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THE Yallourn chimney has aroused interest, as it is, for the time being, the tallest structural erection in Australia. Its height was not decided on, however, with the object of breaking records, but is purely incidental to the purpose which it serves. Theboiler plant at the briquetting works (first instalment) consists of five Babcock and Wilcox land-type water-tube boilers, each of 4510 sq ft. heating su:r£ace and 225 sq. ft. grate area in the form of step grates. Four boilers will normally produce 73,000 lb. of steam per hour at a gauge pressure of 265 lb. and a temperature of 6500 F., the fifth boiler being a reserve. Each boiler will consume about 100 tons of Yallourn coal per 24 hours. Provision is made for future installation of economizers, should it be found desirable. Designing for this condition, and allowing for a waste gas temperature of 3500 F. and an air temperature exceeding 1000 it was found necessary to have a draft of about 1.3 in. (water gauge) at the base of the chimney, and to deal with about 2000 cub. ft. of gases per second. Estimates were made of the cost of providing the necessary draught by means of fans and by means of a tall chill).ney. The annual charges of the two methods differed only slightly, and the tall chimney wasselected as being the more general practice in briquetting factories.Estimates were prepared for brick and concrete chiIlllleys. Yallourn bricks at that time were hand-made, and, while very suitable for domestic work, were not capable of withstanding high compressive stresses. The chimney design to suit these bricks thus required to be on very ample lines, resulting in high cost. Machine-made bricks from Melbourne would cost about £5 10s. per thousand on the site, with extra for radials, so that high cost again resulted. On the score...

Jan 1, 1924

By Best R. J, Poulos H. G

The method for design of primary roof support for the large todoidal cavern constructed to house the Sydney Opera House parking station is presented. The cavern was constructed with 5 m of rock cover beneath Sydney's Royal Botanic Gardens. Design of rock reinfonnent using a combination of fully grouted rock dowels and Macalloy bars was based on control of horizontal shear movement along bedding features in the roof. A combination of linear arch type analyses and non-linear jointed finite element analyses were used in the design study together with an analysis of the shear resistance offered by fully grouted bolts under shear deformation.

Jan 1, 1993

The basic rule for correct design of a sample plant is that all parts of the material being sampled must have an equal probability of being collected and becoming part of the final sample for analysis. However, this rule is often ignored in the design of sample plants to save capital costs. This is false economy, because the samples taken are likely to be seriously biased and the precision may be compromised. The introduction of bias is particularly serious, because no amount of replicate sampling and analysis will reduce bias once it is present and it is often quite difficult and expensive to subsequently rectify the problem due to space limitations around the primary sampling location. This is also true of secondary and tertiary sampling stages, particularly in terms of the relationship between particle size and retained sample mass. The best strategy is to seek expert sampling advice and design the sample plant correctly at the outset.

Jan 1, 2005

By S Pradhan, A Kuras, R Mahajan

This paper describes the design of the precast concrete segmental lining for the 13.1 m internal diameter and 450 mm thick, 2.4 km long mainline tunnels for the Waterview Connection project in Auckland for the New Zealand Transport Agency.The design and detailing of this segmental lining presented some noteworthy challenges, including an alignment that has sections of low cover in soft ground. Key points of interest are that this precast segmental lining is the largest to ever include steel fibres as the primary method of reinforcement and the lining includes cams on circumferential joints to control ring deformation.The paper describes some of the key design decisions that were made in a collaborative manner with the construction team, tunnel boring machine manufacturer, segment manufacturer and the designers.CITATION:Mahajan, R, Kuras, A and Pradhan, S, 2014. Design of segmental lining for Waterview Project, Auckland, New?Zealand, in Proceedings 15th Australasian Tunnelling Conference 2014 , pp 289–294 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 17, 2014

By S Pollak, A Amon

This paper describes the current and finished design work which has been performed for shallow rock station caverns for New York CityÆs first new subway construction in 60 years. A new robust, sophisticated, design procedure has been developed for two up to 30 m wide caverns, with overburden of less then 12 m, and rock cover to span ratios (C/S) in the order of 0.25. The design is based on empirical input parameters like the Q-value, rock mass rating (RMR) values, rock mass class after Cording (1984), cover to span ratios, which have been validated by the use of structural computer models as well as two- and three-dimensional numerical discontinuum models. The design approach is a staged approach using first principles, empirical models and non-linear FEM and DEM models. In addition, the paper describes the factors and circumstances why shallow caverns have been selected instead of cut-and-cover structures and why all the underground station structures have been developed as drained structures.

Jan 1, 2008

By M Chappell

This paper describes the design of the steel fibre reinforced precast concrete (SFRC) segmental lining for the intake and discharge tunnels for the Gold Coast desalination plant in Queensland. In addition, the key design requirements and design methods for the lining of these 2 km long, 2.8 m internal diameter tunnels, including structural, durability and maintenance requirements are discussed. Details of the segment configuration and erection process are presented along with information on the manufacture and trial testing of the concrete for the segments. The paper also gives a brief introduction to steel fibre reinforced concrete behaviour. Construction of the tunnels commenced in April 2007, and the authors believe this is the first application of this technology in Australia.

Jan 1, 2008

By G Lane, S Morrell

The design of the 12 m diameter SAG mill installed at the Cadia Hill Mine in New South Wales followed after two years of extensive laboratory and pilot plant testwork. The testwork showed the Cadia ores to be hard and competent necessitating the use of both a variable speed SAG mill drive and pebble crushing. The grinding power requirements for the SAG mill was based on engineering in-house grinding software, pilot plant data and simulations using JK SimMet software. Surveys of the SAG mill operation during the first four weeks showed the feed size distribution, transfer size and pebble rate to be lower or less than those for which it was designed. To compensate for the lower pebble rate, the SAG ball load was increased. This resulted in the total comminution circuit power being some 0.5 kWh/t higher than predicted. The JK SimMet SAG model has been modified to take account of these variations.

Jan 1, 2000

By S Porter, R Woodall, N Weeks

Nelsen, Porter and Wilson (1996) provided some preliminary concepts for the design of the Melbourne City Link tunnels. At that time, the City Link project was in the early design phase whereas now it is nearing completion. This paper provides details of the actual design adopted for the various sections of the tunnels as well as some commentary on the design process. The tunnels form a critical element of the project and the design of both driven and cut and cover tunnel sections is a significant factor contributing to successful project execution. Geology, hydrogeology, site constraints, traffic management and program were important design inputs. Design for the cut and cover sections in particular varied significantly in response to these differing inputs.

Jan 1, 1999

The pressure of low commodity prices forced the design process for the second lift of Northparkes E26 Mine to adopt a continuous improvement philosophy. The emphasis was to minimise capital expenditure while still maintaining the excellent low operating costs achieved on Lift 1. Although the first block cave lift at Northparkes is the most productive underground mine in the world and is held up as a benchmark for the use of technology in mining, areas for improvement were identified. Every area was critically assessed and investigated for the possible application of new techniques and technologies. Key learnings from the construction and production phases of Lift 1 were captured, documented and used as the starting point for the Lift 2 design. This paper shows how and why the design parameters initially used onLift 1 were changed to become the current E26 Lift 2 developmentproposal. The main differences between the two block caves arehighlighted. The alternative techniques and equipment that wereconsidered are also discussed. * Originally published in the Proceedings of MassMin 2000,published by The AusIMM.

Jan 1, 2001

The West Fork project is located in Reynolds County, Missouri, in the mineralized zone referred to as the Viburnum Trend. The West Fork orebody has a calculated ore re- serve of 13 600 000 tonne (15 000 000 st) con- taining 5.5 per cent lead, 1.2 per cent zinc, and recoverable values of copper and silver. A total of 64 600 tonne (71 200 st) of lead concentrate and 11 300 tonne (12 500 st) of zinc concentrate will be produced annually. The mill was designed to operate at an average capacity of 3450 tonne/day (3800 st/day), based on a 95 per cent availability factor. The mill will operate 24 hours a day, 5 days a week, with maintenance performed, as needed, on weekends. The mine will operate on an identical schedule; but the underground, pri- mary crushing will operate on a six hour/shift, three shift/day schedule. The 1.07m x 1.22m (42in x 48in) jaw crusher will produce a minus 20cm (8 in) material at an average rate of 191 tonne/h (211 st/h). The jaw crusher has almost twice the throughput capacity required, but the decision to install that size of crusher was based on the need to handle over sized rock in the ore.The coarse crushed ore will discharge into a 180 tonne (200 st) skip pocket, which will allow up to a one hour surge capacity prior to hoisting. Hoisted ore will discharge into a 900 tonne (1000 st) storage bin located adjacent to the headframe. The skip pocket and coarse ore silo comprise the total ore storage capacity. The concept of having no intermediate fine ore storage between the secondary crushing and grinding sections was borrowed from the Brushy Creek Mill of St. Joe Minerals, which operates adjacent to the West Fork property. Integration of the secondary crushing and grinding circuits has worked ' successfully for years at the Brushy Creek Mill. The most obvious advantage to eliminating the intermediate fine ore storage is'capital expen- diture savings. The capital expenditure savings include the cost of silos, feeders, and the cost of additional conveyor length and eleva- tion. Savings in operating costs will also be gained, particularly in reduced maintenance costs. Other factors which influenced the decision to eliminate fine ore storage were the simplicity of the secondary crushing sec- tion and the limited area available for con struction of the facility

Jan 1, 1978

By Darby H. P, Vincent R. J

Sydney's Eastern Suburbs Railway from Central to Bondi Junction required the construc- tion of 10.4 km of single-track tunnel and five underground stations. Much of this work took place beneath the commercial centre of Australia's largest city. This paper discusses the general precautions taken and the specific design solutions made for such problems as support of a 15-storey building with foundations several metres above the excavation to ensure negligible differential settlement, excavation immediately below running tunnels, underpinning of multi-storey buildings, tunnelling under massive masonry retaining walls and demolition and rebuilding of part-completed structures.

Jan 1, 1981

A standard practice of auditing mill designs has developed in the mining industry. The purported aim of this task is to ensure that the mill being offered conforms to the design specification, thus reducing the purchaserÆs risk. However, careful examination of the auditing methods used in the past shows that this is not the case. In some cases, what auditors have been providing is effectively a quality assurance check of the input data, not a full independent audit of the vendorÆs design. It will be shown that these past auditing methods have contributed to the stagnation of mill specification development. This lack of specification improvement combined with the current trend towards increased allowable fatigue stress ranges can result in an increase in risk for the purchaser.

Jan 1, 2002

By Bhattacharyya A. K

A major constraint on sustaining high rates of production in the collieries of the Southern Coalfield of New South Wales is the inability to develop panels fast enough to match the rates of extraction. This inability is particularly crippling in the case of retreat longwall mining and is due to nearly half the time in roadway drivage being spent on strata control operations such as roof support.Increased rates of roadway drivage and significantly improved roadway stability can be achieved by the application of yield pillars between parallel roadways. These pillars are designed to yield immediately upon formation and transfer the damaging roof loads away from the immediate vicinity of the roadways. Since the width of the yield pillar is the key to their successful application, it was determined through the Yield Pillar Experiment conducted by Kembla Coal and Coke Pty Ltd at West Cliff Colliery.Three experimental headings, each nominally 5.5 m wide and 2.8 m high, were driven to form two tapering pillars. The width of these pillars progressively decreased from 24 m to 3 m over a length of 154 m. The convergence between the roof and floor of the headings measured at various cross-sections corresponding to predetermined widths of the pillars are analysed in this paper to evaluate the stability of the tapering pillars at the different widths.The width of the yield pillar in a three heading development layout at West Cliff Colliery was determined to be 7.5 m.

Jan 1, 1995

By Bhattacharyya AK

With increasing demand for more efficient production from the underground coal mines in the Southern Coalfields- of New South Wales, their design and operational aspects are constantly being reviewed and improved. One key area in such pursuits is the reliable design of stable and yielding pillars. The current designs of pillars based mostly on experience leads to unnecessary sterilisation of coal or strata control problems. To explore such mine design problems, computer based modelling is increasingly being applied. In the study described in this paper, the object was to determine the particular width of pillars separating three roadways in a panel at which the pillars yielded completely and their loads largely transferred to the unmined coal at the flanks of the panel. This was approached through a computer simulation of the behaviour of the strata around a panel, in which the three roadways were separated by pillars of progressively decreasing width. A computer program called FLAC based on the finite difference method was used to simulate the relevant strata behaviour in vertical sections. The appropriate in situ values of the deformability parameters relating to the coal seam, roof and floor were determined from the back analysis of some displacement measurements in such a panel. The process involved successive modelling of a vertical section through such a panel,starting with realistic values of the parameters and varying them until the measured and the modelled displacements agreed closely. Based on the results of the numerical modelling, the width of a yielding pillar for the given conditions is Suggested.

Jan 1, 1992

The central thickened discharge system of tailings disposal takes advantage of the natural beach slope formed by sub-aerially discharged tailings, and the non-segregating properties of thickened tailings, to create a homogeneous conical stack. The need for containing embankments can be largely avoided leading to capital and operating cost savings. Methods for estimating beach slopes and tailings density, essential parameters for the design of such a system, are described. Case histories from three mining operations are used to illustrate the application of the technique, There are also seen to be potential advantages in the areas of water management, seepage, and rehabilitation. Laboratory and in-situ testing enable parameters to be determined.

Jan 1, 1991

By P Andersson, P Marklund

Evaluation of different techniques for bottom fill stabilisation showed that frozen fill was the most economical method. In order to test the method a full-scale field test was performed in the Rehnstr÷m mine. The test was instrumented with temperature gauges and extensometers. Before the field test, frozen fill was tested at the laboratory. The mechanical properties of the frozen fill were determined by uniaxial compression and creep tests. A deformation model for the frozen fill was set up. Calculation procedure for design of spacing between the freezing tubes, time for freezing and calculation of the necessary capacity of the refrigeration plant was developed. These procedures were calibrated against the field test. The results of these investigations allow the following conclusions: From a mechanical point of view, frozen fill has excellent properties as a structural member and it also has excellent properties to support itself and the fill above. Methods for the thermal and mechanical design of freeze stabilisation have been developed and found adequate. The need to place the freezing tubes several years in advance of the future sill pillar mining, requires careful long-term planning and accurate documentation.

Jan 1, 1998

The Mt Leyshon Gold Mine is located 30 kilometres south of Charters Towers in Northern Queensland. The current open cut mine has been in operation since 1986. In 1992 a feasibility study was completed that recommended an increase in production to over 240 000 ounces of gold per year. This proposal required an upgrade of the processing plant to five million tonnes per year, and an enlarged mining fleet to provide additional ore, and to meet the increased waste removal requirements. The implementation of the mine expansion program during 1993 required the Life of Mine plan to be extensively revised. This required the assessment and management of potential risks associated with the mine design. The updated geological model using the 1992 drilling results along with the actual contract mining and processing costs were used to establish a series of nested optimised pit shells. The total and incremental quantities and costs were then analysed to determine a suitable pit perimeter. The pit and phase plans were then created and used to devise a staged development plan. The block layout plans for each bench were then established from which a detailed life of mine production schedule was created.

Jan 1, 1994

By Hawes GW

Until 1980 copper, lead and zinc sulphide slurries have been success- fully dewatered for rail and sea transport for many years at the Rose- bery site of North Broken Hill Holdings Ltd. utilizing conventional vacuum disc filtration systems. An upgrading and mill expansion program completed in 1981, which also permitted the introduction of ore streams changes, had resulted in difficulties dewatering copper and lead sulphide slurries to comply with transportable moisture limits. Following an extensive investigation which included both laboratory and pilot plant testing a program was commenced to replace the 2 vacuum disc filtration systems with 2 pressure filtration systems for use on copper and lead slurry dewatering and also to retain other existing vacuum disc filters as standby. An analysis of mill operations performance resulted in slurry storage tanks with a capacity equivalent to 20 hours of normal production being incorporated into the project. The pressure filters are mounted above the concentrate stock- piles. A sealed sloping floor incorporating launders is used to prevent any accidental contamination of the concentrate from pipe leakages, spillage, or from water hoses used for clean up purposes around the area. The project was completed in 1985 and operating performance has been better than that predicted from testwork. Equipment availability at 95076 together with the slurry storage capacity provided results in minimal requirement for the standby vacuum filtration system. Some typical operating results are given.

Jan 1, 1988

By J Hudson

Autogenous (AG) and Semi Autogenous (SAG) grinding mills are the conventional selection for large-scale grinding circuits. It is accepted that these forms of comminution are not the most energy efficient available. This efficiency combined with escalating energy prices, steel prices and the requirement to process larger, lower grade deposits has necessitated that better comminution techniques are found to challenge the dominant position of AG/SAG mills in the grinding circuit. Recent advances in high pressure grinding rolls (HPGR), particularly in terms of roll surface protection have meant that, depending on the application, an economic alternative is available to the large diameter AG/SAG mills. Mining companies now recognise the potential benefits of HPGR and so they need proper assessment in the design of new or upgrade of existing grinding processes. Of course, the answer to the question AG/SAG or HPGR is not straightforward and the impact of the grinding process on the whole metallurgical process needs to be evaluated. Clearly this is a complex decision to make and requires substantial metallurgical knowledge, test work, and objective analysis. The perceived downstream processing benefits will differ between different plants depending on the ore type and processing conditions. The optimal design of the comminution circuit requires that a robust methodology is followed to objectively characterise the ore, size the equipment and determine the downstream processing benefits. The paper gives a brief comparison of the capital and operating costs for both grinding systems, and then outlines the appropriate test work that is required to make an informed decision.

Jan 1, 2006

By A Kemp, I Taylor, S C. Lamoureux

Detailed landform designs were completed for six (integrated) iron ore waste rock dumps at a Western Australian iron ore mine site to meet closure objectives and to optimise material movements for closure. The designs were based on specific physical and geochemical properties of waste material and the design was undertaken to enhance long-term stability of the dumps and optimise material movements, and therefore minimise closure cost. Construction of the re-shaped waste rock dumps have been completed. Following construction, surface material characteristics were found to deviate from those used in the design assessment. Materials present at surface following re-shaping were generally finer textured than those sampled for modelling. It is anticipated that the embankment slopes may experience increased rates of surface erosion compared to the rates predicted from modelling and used in design. The finer textured material is thought to be generated from exposing finer material that has migrated into the coarser matrix over time or that was not present in the sampled top surface of the landforms. This is due to armouring processes over time and this phenomenon is likely to recur following further wet seasons. The majority of the waste materials present in the waste rock dumps were subgrade banded iron formations (BIF) and chert, which are generally competent and geochemically inert. Some waste material was known to have an elevated risk of erosion but present in relatively small quantities. The presence of a large number of dolerite dyke swarms indicates appreciable volumes of dolerite were produced as waste from the pits. This material has an elevated risk of being highly erodible/dispersive. Clays and shales are also likely to be present in the dumps and are considered to be less competent material (relative to the BIF/chert). This paper presents the process from upfront materials assessment through detailed design to construction of the rehabilitated waste rock dumps, and post-construction sampling and testing to validate model findings.CITATION:Kemp, A, Taylor, I and Lamoureux, S C, 2017. Design to closure – construction of detailed rehabilitation designed iron ore waste rock dumps based on upfront site specific assessment, in Proceedings Iron Ore 2017, pp 353–358 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 24, 2017