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By L Barrere, J P. Sykes, A Trench, R S. Davies

Western Australia (WA), alongside Brazil, has remained at the forefront of the global seaborne traded iron ore market for over 40 years. Despite this apparent stability and strong market position, WA continues to face strong external international supply-side competition, mainly from Brazil, but also periodically from often marginal, non-traditional sources of iron ore. Additionally, WA iron ore supply has undergone significant decadal change internally, both of an evolutionary (brownfields expansion) and revolutionary nature (major new greenfields projects). Since 2006, a new generation of WA-focused iron ore explorers, developers and producers have emerged.The majors, BHP Billiton and Rio Tinto, have expanded mine production to record levels and the Roy Hill project is now approaching nameplate capacity. Fortescue Metals Group (FMG) is, however, the largest new market entrant of the last decade, delivering upon their vision of becoming the ‘new force in iron ore’. Unlike most of the other new WA market entrants, FMG’s operations are substantive. Most of the other smaller, new WA iron ore miners have struggled during the period of falling prices, though it is worth noting that collectively they have made a material supply-side impact during the price boom – typical of marginal supply. Finally there have been some contributions from new magnetite projects, however, the delivery and economics of these projects have not met expectations.In this paper, we touch briefly upon the key global market changes of the last decade, namely China-driven demand growth and the changes to the pricing mechanisms for iron ores – before reviewing the rise in WA iron ore supply in response to these markets. We finish by focusing on the most significant WA-focused supply-side development of the last decade, the rise of FMG as a major new supplier and the strategic situation that facilitated its rise. The unprecedented China-led rise in iron ore prices felled many traditional barriers to market entry into an oligopolistic industry, allowing many new market entrants (in WA and around the world). However, the downturn in iron ore prices resurrected these barriers to entry, with only FMG (thus far) breaking the entry barrier with significant scale. Difficult corporate decisions have been forced upon the smaller WA iron ore miners who, in some cases, will now struggle to further expand, or indeed continue to operate in the longer run.The changes that have taken place over the last decade of WA iron ore production hold insights for other emergent mineral commodity exports from the state. Successful market entry, even when industry barriers are high, does not always require an immediate low-cost production assumption alongside a strong balance sheet. FMG could see a new market, within an established commodity market, target an appropriate and new product at it, overcome temporarily-felled barriers to entry in infrastructure and finance, then innovate and aggressively cut costs ensuring it was behind the barriers to entry when they rose again after the price boom.CITATION:Barrere, L, Trench, A, Sykes, J P and Davies, R S, 2017. New generation Western Australian iron ore – strategic insights far beyond the Pilbara?, in Proceedings Iron Ore 2017, pp 375–386 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 24, 2017

By P Meehan, R McAree, Z Guan

Equipment maintenance is 30 - 50 per cent of the operating costs for a typical mining company. While this is substantial, its importance is beyond its significance as a cost heading. Modern mining requires large amounts of investment in capital infrastructure and equipment to produce a product sold at a low unit cost. To stay competitive, such a business has to focus on full realisation of its capital investment, ie sustained production at high levels. Maintenance plays an essential role in achieving this goal. Mining companies typically use a mix of breakdown or corrective maintenance, planned maintenance, and some condition-based maintenance. The share of breakdown maintenance has been coming down through more effective planned maintenance and better condition monitoring tools. Planned or preventive maintenance (PM) is playing an increasingly important role in todayÆs mining maintenance. This is the suite of inspection and repair/replacement actions performed at scheduled time intervals as part of a preplanned activity. The activities are scheduled well in advance and, usually, the current wear-state of the machine is irrelevant. For example, the replacement of a major gear may have been planned 18 months in advance; replacement is carried out when the time comes regardless of the actual condition of the gear. The PM costs are significant and include direct cost of parts and labour as well as the opportunity cost of lost production while the machine is under maintenance. It is important to identify the optimum PM effort because over-maintenance should be avoided as much as under-maintenance. A new concept called severity-based maintenance is introduced in this paper. We have seen that measuring equipment ageing in mining merely by counting the engine hours is a very imprecise way of planning and scheduling maintenance because the damage accumulated in one hour varies enormously from operator to operator and with changing pit conditions. We recommend continuous monitoring of duty on all major equipment. This is feasible without having to fit out the machine with an army of sensors because most of the physical sensors required by dutymeters are already installed and maintained as part of the existing performance monitors. While the investment is modest, the potential benefits are huge and can be grouped under three headings:Immediate benefits will come from providing operators with direct feedback on the effect of their behaviour on machine health and training them to use this feedback to correct their operating style. The equipment can operate closer to the limits of capacity, producing more without unduly sacrificing the availability by monitoring and controlling the severity of the operation, ie the duty on the machine. Longer term benefits accrue from establishing correlations between actual time to failure data and measured equipment duty and using these correlations to optimise maintenance effort as well as planning new equipment purchases and warranty conditions.

Jan 1, 2002

By Eric Eisold

The Wachovia Headquarters and Arts and Cultural Campus project in Charlotte, NC includes a 1.5 million square foot, 48-story office tower, two museums, an Afro-American cultural center and a 1,200 seat theater for the performing arts. Public access to the Cultural Campus is through two pedestrian tunnels constructed under city streets connecting to parking garages. The 5.7 m wide by 4.7 m high mined tunnels were procured through a design-build contract. The tunnels were designed as initial/final shotcrete linings with a sprayed water barrier sandwiched between layers of shotcrete. In addition, the mix design was supplemented with a cementitious admixture to develop internal water resistant properties in the shotcrete.

By Thomas M. Barczak

Secondary roof support systems play a vital role in preserving the safety of underground mine workers by preventing the unintentional collapse of the mine roof. Hundreds of thousands of standing roof supports are constructed each year in underground coal mines. Historically, wood and concrete cribs and timber posts have been used for secondary roof support. These support constructions require the handling of heavy and bulky materials, causing numerous injuries to the mine workers and resulting in more than 40,000 lost workdays in the past 9 years. Since 1993, various alternative support technologies have been developed. These new support technologies not only provide superior roof support, but many also have significant material handling advantages by using smaller and lighter weight materials, fewer components, mechanically installed support systems, and pumpable support systems. The National Institute for Occupational Safety and Health (NIOSH) has conducted extensive material handling research and has developed recommended lifting thresholds to reduce material handling injuries. An analysis of roof support construction reveals that conventional support materials used in wood and concrete cribbing exceed the recommended lifting thresholds, while the engineered support systems are closer to the recommended weight thresholds. Finally, recommendations are made relative to proper lifting techniques and material handling practices to prevent injury to mine workers when constructing roof supports in underground coal mines.

Jan 10, 2000

By T. Lindstad, J. Kaczorowski

The Boudouard reactivity of single cokes produced from selected bituminous coals and commercial cokes has been investigated in a thermo gravimetric furnace. The effect of potassium as a catalyst for this reaction was studied, as it is known to accumulate in ferromanganese furnaces. A gaseous impregnation technique using K2CO3 as the potassium source was applied to impregnate the coke samples. The reactivity experiments were designed to simulate conditions occurring in an industrial furnace, as used for production of Mn-alloys. The coke particle size varied from 3.35 to 6.63 mm, while the temperature was maintained between 800- 1100oC with a gas composition from 50 to 75% CO2 in a CO/CO2 mixture. To determine the catalytic effect of potassium, the concentration varied from a fraction of a percent up to 15%wt. The results show that single chars vary significantly in reactivity, depending on the properties of the parent coal, while commercial cokes exhibit similar reaction rates. Temperature and partial pressure of CO2 have the strongest influence on the reactivity, while the influence of gas flow rate and coke particle size were found to be negligible. The catalytic studies revealed that the relative reactivity of non-impregnated samples are preserved after the impregnation, so the least reactive coke is still the least reactive after the impregnation for the whole range of potassium loads. Also, it has been confirmed that the Boudouard reactivity reaches a plateau at potassium concentration of 4%wt.

Jan 1, 2007

The Annual General Meeting of the South African Institute of Mining and Metallurgy was held in Kelvin House on Wednesday, 24th August, 1977. Dr M. D. G. Salamon (President) was in the chair and declared the meeting open at 16h00. Obituaries The President: It is my sad duty to announce the death of the following members of the Institute : C. G. Evans, J. P. Rees, Life Fellows ; S. R. Bryant, H. MacConachie, M. Mrost, and A. W. van Zyl, Fellows; L. T. Campbell-Pitt, F. W. Collins, A. J. Duncan, I. G. Evans, F. W. Kleinschmidt, P. L. Vaughan, R. W. Wallace, and H. Wason, Members. As a mark of respect to the memory of the deceased and in sympathy with the bereaved, I would ask you to rise and observe a few moments' silence. Minutes The President: May we confirm the minutes of the General Meeting held on 23rd March, 1977, as published in the June issue of the Journal? Agreed.

Jan 1, 1978

By W Shamu

The mechanical properties of rock samples of identical lithologicalcomposition may vary significantly due to existence of materialdiscontinuities. Laboratory tests were carried out to determine the effect of material discontinuities on rock sample mechanical properties. The investigations consisted of detecting discontinuities, observing the failure mechanisms during uniaxial compressive strength tests, and analysing of the factors affecting the strength. A non-destructive testing method has been adopted to assist in thedetection of discontinuities. Laboratory testing proved that fractures leading to failures initiated on the detected discontinuities. The location, orientation, size, density and extent of the discontinuities contribute to different modes of failure and these affect the mechanical parameters of rock samples. Four modes of failure were distinguished for hard and brittlecylindrical rock samples. These modes were referred to as simple shear failure, multiple shear failure, multiple fracturing and vertical splitting. To evaluate the effect of discontinuities on mechanical parameters, the ratio of uniaxial compressive to tensile (Brazilian) strength was calculated and analysed for the different modes of failure. It was found that the value of the ratio depended on the mode of sample failure. The lowest value of the ratio was observed for shear mode of failure and the highest for vertical splitting mode of failure.

Jan 1, 1999

By D. Wolfe, R. Cleminson

"The Aurora North mine has been operating for more than ten years, and is the source of over half of Syncrude’s bitumen production. The slurry systems at Aurora experience high rates of wear, and mission lengths on current slurry pumps are nominally 1500-2000 hours. Recent work has enabled a better understanding of the significant adverse effect of large particle impingement damage to impeller vane leading edges - which is the known life determining issue for Aurora hydrotransport pumps. A new pump design has been developed with a larger diameter impeller and increased vane lengths, and is expected to triple Aurora’s mission length for hydrotransport pumps.INTRODUCTIONSlurry Pumps are Critical Equipment at SyncrudeSlurry pumps are a critical component in Syncrude’s operations. In a typical Aurora application, each pump stage helps move over 8000 dry tonnes per hour of oil sand, plus an equal volume of process water that has been added to create the slurry. The average impeller life in oil sand hydrotransport service at Aurora has been nominally 1500-2000 hours, or 12-16 million tonnes of oil sand pumped. Generally, the slurry pump application at Aurora has proven very difficult to improve due to the unique combination of high sand abrasivity, 125 mm (5”) large particle top size (lumps), and high flow rate relative to basic pump size; a factor that results in higher than optimal impeller vane speeds for the service conditions.PROJECT BASISSlurry Pumps are the Reliability Bottleneck at AuroraSlurry pumps are currently the shortest-lived components that determine the overall system run length at Aurora, in Hydrotransport, Extraction and Tailings. Vibrating screens and piping had been previous bottlenecks, but their reliability has been improved through upgrades in equipment design and wear materials. Both vibrating screens and piping can now achieve 4000 hour mission lengths."

Jan 1, 2013

By M. Iberico

A partir de los años 70 se incrementó el proceso de exploración y desarrollo de los yacimientos mineros submarinos. En este sentido, el presente trabajo describe el origen de los depósitos a partir de los descubrimientos de módulos manganíferos en el océano pacífico que hicieron Thompson y Murray. Posteriormente Buchanam demuestra la existencia de módulos ferro-manganíferos en aguas poco profundas ( 200 m. ), de composición diferente de las provenientes de aguas profundas. De otro lado, el trabajo señala también la división de los minerales marinos en tres categorías: las sales disueltas y en organismos, los sedimentos y depósitos en el suelo profundo submarino y los depósitos consolidados e inconsolidados de la plataforma continental. Por último, se describe los procesos de beneficio y las ventajas de la explotación de los recursos submarinos en el futuro de la minería submarina.

Nov 20, 1972

By J. B. Zadra, S. M. Shelton, R. B. Fisher, M. M. Fine

"INTRODUCTION An extensive test program is in progress by the Bureau of Mines to determine ways and means of recovering ferromanganese ore 5/ from the widespread domestic manganese and manganiferous iron deposits.Samples were received from the Stance property in southwestern Virginia, 12 miles northwest of Stoney Gap, in Bland County.The Stange mine is situated on the crest of Flat Top Mountain and is developed by open-cuts extending over several acres. The manganese deposit occurs in the Oriskany sandstone largely as a replacement of the sandstone, to some extent as breccia filling in the crusted parts of the sandstone, and as veins along joints, and bedding planes.The mine was first worked in 1917 and was operated during the war years. A long period of idleness was followed by intermittent operations in recent years. A small log-washing plant, consisting of a 20-foot log washer, was operated 1-1/4 miles northwest of the mine. The log-washer concentrates were crushed to minus- 1/2 inch and then washed in a second log washer to remove as much of the siliceous sandstone as possible. According to a communication from the operator, the double-washed concentrates were jigged and the jig concentrates marketed without further beneficiation."

Apr 1, 1942

By P. Fredriksson, S. Seetharaman

In the ladle refining process, the ?FeO?-content of the ladle slag is of great importance in the chemistry as well as the energetics of the process. An optimization of the process requires an accurate knowledge of the thermodynamic activities of ?FeO? in the ladle slags. Due to the discrepancies in the existing data, renewed attempts are being made at the Royal Institute of Technology to generate reliable data for binary, ternary and multi component slags containing ?FeO? at steelmaking temperatures. In order to measure the activities of ?FeO? in the slags, a gas equilibration technique was employed in the present work. The slags, kept in Pt-crucibles, were equilibrated with a CO-CO2-Ar gas mixture and quenched after equilibration. The chemical composition of the slag was analyszed. From a knowledge of the thermodynamics of Fe-Pt system, the ?FeO? activities in the slag could be evaluated. The results of the present studies, together with other literature values, were optimized in the slag software, THERMOSLAG® developed in the Royal Institute of Technology, Sweden. The results of the optimization are presented. Model calculations were performed with the KTH slag software, THERMOSLAG®, by using plant data from OVAKO Steel, Hofors, Sweden. It was found that oxygen estimations in the metal from the ?FeO? analyses of slags, obtained by conventional sampling and analysis methods, where less reliable. Estimation of the oxygen levels utilizing the sulphur partition between the slag and the metal were carried out using the THERMOSLAG® software. Reasonable estimations of the oxygen contents in the metal confirmed that this could be a very useful tool for the plant operator. Keywords: ladle, thermodynamics, slags, ?FeO?, experimentation, modelling, sulphur partition

Jan 1, 2004

By S. A. Hovanessian

The method of characteristics which reduces the Buckley-Leverett mnlineur, partial differential equation to two first-order, linear differential equations is applied to the solution of a waterffood recovery problem for multiple lines of producing wells and one line of injection wells. The application of the method is described by a numerical example, and a brief theoretical background is given. From the results of this study, it is concluded that the cumulative water injected and oil produced are the same for single and multiple sets of producing wells. INTRODUCTION In this paper, the method of characteristics is applied to the solution of a waterflood recovery problem with multiple lines of producing wells and one line of injection wells. The application of the method to this type of recovery problem considerably simplifies the procedure of obtaining a numerical solution. It differs from the method described by Kern1 because it eliminates the need for integration in obtaining saturation fronts. In addition, the saturation history at any location within the field is obtained from a single diagram (time vs distance with saturation as a parameter)'. The paper includes a brief theory of the method of characteristics and its application to the solution of oil recovery problems. A numerical example is worked out, and the cumulative oil recovery-vs-time curve for a system with multiple sets of producing wells is obtained. This curve is then compared with the recovery curve of a system with only one set of producing wells. From this study, it is concluded that the cumulative water injected and oil produced are the same for single and multiple lines of producing wells. However, the recovery time is considerably longer for multiple sets of producing wells.

By C. Doucet

Since 2001, CANMET Mining and Mineral Sciences Laboratories (MMSL) have worked with Falconbridge Ltd. (now Xstrata Nickel) to evaluate trends in the strength development and water retention properties of a novel backfill material for underground mining, called gelfill. Between 2004 and 2006, extensive laboratory tests were undertaken under the leadership of the Deep Mining Research Consortium (DMRC). This paper compares results obtained from samples circulated through a mini-flow loop and a simple mixer. Although many parameters were studied over the last five (5) years, this paper focuses on the investigation of the effect of the mixing method, sequence and time, and the curing environment on strength development and water retention of gelfill. It was found that binder should be added as a powder to the mix in the mini-flow loop, and that mixing slurry in the mini-flow loop as opposed to the mixer generally yielded higher strengths. The practical implications of these observations are the subject of an on-going underground trial that will compare laboratory and in situ properties of regular slurry fill with gelfill.

May 1, 2007

By E. R. Davis, R. J. Knott

The paper discusses some of the tools of management in the field of project control, especially in engineering. Project control includes planning and cost engineering, and involves various phases: the conceptual Design and Planning Phase, the Definitive Design and Capital Budgeting Phase, and the Implementation Phase. Each of these phases is discussed in in, together with the use that can be made of data banks, progress reports, and computer systems.

Jan 1, 1982

By T. S. Seleka

Laser surface melting has been conducted on a 304 stainless steel (SS) with the aim of enhancing pitting corrosion resistance of the material. This process involves rapid melting of the material?s surface followed by rapid solidification to refine the microstructure. This includes the dissolution of inclusions such as MnS, FeS, CrxCy, and other minor constituents. The microstructures as a result of laser treatment were observed by means of optical microscope and also confirmed by the XRD. The glow discharge optical emission spectroscopy (GDOES) was utilized for chemical analysis. Changes in hardness were observed by using a Vickers microhardness tester. Pitting corrosion tests on laser treated and untreated samples were conducted according to ASTM G48-92 to evaluate mass loss and pitting morphology. Laser surface melting improved the pitting corrosion resistance of this material in a chloride-containing environment.

Jan 1, 2007

By M. Helinski

In the authors? experience inappropriate water management in hydraulic fill masses has been the root cause of most barricade failures. Inappropriate water management can lead to high water pressures, reduced effective stresses and increased barricade stresses (Kuganathan 2002). In addition the high hydraulic conductivity and non-plastic nature of most hydraulic fills makes susceptibility to piping failure (Cowling et al. 1987) a high possibility in many hydraulic backfills where a static water head is available. In order to avert both of these failure mechanisms it is essential to control the elevation of the phreatic surface within the fill mass. This is usually achieved through campaigned filling and resting periods. The duration of filling and resting periods are often estimated using some form of stope drainage simulator. Due to the random nature of many characteristics that influence the fill mass hydraulic conductivity, simulation of hydraulic fill drainage can be difficult. The high consequences of inaccurate phreatic surface estimates combined with the high variability in drainage properties often results in operators taking a conservative approach to this modelling. This conservative approach can lead to significant delays in the filling cycle which can have a major impact on the productivity of many hydraulic fill operations and can often results in an unnecessary movement towards capital intensive paste fill systems. This paper presents a water management technique which combines a simplified drainage model with in-situ monitoring to provide a rational approach to water management. With an accurate drainage model filling operations can be carried out at optimum efficiency without compromising safety. The implementation of this strategy has lead to a significant increase in filling rates at a number of Australian filling operations. A brief case study from one of these sites has been presented.

May 1, 2007

By S. K. Singh

To meet increasing demand of coal, underground mining is largely being replaced by the exploitation at deeper horizons and with greater complexities. The exploitation-proposition may be below not-to-be-disturbed surface properties or below water-bodies, posing a constant threat of inundation. Also, the mounting pressures to limit the adverse impacts on the environment bring the extraction-undertaking to face more challenges. An understanding of subsidence-mechanism and a rational quantification of subsidence parameters is a requisite herein. This paper presents such pragmatic quantification, validated at mine-sites in India. In comparison, better productivity, conservation and safety is ensured in this approach.

Jan 1, 1999

By D. W. Rich

An environmental management system (EMS) is a key part of a company?s environmental stewardship. Procedures and practices to continually improve environmental performance can provide great benefits in operating the company. Managing site environmental quality data is a key component of this. An environmental data management system (EDMS) is an important element of the EMS for mining and other projects, providing project staff with the information that they need to make decisions that can have a significant impact on public health. Improvements in computers, data communications, and transfer formats have made it much easier to implement an integrated EDMS program for gathering, managing, selecting, and displaying data from the field and the lab. Software now lets users define sampling plans, create files for field data entry, and print Chains of Custody. Laptop and handheld computers facilitate field data entry and may provide automated communication back to the office. Most labs can now create usable electronic data deliverables. QC checks and limit comparisons can be largely automated. The result is organized data that can be efficiently used for reporting, graphing, and mapping, to better understand project issues.

Jan 1, 2009

By Daniel Hodouin, Claude Bazin, René del Villar

"A traditional linkage has long been established at Laval University's Department of Mining & Metallurgy between the Mineral Process (MP) and the Mining Exploitation (Min) on one hand, and between the Extractive Metallurgy (EM) and the Materials Engineering (Mat) on the other. This academic separation of Mineral Processing from Extractive Metallurgy at the educational level has become increasingly at odds with today's industrial practice in which both disciplines are not only complementary but also often intertwined. For instance, in gold ore processing, comminution, flotation, and gravity separation units are interfaced with atmospheric or pressure leaching modules and with carbon adsorption and electrowinning units. The new copper plants in South America combine comminution and flotation circuits with heap leaching, solvent extraction and electrowinning processes.In order to reflect this new industrial reality and to harmonise the options offered in both its engineering programs, the Department of Mining and Metallurgy of Laval University has introduced major changes in its curriculum in 1996. These changes reflect also the recognition that the somewhat secondary status given so far to Mineral Processing and to Extractive Metallurgy within their ""mother"" programs, Mining/Mineral Engineering and Materials metallurgical Engineering respectively, was in sharp contrast with their actual significance for the Canadian economy. Leading industrial voices have raised similar concerns and the Canadian Engineering Accreditation Board has also addressed this problem in its latest program evaluation.The changes implemented at Laval aimed at a) better representing MP and EM within the two undergraduate programs; b) training top-level versatile and multidisciplinary engineers, fluent in all aspects of MP and EM, irrespectively of which of the two ((mother)) programs they had chosen and capable of meeting today's industrial requirements; c) training students in process analysis, optimisation and automatic control using state-of-the-art software, and d) taking into account the co-operative nature of both undergraduate programs.Results are very encouraging in terms of student enrolment and industrial response. However, some concern is expressed on the sustainability of the renewed curriculum considering the drastic budget restrictions in effect at Laval as in most other Canadian universities."

Jan 1, 1999

By M. Sanchez, I. Imris, G. Achurra

The Smelting and Converting El Teniente Process for copper concentrates as well as Slag Cleaning Furnace Technologies to treat slags coming out from the El Teniente Furnaces are widely applied today in Chile and around the world. Several industrial applications of this process have shown their capability to treat copper concentrates in a wide range of chemical and mineralogical compositions. Main operational parameters determining performance of the process are: oxygen enriched air flow rate, degree of oxygen enrichment, moisture content of the solid materials processed, molten material levels inside the vessel, frequency of molten materials tapping, bath temperature and copper losses in slags. In this work, the copper losses in the slags from El Teniente pyrometallurgical process are predicted by calculation from thermodynamic data and compared with those determined by microscopic examination and slag industrial data. Results obtained show that the main part of copper losses in the slag from El Teniente Furnace are mechanically entrapped or floated unsettled droplets of the coexisting matte phase. by the contrary the very low copper losses in the slag from slag cleaning furnace are limited by the physico-chemical form.

Jan 1, 2004