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By L McCallum, G Dale, B Silverwood, T Roscoe, A Costin

The introduction of Progressive Closure and Rehabilitation Plans (PCRPs) in Queensland from 2019 places greater importance on planning and implementation of mine rehabilitation activities. The progress and outcomes of progressive rehabilitation activities is monitored and reported upon to demonstrate success in achieving progress towards the approved post-mining landform, and to inform corrective action where required. The requirements of PCRPs place additional emphasis on mine sites to quantify the risks of successfully achieving planned outcomes. This is particularly challenging given mined-land rehabilitation is a complex process involving decisions on multiple inter-acting management interventions, climatic conditions and spatially variable site characteristics.

Aug 2, 2023

The paper focuses on how rock bolts are loaded in different rock masses, as well as in pullout tests. Three analytical models for rock bolts are presented in brief, one for bolts in continuously deformed rock masses, one for bolts in blocky rock masses, and one for bolts in pullout tests. The bolt models are used to interpret measurement data for rock bolts from three sources and to help specify the modes of axial load in the rock bolts. It is found that in continuously deformed rock formations fully coupled rock bolts have only one axial stress peak. The position of the axial stress peak moves towards the far end of the bolts with increasing rock deformation. In blocky rock masses several axial stress peaks may appear in the rock bolt. The position of this kind of axial stress peak does not change during the entire loading process. For rock bolts in pullout tests, decoupling of the interface always occurs first at the loading point. The decoupling front moves towards the far end of the bolt with an increase in the applied pull load.

Jan 1, 2000

By M Camarda, A Pirson, F Vasconcelos, J Mesquita

ArcelorMittal Prijedor is a goethitic iron ore mine located in the north-west of Bosnia and Herzegovina, which mainly supplies ArcelorMittal’s European subsidiaries. Annual production of the asset stands at the level of 1.5–2.1 million tons of iron ore product which is sent to ArcelorMittal Zenica steelmaking plant. Two types of products with approximately 50 per cent Fe are generated in Prijedor through a process composed by crushing, screening, and magnetic separation stages. Within this process one of the tailings produced is called ‘ultrafines’. The ‘ultrafines’ product corresponds to the desliming hydrocyclones overflow in Prijedor plant, which is classified in a size fraction below 25 μm and corresponds to about 5 per cent of feed. This material is richer in iron than the coarser size fractions of the ore but do not present a good performance in concentration processes. In this way, several studies have been carried out during the last years to find solutions to use the ‘ultrafines’ material without success. In this context, the possibility of dehydroxylate the goethite contained in the material transforming the mineral into hematite and thus increasing the iron grade of the final product was investigated. During the research, several dehydroxylation tests with different temperatures and time of exposure were performed. Using dihydroxylation process at temperatures higher than 800°C it was possible to produce a material with 43 per cent Fe from the original 39 per cent Fe ‘ultrafines’ sample. In addition, the dehydroxylation tests confirmed that goethite becomes completely transformed into hematite at 400°C (with an exposure time of 60 mins) and material is completely sintered at 1200°C. A simulation study based on dehydroxylation tests results showed that it would be possible to use a ‘ultrafines’ product with Fe grade higher than 45 per cent to produce a material with 50 per cent Fe through a complete dehydroxylation process.

Sep 18, 2023

The minerals industry focus over much of the past twenty years has been on cost reduction and production growth supported, but not driven, by technology improvements. Mergers and acquisitions, and the demands of financial markets, have been high priority items whereas research and development and technology based innovation have received less attention and have been cut back in many companies. Technology improvements will be critical if the industry is to make progress on the stated aims of improving energy efficiency, reducing water usage and maximising recovery from deposits. They will also be important for improving capital efficiency and in treating difficult deposits. However the role technology based innovation will play both in the overall industry, and within individual companies, during the next decade is quite uncertain. There are major challenges in progressing technology based innovation in an industry with limited technical resources which is dominated by long life high capital operations. Specific opportunities for energy and productivity improvements exist but face significant technical and structural barriers that need to be overcome if the industry is to significantly improve performance. Current evidence suggests that changes in approach will be needed for these improvements to be realised. Recent studies in the United States and Canada have highlighted the wide range of energy performance across the industry and the scope for marked improvement from both incremental improvements and increased research and development. Comminution, material transportation and underground mine ventilation were identified as high priority areas. Opportunities within these areas are discussed both in respect of specific technologies and in how they may change performance. The role of open innovation as a source of new technology is also discussed. This is an abstract only. No full paper was prepared for this presentation.

Sep 13, 2010

Estimation of operating costs in the nickel production industry requires a detailed analysis of material flows from mine to smelter to refinery. Despite the small number of nickel producers compared to other base metals, the existence of two very different ore types (sulphide and laterite) and a wide variety of mining and processing technologies make the identification of these flows of critical importance if an accurate global picture is to be obtained. Smelting and refining processes in nickel metallurgy have evolved with a high degree of adaptation to specific operating conditions in different locations. Overall costs are calculated by combining individual cost elements for each unit in production chains from mine to saleable metal product. The average cost of western world primary nickel production in 1995 was US$2.07/lb ($4560/tonne). Average operating costs remained virtually unchanged in the three years to 1995 after an 8.5 per cent fall in 1993, but a 3.9 per cent increase to $2.15/lb is expected for 1996. A major factor in this rise results from the lower prices of copper and cobalt this year, reducing the by-product credits available to major producers.

Jan 1, 1996

By Christie GB, Mainwaring DE, Leong YK

High solids brown coal slurries have been prepared with concentrations approaching those achieved with bituminous black coals. The high inherent water content and macroporosity of Victorian brown coals have been reduced in a controlled manner by chemical and mechanical means. The hydrophobicity of the coal surface has been increased sufficiently to reduce the tendency for swelling and water uptake. This together with densification has allowed the solids content to be progressively improved from 25% solids with raw coal to 65% solids with modified coals. Both raw brown coal and modified brown coal suspensions show shear thinning behaviour resulting in lower viscosities at higher flow rates. All coal suspensions displayed a yield stress once sufficient solids concentration was achieved. This yield stress can be used in the prevention of solids settling. Under simple shear mixing the network structure that provides the yield stress quickly breaks down to a low viscosity fluid with reduced yield stress and a pumpable consistency. The time necessary for structural recovery is in the order of days permitting shut-down and start-up of fuel delivery systems.

Jan 1, 1987

In October 1993 it was decided to undertake the fourth phase of mining at Big Bell. This decision followed the exhaustion of open pit reserves in January 1993. Two stages of mining were proposed for the new underground mine. The initial stage would mine the remnant ore, consisting of the rib and crown pillars and lower grade ore on the hangingwall and footwall side of the old open stopes, which were mined from the 1930s to 1950s. Most of the old open stopes were backfilled with either deslimed mill tailings or development mullock, both of which were economic to recover. However, the mineable ore from this resource was difficult to evaluate. The second stage focused on mining ore outside the remnant areas and was initially proposed as a Core and Shell method under a caving hangingwall. This method has since been superseded with sublevel caving, in part due to the very high and deviatoric stress conditions encountered at Big Bell and the relatively long mining cycle required for open stoping. The problems and challenges discussed in this paper will cover the identification of remnant ore reserves, dewatering the old workings, and remnant mining.

Jan 1, 1998

By L Lorenzen, H Muller, L Bernard

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

Sep 26, 2013

By G Gilchrist, S C. Dominy, T Jashashvili, R C. A Minnitt

The grouping and segregation error is one of Gy’s seven errors that cannot be measured in any qualitative manner because of its transient and changing characteristics each time the sample is handled mechanically. Attempts to calculate the mean and variance of the segregation error is considered by some as ‘an exercise in futility’ that would not help us achieve representative sampling. This research is aimed at understanding the process of segregation of dense, finely divided and dilute particulate materials supported in a clean quartz substrate during intense agitation. Several mixtures of fine-grained materials including steel, tungsten carbide and gold grains were used in these experiments. Four hundred grains of each of the minerals and metals at a top size of 2 mm were mixed with approximately 600 g of finely ground quartz material (95 per cent passing 2000 microns) in a 500 ml plastic jar with a sealable lid. The mineral–?metal mixtures were analysed in three steps using microfocus X-ray computed tomography. Step one consisted of rolling the containers on a flat surface in an attempt to concentrate the mineral and metal grains in the core of the supporting substrate; this is a base case that can be reconstructed after each session of analysis. The second step involved gentle and vigorous shaking of the mixtures in order to segregate the denser minerals and metals from the supporting quartz substrate. In some cases, a third step involved splitting the sample through a riffle splitter. Three-?dimensional images of the surface of each grain, its volume and its X-, Y- and Z-coordinates, before and after intense agitation of the container, were interpreted from the reconstruction of the tomographic X-ray data. The spatial analysis of grains using cell declustering and 3D variography provided a useful means of characterising the distribution of the grains in space and the extent to which they had become segregated during the process of agitation. Spatial analysis indicates that in general, grouping and continuity of grains is weakly developed. The modelled nugget effect remains high for most tests, indicating that grains of similar size did not group together strongly. Agitation through rolling provided the best continuity, although not consistently in the long axis of the plastic jar. The nugget effect was consistently highest, and the range of continuity shortest in samples that had been split, indicating that the grouping and continuity were reduced through splitting the sample. Initial results indicate that very little segregation of the minerals and metals occurs in the quartz substrate. This is somewhat counter-intuitive, but suggests that the effects of agitation on mixtures of dense minerals and metals in substrates of lower density do not lead to excessive segregation. Differences in behaviour between dense materials in response to agitation are evident. Grains of different composition and shape did not group and segregate in a predictable manner in response to the agitation methods. Initial results indicate that the degree to which a material groups and segregates relates more to the characteristics of the denser material itself, rather than the agitation method employed.CITATION:Minnitt, R C A, Jashashvili, T, Gilchrist, G and Dominy, S C, 2017. Quantifying segregation of minerals and metals in particulate materials using computed X-ray tomography and variography, in Proceedings Eighth World Conference on Sampling and Blending , pp 173–182 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2017

By C Laming, P M. Hetherington, F A. Pym, M P. Murphy, K E. Crook

Reconciliation is a powerful tool used by mining operations to compare the mass and grade of ore produced with what was estimated before mining. The primary objective of reconciliation is to verify that the estimated planned metal production is achieved during processing, allowing issues to be identified for which adjustments can be made throughout the mining value chain to improve recovery and maximise efficiency. Traditionally, the mine plan is based on estimated mine grades using sampled exploration drill hole or blasthole grades. Reconciliation discrepancies between the mine plan and mill are common due to such factors as insufficient or non-representative sampling, poorly conceived models, or unrecognised blast movement. MineSense Technologies Limited® (MTL) has developed an X-ray fluorescence (XRF) sensor-based ore classification system that is installed on mining equipment to provide real-time grade estimates of run-of-mine material at bucket, truck, or belt-scale. Bucket level grade estimates provide insights into grade variations at the mine face that were never before available. This data set eliminates some of the leading causes of reconciliation discrepancies and enables tracking of tonnages and grades from the mine face to the processing plant at bucket resolution with confidence. Bucket-by-bucket grades at the mine face enable dynamic optimisation of the mine plan to stabilise the mill feed grade through blending of mine and stockpile loads. Beyond stabilising feed grade, Mine to Mill reconciliation combined with the full XRF spectrum response can generate proxy relationships to ore characteristics like hardness and recovery. These properties can then be predicted at the mine face, enabling further optimisation of the downstream mill feed, not only for grade, but also for power and water consumption, reagent addition, and recovery. This paper presents the benefits of MTL technology for grade reconciliation and mill performance optimisation at a Cu Mine in BC (Canada).

Mar 22, 2022

By L Manca, P B. Hills, D Tyler, N Pollington

This paper describes a collaborative project undertaken by Newcrest Mining Limited (Newcrest) and pitt&sherry to identify, develop and then implement global best practices to manage the exposure to inrush (dry and mud) hazards in underground mining operations. An extensive literature review was undertaken to identify past experience globally and the current state of knowledge and practice in managing inrush hazard. A key requirement of the literature review was the development of a list of guiding questions which would form a framework for approaching operators to discuss the topic, capture recent learnings and understand current operating practices to allow the development of a best practice solution. An initial cohort of 14 mines across four continents chose to contribute and detailed interviews were carried out by the project team. The outcome from the literature review, interviews with participating mines and various internal discussions was a comprehensive summary document detailing Basic versus Best Practice management of the inrush hazard. This document is being used as a gap analysis tool by Newcrest to assess and guide the management of inrush hazard at their existing and future operations. The summary document has also been provided to the participating mines for their consideration. The project is iterative and will continue to evolve as new experiences, knowledge and practices come to light.

Mar 15, 2021

By T Baumgartl, A Costine, B Boshrouyeh, M Edraki

In mineral processing, the management of tailings may become increasingly more challenging with a change of ore type and the quality of water used in the plant. This, in turn, may affect the overall costs of the operation and water usage and, in the long-term, pose challenges for mine closure and rehabilitation. Depending on the applied treatment technique, the short and long-term properties of tailings are largely determined by the fine particles. Most clay materials and ultrafine particles exist in tailings from oil sands, coalmines and base metals, bringing about challenges in dewatering performance. Moreover, given the growing concern for water scarcity, the minerals industry is increasingly turning towards the use of saline water, which poses yet another challenge for tailings management. The high salt content alters the behaviour of clay particles, making dewatering a more complex process than in freshwater systems (Boshrouyeh Ghandashtani et al, 2022; Costine et al, 2018). High-density techniques for tailings management have been used for several years in the mineral industry. In this regard, one of the novel and promising dewatering methods is in-pipe or inline flocculation, where the polymer is added at high dosages to thickener underflows, giving additional (likely denser) aggregation, releasing more water on deposition compared to low solids thickening. Previous research in the field of flocculation has primarily focused on the process of flocculation itself, specifically the settling rate and size of aggregates, rather than the long-term impacts of the produced tailings materials (Liu et al, 2020; Jeldres et al, 2017). This is particularly true for the novel method of this technology, where polymer is added to the thickener underflow. Furthermore, these studies have used small-scale set-ups using buckets/beakers, plungers and mechanical stirrers for the flocculation process. Unfortunately, these methods lack the necessary control over the properties of the treated tailings, which can lead to irreproducible mixing and dispersion of viscous polymer solutions (Fawell, Costine and Grabsch, 2015). Consequently, a system that can work with a wide range of operational conditions for high-solid tailings material is essential for reliable and reproducible results. The objectives of this study were to determine the effect of different type of polymers in the presence of monovalent and divalent salts on the inline flocculation of artificial tailings. The next step was to evaluate the impact of high-dosage polymer addition on geotechnical properties such as settling rate, consolidated density, rate of consolidation and the hydraulic conductivity of tailings. In addition, this research aimed to fill a knowledge gap and investigate the feasibility of using polymer-treated tailing in removing the copper ions and then quantify the performance of produced aggregates under time-dependent processes.

Aug 2, 2023

By D Stepanenko, G Stovpchenko, L Lisova, D Togobitskaya, L Medovar

Classical electroslag remelting of consumable electrodes is a drop-by-drop melt feeding through a slag layer into a renewing molten metal bath, slowly solidifying into a homogeneous, dense, defectfree ingot in a copper water-cooled mould. The new look at the additive nature of the electroslag remelting (ESR) process in a protective atmosphere allowed us to formulate the principles of a comprehensive thermodynamic-based model that can predict dynamic changes in slag and metal composition at certain ingot remelting. The model considers drastically different slag-to-metal mass ratios at the beginning and end of remelting and predicts gas, slag and metal composition in a chain of thermodynamic subsystems. Despite consisting of calcium fluoride and stable oxides, the ESR slag can oxidise main and active elements from steel and alloys (primarily aluminium, titanium and silicon) due to chemical reactions between slag and metal. ESR is not an electrochemical process in its nature. However, slags are ionic melts and deviation in their composition causes a change in their properties, affecting both operation mode and ingot quality. Another important understanding derived from the modern metallurgy technological route is that the ability to refine metal from impurities is not a priority for the ESR because consumable electrode has already passed all stages of refining and deep degassing at ladle treatment that changes ESR slags engineering principles. The critical importance became slag’s ability to generate process heat and keep the melting composition in the metal bath unchanged (except for non-metallic inclusions assimilation). Slag engineering for ESR required a compromise between chemical inertness to a metal composition and desired physical properties deriving from technological reasons. The Directed Chemical Bonds Concept (DCBC) in a multicomponent oxide system was used to build predictive models of electric conductivity and the melting temperature of fluoride-oxide slag based on their chemical composition. Both models help to design a customised composition of effective slags for steel and alloy groups or individual grades, and they are significant steps in the development of a comprehensive model of electroslag remelting.

Aug 21, 2024

By E Topal

Stopes are used in several underground mining methods. Boundary determination of these stopes is generally based on simple rules of thumb. While several stope boundary optimisation techniques are available, they fail to guarantee true optimum results. The first part of this paper reviews some important stope boundary optimisation studies and proposes a new algorithm to optimise stope boundaries and layouts for underground operations. The second part applies the proposed algorithm to a block model to test its ability to produce optimum results and demonstrate its applicability in a number of different scenarios. The results demonstrate that the proposed algorithm can find optimum stope boundaries and layouts in three dimensions for different stope sizes and economic conditions.

Jan 1, 2009

By J Robinson, D Herbert

Bench stoping operations at the Isa Lead mine have been underway for over 11 years. They were implemented to address safety, productivity and mining cost concerns noted with cut and fill mining operations which were then being used to extract ore from the Racecourse orebodies. This paper describes the main features of benching operations at the Isa Lead mine and identifies the key elements for the success of the method. Four case histories are presented which highlight several of these factors.

Jan 1, 1998

Delivery of effective plant shutdowns is primary to the business success of mining and processing plant operations. This paper sets out a methodology that starts with understanding the business objectives of the shutdown and promotes rigorous detailed planning, effective communication, appropriate governance and effective participation of plant operations personnel. The result is delivery of business effective outcomes.

Jan 1, 2004

Water rights and availability are extremely contentious issues in many mining regions around the world, in some instances leading to violent confrontation. This situation has the potential to only get worse because competition for 'scarce' water resources will increase with population growth. In this environment the dilemma facing the mining industry is how to generate confidence in developing a responsible, sustainable and transparent water management strategy that is recognised as such by all stakeholders. Whilst the water needs of the mining industry are minor compared to those of agriculture, an operating mine requires a relatively large quantity of water on a daily basis to carry out operations. Another contentious aspects of new mine development is the debate between all stakeholders on the amount and quality of water that a mine is able to discharge into the environment should this be required. There are a multitude of water resources available to the mining industry for operational needs however much of this water is saline and over the last two decades there has been a continual decline in water quality (ie salinity has increased). In today's world there are enormous internal and external pressures to reduce water consumption at a mine and/or alternatively use water not considered a resource by the local community (ie sewage, saline or salt water, desalinated water). Strategies to meet these objectives can be achieved by implementing good water management practices, by recycling process water, reducing water losses by evaporation and seepage (ie by increasing and improving dewatering practices) and employing new technologies such as dry stacking and dry processing. Recycled water, acid mine drainage water and water collected in the mining area have the potential to impact mineral processing performance, unless they are treated, because of the build up of mineral salts and decomposed chemical products in these types of waters. Besides this the regulatory requirements of any water discharged from a mine site (quantity and quality) have also become more stringent. For these reasons there is now some form of water treatment practiced at most mining operations around the world. This paper provides an overview of water stewardship undertaken in the mining industry over the last two decades and provides examples of water treatment practices that have recently been installed at mining operations that may be of interest to the reader.

Sep 13, 2010

By G P. S Resende, D E. G Oliveira, E A. S Baeta, T F. Bravin

There is currently in the mining industry, as well as in other industries, a movement seeking to increase investments in decarbonisation processes to help combat global warming. Among some initiatives taken is replacing diesel-powered mobile equipment in the mines with electricity-powered equipment, such as electric off-highway trucks or even belt conveyors in the mining operation. Samarco is a Brazilian mining company that since its conception has used a conveyor belt mining system in its mining operation, using only a small number of trucks to complement the mining process. This mining process that combines conveyor belts and trucks has brought environmental gains for the company since the environmental impact of conventional truck-only mining is greater than that of the combined system. To measure these gains, a medium-term mining plan was developed in which two fleet scenarios were detailed. One scenario contemplated a high level of detail of belt mining seeking its maximisation, while the other considered the operation performed 100 per cent by trucks, eliminating the use of conveyor belts. Through the comparison of these two scenarios, it was possible to make an inventory of atmospheric emissions and greenhouse gases for each one of them considering data such as types of equipment, diesel consumption, total distance travelled and energy consumption. The results showed that the fleet scenario with conveyor belts results in periods with up to 15 per cent less greenhouse gas emissions and 37 per cent less total particulates compared with the truck-only scenario. Therefore, the results confirm the environmental benefits of the method and the need to look for ways to even expand it in future operations through a study to identify the potential areas in the long-term mining plan.

Sep 18, 2023

By M Fahey, A B. Fourie

Over the past ten years, the mining industry has witnessed the introduction of a new and innovative mine filling technique known as paste fill, which consists of placing full stream tailings with small amounts of binder and water into underground stopes. Paste fill has benefits over traditional backfill methods, such as higher solids contents than hydraulic fill and easier transportation than rock fill. From a geotechnical perspective, the behaviour of very fine material in a fully saturated state can be complex, particularly when binder is added. Previously, there has been no rigorous solution to understanding the paste fill deposition process, resulting in uncertainty regarding critical aspects such as barricade load calculations. This uncertainty has the obvious consequences of potential barricade failures (including at least 12 over the past four years), and for many operations attempts to deal with this uncertainty has led to excessively conservative filling schedules, restricting production. This paper presents an application of Minefill-2D, the first rigorous model capable of representing the paste fill deposition process. The model couples the processes of material accretion, consolidation and cement hydration to calculate the distribution of stress around a stope (including the total stress applied to barricade structures) during filling. Minefill-2D is a finite element numerical program, which has been verified using laboratory element tests, centrifuge tests and in situ measurements (Helinski, 2008). The authors present a sensitivity analysis, carried out using the model, to demonstrate some of the critical and less critical aspects relating to paste backfill deposition. The results of this sensitivity analysis are used to devise a fill management strategy that can be utilised to minimise the risk of barricade failures and maximise fill rates where appropriate.

Jan 1, 2008

By J J. Jiang, B G. Bow

Atlas Iron Limited’s (Atlas) Abydos Mine has developed its Scarborough open pit proximal to a rock shelter that has been assessed as a significant Aboriginal heritage site by the Traditional Owners of the land. The rock shelter, named Yurlu Kankala, is located to the north-west of the pit with a stand-off distance of 35 m. Within Atlas’ Native Title Agreement with the Traditional Owners, and approvals from the Western Australian Department of Aboriginal Affairs, commitments have been made to conduct mining in a way that avoids or at least minimises disturbance and damage to the rock shelter. This complies with the Aboriginal Heritage Act 1972 (WA) and respects the heritage and culture of the Traditional Owners.CITATION:Bow, B G and Jiang, J J, 2018. Iron ore mining in proximity to a significant Aboriginal heritage rock shelter, Pilbara Region, Western Australia, in Proceedings Life-of-Mine 2018, pp 2–5 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 25, 2018