk materials and has some advantages for bulk ore sorting. In order to enable effective bulk ore sorting, however, a PGNAA/PFTNA analyser must be designed to provide a representative bulk ore analysis with the necessary accuracy and precision. Examples are presented to provide an understanding of the factors affecting PGNAA/PFTNA performance in relation to effective bulk ore sorting.

Nov 10, 2020

By R Jia, J T. Waldram

"The Caijiaying lead zinc mine is located in China, north-west of Beijing, in Hebei Province. The region experiences severe winters, below -35°C, and warm summers, up to 30°C. The mine and concentrator commenced operations in the second half of 2005 with a conventional tailings disposal system consisting of a tailings dam with peripheral ring main discharge and central water recovery. A second similar dam sharing one common wall was added later. In view of the extreme winter conditions tailings lines and ring mains plus spigots, together with return water lines, require insulation and electrical trace heating. The volume of process water trapped as ice in the tailings dam ponds each winter is significant. This seasonal variation presents a major difficulty in the management of process water availability. Although Caijiaying is an underground mine there was no backfill plant at the start of operations. As plant throughput increased more quickly than originally anticipated, tailings storage capacity became a prime concern. The construction of a backfill plant in 2007 reduced the pressure on surface tailings storage area requirements, but as suitable land on which to construct further tailings storage was both expensive and difficult to acquire, a more efficient use of the available area was required. Dry tailings storage, where flotation tailings are filtered to provide an immediate return of process water plus ‘dry’ tailings filter cake for stacking, provided an answer to both the land area required, and the water management difficulties. The paper details the reasoning behind the change and the benefits obtained at Caijiaying by moving from ‘wet’ tailings storage to ‘dry’ tailings storage.Citation:Waldram, J T and Jia, R, 2016. Caijiaying Dry Tailings Storage, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 379–382 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By H Lehtonen, H Mansikkaviita

In primary copper smelters, the received copper concentrate and other materials contain a certain amount of moisture, ranging from six to 14 per cent. Moisture in wet concentrate has a negative effect on the performance of the smelting furnaces when it is fed directly to the furnaces, namely increasing the energy consumption and the off-gas flow. There are several drying technologies available for drying copper concentrate, varying from direct heated rotary dryers and flash dryers to indirect heated steam dryers. Application of steam dryers has changed the drying process for copper smelters. Produced from a waste heat boiler, steam as heating medium enables plant-wide heat utilisation. Fossil fuel used from outside sources to remove water is no longer required and the combustion chamber is not required. In addition special attention has been paid to overcome the known problems of pollution emissions, excessive wear, clogging and frequent maintenance. The Kumera steam dryer is featured with many advantages based on principal improvements in reducing tube element wear and increasing drying efficiency. Thus, it has been considered as the first choice for those smelters where steam is available.

Jan 1, 2006