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By R Jones

OneSteel Whyalla’s grate-kiln-cooler pelletising plant was commissioned in 1968 processing haematite feed from the local South Middleback Ranges mining area. The existence of a magnetite resource beneath the haematite ore at Iron Duke had been known for some time. In 2004, a decision was made to covert the primary iron source for the Whyalla steelworks from haematite to magnetite – known as project magnet. The intent of the project was to convert the feed to the steelworks from haematite to magnetite and to free up the remaining haematite resource for export. The pelletising plant was cut over to a magnetite feed in 2007.The thermochemical differences of magnetite compared to haematite are threefold:1. the introduction of an exothermic reaction during conversion of magnetite to haematite,2. the absence of bound water which existed within the haematite, and3. lower gangue content requiring lower fluxing levels and therefore lower calcination energy demand.The combination of these differences results in a significantly different induration requirement for magnetite as compared to haematite. The change therefore required extensive research and test work to design modifications to the furnace and to ensure appropriate risk mitigation for the Whyalla steelworks.Preliminary pot-grate test work was performed to define the pellet chemistry and confirm the suitability of the magnetite to produce pellets suitable for the OneSteel blast furnace. A heating curve was developed by use of computer-based heat and mass balance modelling. Extensive pilot scale grate-kiln-cooler test work was then performed to confirm the heating curve and to verify and fine-tune the pellet properties. Computation fluid dynamics was used to design the physical changes to the furnace required to achieve the proposed heating curve.Following installation of an additional preheat zone, including a wall and dilution air fans, into the preheating furnace, and installation of an additional wall into the cooler, the modified furnace was commissioning in December 2007. The plant performed as expected during commissioning with the actual heating curve matching the proposed curve and the produced pellets within blast furnace specifications.

Jul 11, 2011

By M D. Raine, J K. Bartlett, S C. Dominy

The Bendigo Goldfield is located in the state of Victoria, Australia, and is one of a number of fields that make up the Central Victorian Goldfield. Since 1993, Bendigo Mining NL has been carrying out an extensive re-evaluation of the goldfield and is currently well advanced in developing an underground mine. The sediment-hosted auriferous quartz reefs are structurally complex and closely associated with anticlinal axes and reverse faulting. The gold within the quartz reefs is characterised by both its coarse nature (100 up to >5000 ¦m) and its erratic distribution; as a result, the Bendigo Goldfield is classed as an extreme nugget effect system. This characteristic ensures that the Bendigo mineralisation is very challenging to sample and evaluate. In this case, diamond drilling is a good measure of structure and geological continuity, but a poor measure of grade and grade distribution. Drilling, combined with on-reef development, bulk sampling and detailed geological studies are required for resource evaluation. For grade control a balance has to be sought between sample representativness, cost, turn around time and practicality. Extreme nugget effect deposits like Bendigo, require the use of bulk samples in order to be representative. However, the cost and turn around time is significant. As a result, a micro-bulk sampling system has been introduced that attempts to overcome these problems by providing a fast, practical method that can define ore from waste. Bulk sampling and on-vein development are still necessary for resource and reserve estimation.

Jan 1, 2003

By J Rose, D O’Toole, D Grant

Orepasses are a critical element in the transport of ore from the stope drawpoint to the surface ore stockpile, making them an integral part of an underground mine’s ore-handling system. Well-designed and operated orepasses improve productivity and lower operating costs over a long period of time.The Olympic Dam mine, as part of a 6 Mt/a expansion project in 1997, constructed a large network of orepasses feeding a rail haulage system to facilitate the movement of approximately 8 Mt/a to the Clark crusher and hoisting shaft. The orepass network comprises 14 orepasses and currently includes 59 individual tip points. The orepass network has been in operation for over 15 years and in excess of 110 Mt of ore has been moved through the system.Olympic Dam’s management of mine infrastructure includes a program of assessing the condition of the Clark system orepasses. A comprehensive program was initiated in 2011 and consisted of systemically performing volumetric surveys to determine the integrity of the various sections of the orepasses. The current geometrical state of the orepasses provides essential information for comparison of geotechnical and operational parameters and a baseline for understanding the key causes of orepass deterioration to assist in the planning of both usage and potential replacement options.The collection of geotechnical and operating data allowed the review of the current condition, potential longevity and associated risks with the various orepass sections. Initial studies have also reviewed options for rehabilitation and/or replacement.CITATION:Rose, J, Grant, D and O’Toole, D, 2016. Orepass monitoring and management at Olympic Dam Mine, in Proceedings Seventh International Conference and Exhibition on Mass Mining (MassMin 2016), pp 609–616 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2016

By B Chapman, R Nievergelt, J Hill

A major component of Sydney’s new South West Rail Link project is the Hume Highway Underpass (HHU), an 80 m long twin track mined tunnel excavated at a depth of just 5 m below the pavement of the Hume Highway; one of Australia’s busiest road corridors.In order to ensure a safe and efficient construction of the underpass without disruption to the Hume Highway traffic, design of the HHU required specific focus on the prediction and control of ground movements. This paper describes the design and construction solutions adopted in response to these challenging constraints. The paper also provides discussion on the observed behaviour of the underpass during construction and the results of a back analysis that was undertaken during construction.CITATION:Hill, J, Nievergelt, R and Chapman, B, 2014. Design and construction of Sydney’s South West Rail Link Hume Highway Underpass, in Proceedings 15th Australasian Tunnelling Conference 2014 , pp 375–386 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 17, 2014

By D Maldonado

BlueScope Steel’s Port Kembla sinter machine underwent a major upgrade during mid-2009. The mixing and rolling drum (MRD) was thoroughly cleaned during the upgrade. Space factor measurements taken in October 2009 showed that the drum was operating in the cataract regime in the dry mixing section and the cascading regime in the rolling section, which is optimal for granulation. Sampling carried out during an entry into the MRD showed that both the Sauter mean diameter and the predicted bed voidage increase rapidly during wetting, and then decrease in the wet mixing section. In the rolling section, the granule properties remained constant untilthe drum discharge. Frozen particle analysis, using liquid nitrogen as the quenching agent, were carried out on material collected from the MRD discharge. The results, expressed as a Granulation Index, showed there had been a significant improvement in the granulating performance of the MRD following the upgrade. The plant studies were also complemented with laboratory scale experiments which aimed to optimise the granulation process. The effect of burnt lime on green feed permeability was quantifi ed using the laboratory scale drum at different moisture contents. A significant increase in permeability was apparent once the burnt lime dosing rates doubled from 1.1 - 2.2 per cent w/w (feed basis). The capacity of the burnt lime system at the sinter machine will be increased in order to benefi t from the expected higher permeability, permeability, which will enable the machine to sinter at deeper bed heights.

Jul 11, 2011

By Williams M

Sheet flotation is a new two dimensional column flotation cell that produces continuous spectrum of products. Analogous to a shaking table in its performance and analysis, sheet flotation is a sheet of bubbles rising through packing contained between two walls. Feed enters the sheet at the lower left and the product exit along the top and right edges. Iligh grade materials exit at the top left, middlings exit at the top right comer and low grade waste materials exit at the bottom right. As in the case of a shaking table, two motions are required: up and right. Bubbles furnish the upwards movement for hydrophobic particles, slanted packing the rightward movement for hydrophilic particles. The sheet flotation cells is analysed as a 40 x 40 array of simple cells. In practice, 1000 x 1000 arrays of simple cells may be expected. With larger arrays, excellent separations may be expected. Because there is no recycle, there is no build-up of middlings in

Jan 1, 1993

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 X Sun, L B. Zhou, H Yi, X Tang, P Ning

The rapid industrialisation in China has consumed large amounts of various industrial raw materials, which has left behind large quantities of industrial solid wastes produced from the processes of mining, mineral processing and smelting. The storage of huge quantities of industrial solid wastes is an obvious risk to the environment and human well-being. As the first step to fully appreciate the scale of this risk, it is necessary to carry out research for developing a pollution source environmental risk assessment system (PSERAS), especially for the typical staple industrial solid waste (TSISW). This paper aims to discuss the frame of the PSERAS for TSISW for large scale production. This system consists of two aspects: predicted factors and accidental ones, which involve physical, chemical and biological risk assessments, on-site and during transportation process. Two analysis methods, the analytic hierarchy process (AHP) and fuzzy logic assessment (FLA) were used to handle the complexity of environment and non-quantitative data. The risk assessment system for such a complex objective is difficult and the assessment of relative factors is problematic through the usual quantitative analysis. With the proposed PSERAS, it is possible to define the risk class of pollution sources. Furthermore, the risk assessment results will be helpful to the decision-maker, especially when facing unknown risks in the environmental management of industrial solid wastes. In addition, by means of the PSERAS, risk factors can be ranked against their contributions to environmental risk, in order to calculate their relative priorities in decision-making.CITATION:Sun, X, Ning, P, Tang, X, Yi, H and Zhou, L B, 2012. Environmental risk assessment system for typical staple industrial solid wastes, in Proceedings Life-of-Mine 2012 , pp 301-304 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 10, 2012

By T Nassis, P Louw, M R. Fry, T du Toit

Business intelligence (BI) and business analytics (BA) are established IT technologies that are used extensively in the business environment. This paper discusses the use of these technologies in production environments and beneficiation plants.Assmang’s Khumani mine is an iron ore operation located in the Northern Cape, South Africa. Assmang Limited is jointly owned by African Rainbow Minerals Limited and Assore Limited. This paper presents a case study of a BI solution applied to this plant, which is used by metallurgists, supervisors and all levels of operations and management to extract and analyse data to control and optimise the operation of the plant.The main advantage of adopting an established BI solution is the ease with which production personnel can extract and analyse data. The data is easily presented in familiar spreadsheets and no IT staff or specific training is required to achieve this.The solution adopted at Khumani mine uses a data mart with a multidimensional model (called an online analytical processing (OLAP) cube) acting as the main repository and source of data. The OLAP cube simplifies the access and analysis of plant data.The OLAP cube stores data in a specifically-designed way, which allows extraction and analysis to be performed quickly. It is designed to hold large amounts of data on a long-term basis, which could be for the life of the plant. It also performs automatic aggregations over many dimensions on a background process.A major benefit in adopting such a BI solution is that it allows common BA methods to be applied. This is due to both the efficient long-term storage of data and the availability of standard BA tools. BA tools are now able to perform data mining, predictive analytics, forecasting and other machine-learning algorithms. This paper presents the possible use of such advanced data analysis methods in a beneficiation plant.CITATION:Fry, M R, Nassis, T, Louw, P and du Toit, T, 2015. The use of common business intelligence and analytics tools in the operation and optimisation of iron ore process plants, in Proceedings Iron Ore 2015, pp 129–138 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

This paper traces briefly the reasoning which led to the decision to extend the existing internal shaft at the Rosebery Mine and to instal underground a larger winder (No. 2 Hoist) with capacity to handle all hoisting requirements to a depth of approximately 2,500 ft. on an incline varying from 83" to 55" to the horizontal. It then covers the specifications and selection of the winder, the design of the winch chamber, rope raise and bins, the excavation, support and lining of the chambers and the transport to site and installation of the machinery. Finally a brief description is given of the mechanical and electrical parts of the winder.INTRODUCTIONThe existing shaft winder on the internal inclined shaft situated on No. 8 Level of the Rosebery Mine had reached the limit of its capacity. Hoisting 21-ton capacity skips in balance, with a 13/16-in. diameter rope, it required four layers of rope on the 3 ft. 6 in.drums to reach the loading station under No. 12 level at a depth of 864 ft. (Fig. 1). This entailed heavy wear on the multi-layered rope and heavy stresses on the cheeks of the drums. Continuous working on three shifts was necessary to handle ore, men and materials, and a hold-up from any cause whatever meant an interruption to production on the lower levels of the mine. The maximum output of the hoist whilst hoisting from the No. 12 level loading station was 50 tons per hour. It was obvious therefore, that a larger winder was required if output was to be maintained.Diamond drilling had proved the existence of sufficient ore at depths well below No. 12 to warrant exploitation and a decision had to be reached on the means of hoisting this ore.

Jan 1, 1958

By J Heyes

Historically mining engineers haven't spent enough time planning waste dumps, but waste movement costs often outweigh ore haulage costs. There is a real incentive to plan waste dumps right the first time to minimise rehandle and final closure costs. At BHP Billiton Iron Ore there has been an increasing sophistication in waste dump design and they are becoming as important as the pit design. Closure landforms are now included in mining studies. Closure is embedded in the business planning cycle. The results from the recent life of mine study at Whaleback is a case in point where a base case of the shortest hauls with no closure constraints was compared against a closure case. A properly planned and executed waste plan revealed that no rehandle was required and haulage costs were eight per cent less if closure design implementation was carried out concurrent with mining. At cessation of mining the landforms were such that decommissioning of critical acid rock drainage dams and coverage of exposed pyrite areas could occur straight away, without the need for additional rehandle.  The paper also covers design and scheduling elements of waste design both in-pit and ex-pit, management of potentially acid forming material (PAF) and trends in PAF management and designing for final landform closure. This paper illustrates that there is value in terms of costs savings, sustainable outcomes and reputation if the mine planners are involved in the closure planning process.

Jan 1, 2009

By A Keogh, P Allen, P Stoker

"An EXTENDED ABSTRACT is available for download. A full-length paper was not prepared for this presentation. Private equity (PE) firms are comparatively free of mandatory requirements for the level and scope of due diligence applied prior to making investment decisions in minerals projects when compared to listed entities, sovereign funds or financial institutions adopting the Equator Principles (Equator Principles Association, 2013). While this freedom allows for flexibility, agility and innovation in making investment decisions, it can also expose PE firms to material risks that may impact their ability to successfully list the projects or attract later financing.Financial institutions and investors with mandatory due diligence and disclosure standards may refrain from investment in or acquisition of a project if it fails to meet various performance requirements. There are many high-profile projects that have suffered significant write-downs on book value after acquisition because specific non-mining issues were not adequately assessed. Thus, a PE firm may be left with an asset that is difficult to divest and incapable of securing development finance.PE firms can manage this risk by being aware of the growth trend in the adoption of ‘international standards’ in addition to host nation standards and legislative requirements. This paper outlines key issues for PE firms to address to maximise the chances of obtaining funding or successfully taking an exploration or mining project through to listing or divestment. Two steps are required: identification of gaps in performance and priority matters of interest to financial institutions and development of action plans to ensure that the priority requirements are met or capable of being met.A PE firm can set its project for success by understanding the social and environmental performance requirements of international standard financiers and by setting the project on the right path to meeting these requirements, and thus making it an attractive investment.CITATION:Allen, P, Stoker, P and Keogh, A, 2015. Setting for success – private equity exploration and mining project buy-in to listing and divestment , in Proceedings PACRIM 2015 Congress, pp 93–100 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Mar 18, 2015

By H Holmstr÷m, A Widerlund, M Lindvall

At the Kristineberg mine in northern Sweden sulfide-rich, poorly buffered tailings have been deposited in five impoundments located along a valley. The tailings area has been remediated by applying a combination of till cover and flooding. A new method that has been applied to parts of the tailings area is to raise the groundwater table to saturate the tailings. By increasing pH by liming, thereby reducing metal mobility, a water-covered downstream impoundment is functioning as a trap for metals released from the till-covered impoundments upstream. In this paper the efficiency of the system approach used at Kristineberg is evaluated. Progressive changes of water quality from groundwater in the upstream till-covered impoundments via surface streams within the pond system to the water in the flooded downstream pond and its outlet are described. The results show that the system approach used in the design of the remediation programme of the tailings works as planned. The sulfide oxidation rate has decreased in the till-covered impoundments, and, as predicted, there is an out-flush of old weathering products which will continue for at least five years before equilibrium is reached. The groundwater in the till-covered impoundments has high concentrations of Fe, S, Mg and Zn, but the concentrations of metals such as Cu, Cd and Pb are much lower than before the till cover was applied. The limed pond is an efficient metal trap, with concentrations as high as 2.76 per cent Zn and 0.28 per cent Cu in the calcite-gypsum sludge developed on the tailings. The outlet from the flooded pond, and thus from the whole mining area, releases small amounts of metals to the recipient in comparison to the amounts that are in movement within the mining area. During the period May to November, 13 kg dissolved Zn and 111 kg particulate Zn was released to the recipient, whereas a total of 27 000 kg was transported by surface water within the impoundment system during the same period. The results from Kristineberg show that when planning remediation of complex mining areas, it is useful to adopt a system approach in which different methods are used on different parts of the area along the flow path of the drainage water, whereas flooding of the downstream pond is the key to the performance of the entire system.

Jan 1, 2003

By C Tomlin, C Gimber

Historically, key closure risks have been studied during operations and then further assessed as cessation of mining approaches. Only in the past couple of decades or so has progressive rehabilitation and closure become an integral part of regulatory frameworks, sustainable mine planning and more recently, new project and development planning. It is now broadly accepted that the best closure outcomes occur when rehabilitation and closure are properly considered upfront, during the early stages of a mine development project and well before mining occurs. Increasingly, regulatory processes are requiring more diligence on early closure planning, often as part of the environmental impact assessment (EIA) and approvals process, rather than later in dedicated closure study phases. There is an opportunity to use the information generated during this phase to make better decisions on project selection, design, mining methodology and all other facets of the mining operation.

Aug 2, 2023

By W Potma, C Brauhart, S Halley, S Urbisinov, A Scogings

Truly integrated, quantitative, 3D GEOmetallurgical (or mineral system) characterisation, classification and 3D modelling should provide a cradle to grave unifying link across the exploration and mining value chain. All too often, spatially representative (quantitative) characterisation and modelling of a mineral system is delayed until feasibility stage, incurring a significant opportunity cost. The application of robust GEOmet characterisation methods early in the project lifecycle (at exploration stage) improves ground selection, exploration, and Mineral Resource estimation outcomes, long before there is a need for metallurgical test work. The value of this early provision of quantitative 3D mineralogy models is compounded at project feasibility stage, and continues to accrue over the entire project lifecycle, delivering cost savings, improved decision making and early warning of issues and opportunities.CITATION: Potma, W, Halley, S, Scogings, A, Urbisinov, S and Brauhart, C, 2018. Putting the ‘GEO’ back in front of GEOmetallurgy: importance of early implementation of quantitative mineral system characterisation, classification and modelling, in Proceedings Complex Orebodies Conference 2018, pp 55–57 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 21, 2018

This paper attempts to draw together the experience of over 30 years of research and practice in the United Kingdom on the rehabilitation of abandoned metalliferous mining wastes. The reliance on water when the mines were operating has implications for water quality and the techniques used to restore sites to alleviate the principal impacts of the mines. Drivers of reclamation included concerns about human health from wind blown dust and pollution of watercourses as well as perceptions of dereliction. Techniques of reclamation used involved removal of spoil from near to surface watercourses, capping of spoil, diversion of watercourses, use of impermeable membranes, prevention of surface sinks into underground workings and the use of constructed wetlands. The issues to be dealt with in mine reclamation have become more complex and sometimes diverge. The schemes in the 1990s described have been effective in dealing with pollution from spoil heaps and small but significant adit discharges; however, significant issues, particularly those of large flows of polluted water from mine sites, still need to be dealt with. Although the paper describes the legacy of mining, which largely finished in the late 19th/early 20th century, similar issues but on a larger scale are to be found in more recent mining, for example Eastern Europe. In many of these areas minerals still remain to be won and dealing with this legacy may fall on new mining developments.

Jan 1, 2006

By P J. Fairfield

"This paper reflects on the author’s experiences in undertaking mining studies and reviewing mining projects and technical reports, particularly over the past five years, and the impact of recent changes in reporting standards and listing requirements pertaining to mining-related evaluation and valuation exercises. It also discusses contemporary changes in the expectations of the investment community and the implications for the role of the technical specialist in providing advice to such stakeholders.Not for the first time in history, the resources industry has experienced a significant downturn after a period of strong, sustained growth in line with the traditional view of the cyclical nature of commodity markets. The resource industry is currently faced with capital austerity in the wake of projects ‘failing’ (not delivering to expectations). In response, the industry has experienced changes in investment behaviour (slowing of investment) and an increasing regulatory burden as stakeholders seek a greater understanding of mining project risks.This paper discusses this response and uses case studies to highlight the key learnings (perhaps re-learnt) by the industry. It also discusses the challenges faced by technical specialists in communicating the results of technical and valuation studies to the investment community.As investors seek to take advantage of the current stage in the investment cycle, the key challenge of the technical specialist is to effectively communicate the uncertainty in technical assumptions, risks and opportunities that drive project value.CITATION:Fairfield, P J, 2016. Managing expectations – from buyer beware to buyer be aware, in Proceedings Project Evaluation 2016, pp 66–74 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Mar 8, 2016

By P J. Handley

"Predicting how coal seams will be beneficiated through the coal handling processing plant (CHPP) has long been challenging within BHP Coal. Various coal seams from different areas are mined and stockpiled separately, often depending upon a deleterious coal quality parameter; high/low trace elements for example. These stockpiles are then fed in different ratios into the CHPP to produce the desired product/s. In understanding the washability characteristics of the feed source, mine geologists and process engineers work together to improve the beneficiation of different coal materials through the CHPP.For the majority of the BHP Coal deposits, the washability data is available for the coal seams across the deposits. However, no previous standardised modelling and prediction technique existed that could ensure the correct information was available for forecasting and refining CHPP processes. This paper will discuss the steps undertaken to implement a geometallurgical prediction tool that simplified and streamlined the washability modelling and yield estimation process. The value realised to the BHP Coal assets resulting from this process was: improved compliance to plan increased throughput increased CHPP recovery through improved efficiencies and increased revenues.CITATION:Handley, P J, 2017. Washability modelling and estimation techniques used to improve coal handling preparation plant beneficiation, in Proceedings Tenth International Mining Geology Conference 2017, pp 327–336 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Sep 20, 2017

By E Williams

The role and importance of a well designed test work program during the development of an orebody is often underestimated. A test work program should be tailored to deliver very specific answers to relevant questions. With a clear purpose, the results from the test work program will enhance the outcome of the feasibility study and provide the information required to meet the requirements of all stakeholders. With regard to test work programs there are three main areas that should be considered: orebody characterisation and definition, process flow sheet development and engineering design information.Orebody definition relies on reliable analytical methods to characterise and assess the economic minerals present in the ground. In mineral sands, the physical processing characteristics of the minerals play a significant role in the definition of an orebody. The analytical method therefore has to be customised using a combination of laboratory techniques. These techniques can include heavy liquid separation, gravity separation and magnetic separation and are usually combined with chemical and mineralogical analyses to create a picture of the orebody. During the definition phase of test work programs, an appropriate analytical technique has to be developed to evaluate drilling samples, but also to support the information collected during flow sheet development.Process flow sheet development is usually done once there is a reasonable understanding of the size and variability of the orebody. Selecting the best sample for test work is critical, as any flow sheet design is tied to the specific characteristics of the sample used for development. There are other factors that can improve the outcomes of flow sheet development test work, including the skills and knowledge of the operator and allowing sufficient time to process and analyse the results. Very often this work is conducted under pressure with limited time and resources, only to result in a suboptimal flow sheet. During this phase of flow sheet test work, iterative testing will provide the information required to develop an optimal metallurgical flow sheet. The data collected will provide indicative recoveries and yields that are required for feasibility studies.Equipment specification is often included as part of process flow sheet development. This includes comparative test work between different equipment suppliers, assessment of operating conditions such as the loading to determine the number of processing units required, as well as other design information required such as particle size distributions, density and operating temperatures.While restricting the time and costs expended on test work programs may seem to meet a short term need to meet investor requirements, neglecting to develop a proper framework of the requirements that has to be met in the long-term can lead to significant long-term cost overruns. This is mainly due to a need to repeat test work, or do confirmation test work, as insufficient information was collected during the initial program.

Oct 5, 2011

Longwall mining operations have been in place in Australia since the early 1960s. This mining method is currently used to extract the bulk of coal obtained from underground mines in Australia (CSIRO, 2010). Despite the high tonnages extracted the expected utilisation of much equipment remains relatively low. To some extent this level of utilisation is influenced by the variability in conditions inherent in the mining process. This variability in production rates presents challenges to those attempting to design a coal clearance system. The difficulty is to design a system that has sufficient capacity to support production, without over capitalising or incurring high operating costs. The need to allow for a series of largely unplanned events in the design of a coal clearance system makes simulation modelling an ideal technology to employ. Simulation modelling is a methodology that allows a system with interacting components to be modelled over time, while explicitly taking into account unplanned events that may disrupt operations.This paper discusses how dynamic simulation models have been used to assist in the design of coal clearance systems. Typically this type of modelling has been used to look at the likely profile of production rates from the Longwall shearer and to determine how well various proposed combinations of belts, bins and stockpiles would support production.

Sep 26, 2011