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By G Williams

Somewhat to the surprise of many heavy mineral sands (TiO2 and zircon) producers, there are important geological structures within their typical placers and aeolian sands deposits that affect plant metallurgical performance. After many years of operations, even experienced producers have encountered unexpected changes in production, product quality and recovery. After looking in all the obvious (but wrong) places, it is recognised that the mine has advanced into ore with different separation characteristics. Metallurgical process response can vary significantly between ore sourced from different geological domains. The mineral characteristics that are exploited for effective separation may be associated with differences in the depositional environment, or be post-depositional in origin. Surface coatings that interfere with electrostatic separation might be associated with paleo-water table movements. Major storm events in the deposition history can also leave distorted mineral assemblage through stranded formations or incisions in older deposits.Apart from the influence on capital and operating costs, geometallurgical variances add another dimension to orebody modelling. Each domain could have specific recovery, mineral assemblage and product quality values to be considered in the value model. Project success is often directly dependent on understanding the geometallurgy of the resource. Tailoring the exploration and early process flow sheet development programs to account for such variances should be standard practice. Such practices have had a chequered history in the mineral sands industry, with sophisticated processes having been developed, only to be shelved for ‘economic’ reasons, and then once again ‘discovered’ when problems re-emerge.It is clear that knowledge gained through a higher level understanding of the changing mineral separation characteristics and advance warning of mineral behavioural differences can mean the difference between lost recoveries and disappointed customers or well timed capital plans and maximised revenues.

Oct 5, 2011

By Y Gu, R Fandrich

Traditionally, characterisation of the mineralogy and textures of ore and rock samples were based on observations of hand specimens and thin sections using an optical microscope. The extent of the data collection was limited by the available tools and thus variations in mineralogy and texture were generally not described by quantitative data. These qualitative to semi-quantitative approaches, even though well established over the years, resulted in variable observations and data sets. The data were unlikely to be representative of a sample and limited statistical validity meant the results could not be reliably used in modern digital mining design and planning. With recently developed SEM based quantitative mineralogy tools and the corresponding methodologies, ore textures can be quantified and compared numerically. The numerical data can not only enhance the understanding of an orebody in geological terms, but can also be used in the creation of metallurgical models for mine and mineral processing design and simulation. These capabilities provide valuable inputs to risk assessment studies and the evaluation of mineral projects.

Jan 1, 2007

By R Urie

Dilution and loss of ore during the mining process invariably occur in all underground mining operations. This dilution and ore loss can have a significant effect on the performance and value generated from a mining operation. Further, excessive dilution or greater than anticipated ore loss during mining is often one of the key reasons for the underperformance of a mining project when compared to a feasibility study or annual budget. Mining professionals often go to great lengths preparing detailed mine plans, schedules and economic models only to then apply high-level estimates or rule of thumb values for dilution and mining recovery that can ultimately lead to inaccurate forecasts for the performance of a mine with the resultant loss of value due to the mining of uneconomic material or the loss of potentially valuable ore. This paper discusses processes and practices that can be practically used to manage dilution and mining recovery in an underground mining operation with a focus on understanding and then maximising value. The processes cover items such as the definition and measurement of dilution and mining recovery, techniques for the estimation of dilution and mining recovery, consideration of the economic implications, management of dilution and mining recovery through the stages of the planning cycle, and practices to reduce dilution and improve mining recovery. Common misconceptions and omissions are also discussed.

Mar 29, 2023

By N McKay, J Vann, W Ware, P Hodkiewicz, C Morley

"Geometallurgy is now recognised within the mining industry as an approach that can both maximise value and reduce the risks associated with resource development. The process of spatial ore variability testing for metallurgical response and the use of quick, inexpensive metallurgical proxies has been well developed in the past decade in industry and the literature, and via various collaborative research programs and laboratories. Technology continues to advance with new techniques such as hand-held analytical tools and automated hyperspectral core scanning, allowing for even faster, less expensive in situ geometallurgical testing.In the current mining industry downturn, a critical frontier of geometallurgy is in its application in short-term geological modelling (ore control) and mine planning, and the associated decision-making. This is the end game at which the hard-won knowledge of orebody variability can be exploited to add near-term value. In order for spatial block models to be fit-for-purpose for such tactical uses, they must be populated with key geometallurgical information and then have workflows that use this richer model as a basis of material allocation to destinations so that the true value of the resource is realised.We envision geometallurgy (geomet) programs designed to add and sustain value at two levels:‘Strategic geomet’ has a long-term strategic focus that actively uses all relevant data that helps predict processing performance such as bench-scale metallurgical tests, mineralogy, geochemistry, ore texture etc (‘the geometallurgical database’) to model spatial ore variability and metallurgical response throughout the life-of-mine (LOM). This will enable better resource definition, more optimal mine planning and scheduling, improved process design and sustaining capital strategy over the LOM. The value-realisation is gained by basing all these strategic decisions on spatial models that better reflect the actual value of blocks (or aggregates of blocks) in the model.‘Tactical geomet’ has a short- to medium-term tactical focus that, again, actively uses the geometallurgical database, but also includes new data derived during ore control activities (such as drilling and sampling) to inform allocation-to-destination decisions via the ore control process. This will enable improved efficiency (ie less error) in allocation of mining blocks as direct feed, stockpile or waste. Importantly, this efficiency will be measured in terms of value and not grade, which is an incomplete – and typically biased – proxy for value. The key benefit is that ore control will then be planned and executed on the basis of realised value.We therefore propose a twofold systematic and holistic, value-based geometallurgical process. This process needs to be planned and implemented in an integrated manner, noting that strategic and tactical geometallurgy can be worked on by the same professionals, sharing data, methodologies and potentially models. What differs between the two levels is the required granularity, the business context and (critically) the decision-making time horizons.CITATION:McKay, N, Vann, J, Ware, W, Morley, C, Hodkiewicz, P, 2016. Strategic and Tactical Geometallurgy – a Systematic Process to Add and Sustain Resource Value, in Proceedings The Third AusIMM International Geometallurgy Conference (GeoMet) 2016, pp 29–36 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Jun 15, 2016

By X Li, M-F Zhou

"An EXTENDED ABSTRACT is available for download. A full-length paper was not prepared for this presentation. The Yinachang deposit in south-west China contains large amounts of Fe, Cu and rare earth elements (REEs). Apatite in this deposit records complex REE mineralisation and remobilisation processes.Fe-Cu-(REE) mineralisation at Yinachang occurred at ~1700 Ma, and three stages of alteration and mineralisation are identified: Na-(Fe) alteration, Fe-(REE) mineralisation and Cu-(REE) mineralisation. In the Fe-(REE) mineralisation stage, REE-rich apatite formed together with magnetite. In the Cu-(REE) mineralisation stage, fluids undersaturated with REEs interacted with early-formed REE-rich apatite, during which large proportions of REEs, especially light REEs (LREEs), were leached from apatite.At ~840 Ma, apatite experienced a second interaction with fluid. In that process, REEs were removed from the apatite structure but immediately reprecipitated into new phases within the apatite. Thus, numerous REE mineral inclusions including bastnaesite, monazite and minor Y-phosphate occur in the apatite. There are also a very small portion of LREEs that were transported out of the apatite, resulting in the growth of bastnaesite and monazite grains outside the apatite.This study demonstrates that REEs can be mobilised in multistage hydrothermal activities and highlights the significance of fluid compositions for REE transportation and deposition behaviours in hydrothermal systems.CITATION:Li, X and Zhou, M-F, 2015. Hydrothermal rare earth element mobilisation processes in the Yinachang Fe-Cu-(REE) deposit, south-west China, in Proceedings PACRIM 2015 Congress, pp 265–270 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Mar 18, 2015

By T Hayward, G Lane, M Phillips

In December 2004 Phu Bia Mining Ltd commissioned Ausenco International Limited to conduct a feasibility study for its Phu Kham copper-gold project located in Laos. The feasibility study for a mining and processing operation treating 12 Mtpa of ore averaging 0.56 per cent copper and 0.25 g/t gold to produce an anticipated annual average 200 000 t of concentrate containing 25 per cent copper was completed in early 2006. The plant design incorporates a single processing line and includes a gyratory crusher, overland conveyor, coarse ore stockpile, SAG and ball mill grinding circuit, flotation circuit including regrind and three stages of cleaning, concentrate dewatering and concentrate load-out facilities. The Phu Kham copper-gold mineralisation comprises two principal styles: stockwork-disseminated and banded-massive sulfide within skarn limits. Primary copper in both mineralisation styles occurs as chalcopyrite and secondary copper sulfide minerals. Skarn includes the copper and gold mineralisation contained in pyrite, silicate, magnetite and haematite skarns, and in quartz-pyrite altered sediments. Both the stockwork-disseminated and banded-massive sulfide ores contain relatively high proportions of pyrite relative to the copper and gold mineralisation. Thus, the flotation metallurgy of the Phu Kham orebody is characterised by the need to reject a high proportion of the pyrite during differential flotation to yield a concentrate grade of approximately 25 per cent copper. The rejection of pyrite is accompanied by the rejection of some copper and gold and can result in modest metallurgical recovery. Consequently, the greater the pyrite content, the lower the expected copper and gold recoveries. The relative pyrite content is expressed on the basis of sulfur:copper ratio. For Phu Kham ores, the sulfur:copper ratios are in the range eight to 14 on a blended annual basis, but can be greater than 20 in the skarn components. Higher grades of copper and gold are also present in the skarn mineralisation. The design concepts for the concentrator were influenced by the need to provide a low capital cost approach for the project due to the relatively low grade of the ore and the modest metallurgical recovery. The concepts used to minimise capital cost whilst retaining operating and maintenance flexibility are discussed, together with the metallurgical challenges imposed by the high pyrite mineralisation.

Jan 1, 2007

By D Gerrard, J Begelhole, J Gerber

The Iron Magnet deposit has been mined since 2007 when Arrium (then OneSteel) commissioned the magnetite concentrator to supply feed to the pelletising plant in Whyalla. The concentrate quality requirement for the customer required consistent product with minimal variability. In the early stages of operation, it was identified that the feed variability introduced significant changes in the concentrate quality, which was outside the acceptable customer limits.In 2011, a geometallurgical regression model was developed that allowed for the estimation of concentrate quality produced from the feed material. This was based on a laboratory-scale Davis Tube Recovery (DTR) test performed on the feed material. The objective of the project was to characterise the raw ore in the pit to allow for blending prior to crushing. By blending the feed to the concentrator, minimal concentrate quality variation within the plant was achieved. The orebody was divided into geometallurgical classes, called ore types, based on the mineral texture and magnetic mass recovery. Each geometallurgical class consisted of material with similar metallurgical performances. For each individual blast pattern, the ore was grouped into the geometallurgical classes and a composite sample was created. The composite sample was put through the laboratory-scale DTR test and the results were used to estimate the metallurgical performance of the material.The characterisation process and feed pile build methodology was applied in early 2013 and went through an optimisation and streamlining phase. Since the implementation of the geometallurgical characterisation process, the plant has seen a significant reduction in concentrate variability and measurable throughput gains. The characterisation process has also increased the amount of material that is now classified as ore.CITATION:Gerber, J, Gerrard, D and Begelhole, J, 2015. Geometallurgy of the South Middleback Ranges magnetite deposit – predicting plant performance from the pit, in Proceedings Iron Ore 2015, pp 555–560 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

By A Krishnan, C Garcia, I Luna-Berbesi

The discovery and exploration of deposits are progressively shifting to extremely remote regions and greater depths. As a result, exploration costs and the economic risk of a bad investment increase. Current megatrends in the exploration and mining sector indicate a growing demand for the implementation of automation, digitalisation, and machine learning techniques. The implementation of a multi-sensor-based core logging device (DMT, 2024) was done on 400 m of drill cores to optimise interdisciplinary processes in terms of time and quality, by using interlinked and consistent data in real-time, to obtain reliable predictions that support and speed up decision-making. The results are consistent with the laboratory data previously obtained by the mining company, highlighting the benefits of introducing ANCORELOG into their core logging procedures.

Sep 1, 2024

By S Mitchell

Jetcrete Australia Pty Ltd, shotcrete contractor took the initiative in 2008 to discontinue the use of ‘road registerable’ concrete trucks for all underground works in Australia and internationally.The rationale for this decision was basic, safety. Historically these vehicles have been and still are involved in far too many accidents; this obvious trend needs to be addressed by engineering out the root cause of the problem which in this case is suitability for purpose.Road registerable concrete trucks have been widely used for the delivery of concrete in Australian mines for many years prior to and after the inception of wet shotcrete as ‘in cycle’ ground support in underground excavations around 1992. With this inception came a wide interest in the shotcrete process and an influx of new shotcrete contractors, all using road registerable concrete trucks to deliver the large volumes of Shotcrete required for these services and in turn largely increasing the use of these vehicles underground. The road registerable concrete trucks were difficult to control and each trip underground required the operators to maintain good management of the inherent risks. We virtually had no reasonable alternative for the industry and could only encourage the operators to drive with soft controls such as, reducing overall speed to a maximum of 15 km per hour when declining, regardless of the road conditions, coming to a complete halt prior to turning into any sharp corners, remaining in the same gear both inclining and declining.

Mar 21, 2011

By A Fyans, B Ghahreman-Nejad

This paper discusses the method and results of an options study into selection of the optimal form for a 130 m high tailings/water retaining dam, located in a region of high seismicity in central Iran. The proposed dam is part of a planned expansion project for Sarcheshmeh Copper Mine (SCM), which after construction will provide 550 million tonnes of additional tailings storage over the next 27 years. Geotechnical investigation at the proposed site indicated that adequate suitable low permeability materials (i.e. clay) were not available in the immediate vicinity of the dam site and would need to be imported from a distance of well over 10 km (direct). Given the magnitude of the estimated quantity of material and construction cost it was considered prudent to compare the cost of alternative dam design options for the proposed storage. A total of five dam design options are considered including a conventional rockfill embankment dam with an upstream sloping earth core (ECRD), a geomembrane face rockfill embankment dam (GFRD), a sloping asphalt core rockfill embankment dam (ACRD), a roller compacted concrete dam (RCCD), and a filter rockfill embankment dam for tailings storage together with a separate smaller earthfill core rockfill dam (ECRD) located downstream for storage of decant water. The risks, costing and design of all options are discussed in detail and the outcome of the study is presented.CITATION:Ghahreman-Nejad, B and Fyans, A, 2018. Optimum embankment design for a tailings dam, in Proceedings Mine Waste and Tailings Stewardship Conference 2018, pp 427–438 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 23, 2018

By A Murphy, I Samsonova, N Eastwood, D Whittle

Part XI of the United Nations Convention on the Law of the Sea (UNCLOS or the Convention) (United Nations (UN) Division for Ocean Affairs and the Law of the Sea, 1982) establishes a comprehensive regulatory framework for the conduct of deep seabed mining (DSM) activities of mineral resources in the Area (defined in Article 1(1) of UNCLOS as ‘the seabed and ocean floor and subsoil thereof, beyond the limits of national jurisdiction’). Under that framework, DSM activities can only take place in the Area pursuant to an approved Plan of Work in the form of a contract with the International Seabed Authority (ISA) (the Authority), a 168-member international body created under UNCLOS to administer the Area. Private contractors can undertake DSM activities if they are sponsored by Member States of UNCLOS, providing a dual system of international and domestic regulatory control and oversight for activities in the Area.

Sep 1, 2024

By R P. Varden

This paper looks at the design of the Bentayga raisebore with subsequent back analysis using a LiDAR survey. A search for LiDAR raisebore assessment publications shows little work has been done on this subject. The paper examines the empirical design and RS2 modelling assessment with the bored condition. The high resolution of the LiDAR enabled mapping of weak structures that were located on the geotechnical investigation hole the orientations of which could not be determined. In addition, the scan showed were water ingress was occurring, potential stress overbreak and structural controls on stability. The LiDAR results were able to confirm no additional support work such as a shotcrete liner is necessary. The LiDAR results have been analysed in one metre increments as volume of overbreak against the empirical stability criteria (McCracken & Stacey 1989). The future use of LiDAR mapping over a range of rock mass conditions will provide quantification of the established empirical assessment improving its reliability. It is also a useful and accurate tool to monitor long term stability of a raisebore due to stress change or ore pass due to wear.

Mar 15, 2021

By H Utama, R Heryadi

PT Indo Muro Kencana (PT IMK) is a surface gold and silver mine located in Mt. Muro area, Central Kalimantan province, Indonesia. The mining operations of multiple open pits using combination of excavator and haul truck is operated. This operation is performed in two shifts in a day. The articulated dump truck (ADT) with capacity of 40 t and 60 t deliver ore to the mineral processing plant and discard waste material to the waste dump area. Overall, PT IMK’s mining operation department is consisting of two sections, namely mining operation section and drill and blast section. Firstly, mine operation section is responsible to manage loading, hauling, pit service (mine dewatering, earthwork, road maintenance) and mine operation engineering. Secondly, drill and blast section is in charge to manage drilling and blasting (blast engineering, blasting operation, explosive permit and magazine or explosive storage). Additionally, conventional blasting method (ore-waste blasting) with non-electric initiation system is used and sleep blasting is undertaken as bulk explosive is buried for maximum two days. The first purpose of this paper is to elucidate about role of mining engineer in mining operation department (mining operation engineer and D&B engineer). At this point, mining operation engineering practice (fleet management system, production control and mining manpower management) and also blasting daily practice will be elucidated. Daily blasting practice is consisting of surface blast design, explosive engineering, sleep blast practice and the concept of scaled depth of burial to ensure a safe work environment in blasting activity. Next, the second purpose of this paper is to explore workforce evolution and future skills for mining engineer in surface mining operation. Furthermore, strategy to advance future skills such as mining continuous improvement program, training and skills development for mining engineer (mining operation engineer and D&B engineer) in order to develop their skills is also discussed. It is expected that in the future, these future mining leaders will become new mining leader, for instance mining superintendents, D&B superintendents and mining managers. In conclusion, it is clear that awareness about workforce evolution, professional development, training, skills development, mining economics awareness and mining continuous improvement program are essentially required as professional development for mining engineer (mining operation engineer and D&B engineer), in order to be commercially competitive in their future career and in order to be adapted with future workforce evolution in mining.

Sep 1, 2024

By J Ross

The foundation of effective leadership is communication. You can have all the leadership theories, models and training you want, but in the end it is all about leaders talking to, listening to and understanding the point of view of those below and above them.The foundation of effective safety is peoples’ behaviours. Every incident, every near miss and every safe act comes down to what one person does and how that affects themselves and others. We tend to focus these behavioural considerations on the people at the ‘coal face’, those most in harm’s way. But it is the individual behaviours of everyone in the organisation, particularly those at the top, which are just as (if not more) important. The foundation of effective safety leadership in the mining industry is that it starts at the top, with the individual behaviours of leaders. The behaviours of each and every leader will be reflected in their teams. And where their teams are made up of leaders, these leaders will pass these behaviours on to their teams and so on. It’s the sum total of what people see their leaders do and what they do as a result, that creates the ‘culture’ of the business – and it’s this culture that makes or breaks how safely people work.

Mar 21, 2011

By S Khosrowshahi, A Weeks, W J. Shaw

"To provide an indication of expected performance of the mine and mill, feasibility studies should include an assessment of the expected day-to-day variability in process plant feed. Attempts to do this based on conventional resource models will be flawed as such studies fail to consider and account for the in-built smoothing (averaging) of input data.This can lead to one of two situations: an expensive, over-engineered process plant that can cope with every possible situation, or operational strategies that fail to manage the natural variability within the orebody and the impact of day-to-day operational decision-making.In both cases the value of the project diminishes through excessive capital costs or reduced throughput or recovery during operations.Unlike conventional estimation techniques, the geostatistical method of conditional simulation can reproduce the inherent variability of the deposit. Once a valid model has been developed, it is possible to analyse the model using a transfer function that simulates the proposed mining processes and provides a representation of the likely variation of mill feed characteristics at any time scale.The case study demonstrates how the proposed mining strategy would result in mill feed being considerably more variable than expected, resulting in poor recovery, low throughput and potential breaches of environmental conditions. Mitigation measures included budgeting for additional mining equipment to enable greater flexibility during mining and revised stockpiling and crusher feed strategies.Awareness of the benefits of modelling the variability of geometallurgical parameters will increase the use of this approach in producing more realistic financial models of expected mine performance at the design stage.CITATION:Shaw, W J, Khosrowshahi, S and Weeks, A, 2013. Modelling geometallurgical variability - a case study in managing risk, in Proceedings The Second AusIMM International Geometallurgy Conference (GeoMet) 2013, pp 247-252 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Sep 29, 2013

Since early-2001, Kalgoorlie Consolidated Gold Mines (KCGM) has successfully operated an ultra fine grinding (UFG) circuit to supplement its roaster capacity for the treatment of the refractory gold flotation concentrate. A second UFG mill was installed in 2002 taking the total UFG capacity to over 20 tph while grinding to 11 to 12 microns and achieving over 90 per cent gold recovery. A development program in 2002/3 involving plant trials, pilot plants and laboratory testwork resulted in process improvements and a better understanding of the milling and gold leach processes that assisted in narrowing the gap between UFG and roasting. This paper details the operation of the ultra fine grinding process at KCGM as a non oxidative treatment for the extraction of gold from a refractory ores.

Jan 1, 2003

By T Takayama, R Muroi, M Matsumura

The steel industry occupies 14 per cent of CO2 emissions in Japan, and the sintering process is one of the major emitters. Since most of CO2 released from the sintering process comes from coke fine combustion, replacement of coke fines with biomass char as bonding agent is a potential countermeasure. In order to explore the effective use of biomass char, we chose char made from Palm Kernel Shell (PKS) as a sample. First, the char’s combustion behaviour was examined with varying the char’s particle size by means of admixing the char in alumina ball packed bed placed in an electric furnace. As a result, the finer the PKS char the faster the burning rate and reaching a higher temperature compared to coke fine. In addition, it is also concluded that the optimum size of PKS char was larger than coke fines. Next, the effect of different heat profiles on sinter structure was examined by sintering tablet made of chemical reagents. In this experiment, the chemical composition is designed based on sinter composition. By this sintering test, even at high temperature, rapid cooling is effective to make fine sinter matrix and fine pores, which has possibility for high sinter reducibility. Based on these two experiments, using PKS char as a sinter fine source has the possibility to improve sinter reducibility.

Nov 8, 2021

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 R Moreby

This paper is a demonstration of the techniques developed during an Australian Coal Association Research Program (ACARP) funded research project aimed to develop aids, principally computer based, to assist mine personnel to more efficiently manage significant incidents in coal mines. These aids include software to aid in the location of the incident, electronic information storage and retrieval, online site emergency response manuals and software to aid in decision-making.

Jan 1, 2005

Safety remains a critical priority for the Australian mineral resource industry and will receive increased focus in the future. This is particularly evident in underground coal mines where reserves are becoming deeper and more hazardous to extract. The CSIRO, through its Exploration and Mining Division, have recently delivered on two projects aimed at providing step-change capabilities in real-time risk management and hazard control. This paper describes the key outcomes of these projects.

Jan 1, 2005