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By N Clarke, J Hunt, A Barros, N Guerrero, L Keeney

Grade Engineering® (GE) involves a range of integrated technologies and operating protocols for improving effective feed grade through early rejection of low value material prior to costly processing activities and has the potential to transform the economics of large, low grade, mining operations. Extensive GE test work by AngloGold Ashanti (AGA) and the Cooperative Resource Centre for Optimising Resource Extraction (CRCORE) determined that the Gramalote gold deposit in Colombia is highly amenable to implementation of grade-by-size screening to upgrade the ore at a production scale. To understand the relationships between geology and the upgrade response drill core and bulk samples were analysed at the Centre for Ore Deposit and Earth Sciences (CODES) as part of a larger CRCORE project to understand geological controls on grade-by-size deportment, i.e., the tendency for specific mineral phases to preferentially fractionate during breakage into different size fractions. This work is focussed on understanding the role of mineralogy and texture in influencing rock breakage and natural fractionation at a range of scales. Detailed logging of Gramalote drill core and mineralogical analyses including hyperspectral logging, portable and bench-scale X-ray fluorescence (XRF), plus low resolution Laser Ablation of intact drill core pieces, combined with data from site (drill logs, geochemistry, petrophysics) were used to evaluate the ore and alteration mineralogy, vein paragenesis and textural variability. This provided information on gold deportment and allowed the identification of favourable host veins. Bulk sample material from different ore grade zones was also analysed. A comparison with the results of GE testing shows that positive upgrade results are produced by rocks with abundant veins, particularly those associated with potassic and/or white mica alteration. This work indicates upgrade response can be predicted from drill core using data collected by a combination of automated systems including hyperspectral data, XRF, and detailed drill core logging.

Nov 10, 2020

Professional engineers of today require a wide array of experience and knowledge. It is true that commonly engineering degrees do teach the technical requirements well, but do fall short in the way of teaching other non-technical issues of professionalism to the student. Today calls for an engineer who does not only have a high standard of the technical knowledge required for their degree, but also has a broad range of experience in areas that are becoming increasingly important in engineering. The importance of social responsibility, liability and interpersonal relations is high. Through the face of the changing world, it has become clear that there is a need for a new type of engineer, who has a broad range of expertise, as well as the typical technical abilities required. This paper will outline these non-technical issues and propose ways of combining these ideas into the mainstream engineering degree.

Jan 1, 2004

Dust emissions from mining, material processing and ship loading operations (fugitive dust sources) are an environmental issue of increasing concern to both government regulators and the community. The main concerns relate to potential amenity, health and environmental impacts from the emissions. Therefore it is imperative that mining/ processing operations, as part of their overall environmental management, reduce fugitive particulate emissions to as low a level as is practicably possible. This technical paper outlines the mechanisms that lead to fugitive particulate emissions, the importance of understanding the exact cause of fugitive emissions, monitoring methods that can be used to quantify the emissions from specific sources, the use of atmospheric dispersion modelling in dust management and innovative dust management strategies including predictive meteorology and proactive management.

Jan 1, 2009

By D Readett

The most critical variable in the successful establishment of the Murrin Murrin Heap Leach plant was the effective agglomeration of the Ni laterite ore. This paper describes the test work undertaken to establish the key agglomeration parameters including state of the art testing and analysis procedures. These parameters were then utilised to establish the key design and operational concepts for the world’s first commercial scale Ni laterite heap leach. Following the technical and economic success of the operation, the actual operational data is compared back to the original test work data.

Aug 8, 2011

By B P. Banerjee, S Raval

In the recent past there have been dramatic advancements in the development of remote sensing platforms (satellite, aircraft and unmanned aerial vehicles – UAVs) as well as sensor systems (multispectral, hyperspectral, thermal, light detection and ranging (LiDAR) and radar). However, selection of the appropriate remote sensing technique for a mining application is complex and requires scrutiny on multiple scales including spatial, temporal and imaging capabilities. This presentation highlights various conventional and emerging remote sensing approaches over a mine’s life.CITATION:Banerjee, B P and Raval, S, 2016. Applications of advanced remote sensing systems during a mine life, in Proceedings Life-of-Mine 2016 Conference , pp 116–120 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jun 28, 2016

By J Bolen, I Cameron, M Huerta, M Okrutny, K O’Leary

As greater amounts of fine iron ore concentrates enter the marketplace, new investments in iron ore pelletising capacity are inevitable to deliver these concentrates to steel industry consumers. When investors assess the two well-proven pelletising technologies, the straight grate and grate-kiln, the most appropriate choice may not be immediately evident. Certain technical, market and site-specific factors will favour one technology over the other; investors need to be aware and understand these factors in order to make the best investment decision. Hatch has compared the merits of both technologies regarding plant configuration; type of iron ore processed; energy consumption and flexibility to use a variety of fuels; ability to produce the required pellet quality; required plant capacity and scale; operating and capital costs and environmental performance. A technology assessment checklist that investors should consider when making a new pellet plant investment decision is presented.CITATION:Huerta, M, Bolen, J, Okrutny, M, Cameron, I and O’Leary, K, 2015. Guidelines for selecting pellet plant technology, in Proceedings Iron Ore 2015, pp 45–52 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

By M Graham, R Brunning, C Andringa-Bate, S Westergren

In 2010, Rio Tinto Iron Ore’s operations commenced the planning and design of a sampling and analysis system for the new 50 Mt/a Cape Lambert Port B (CLB) facility. Current sampling systems at the ports consist of automated robotic, mass-based sampling protocols employed at Dampier, and semi-automated, time-based sampling systems operating at Cape Lambert Port A.The new sampling system at CLB has brought together a fully automated sampling and analysis system utilising time-based sampling, with the capacity to sample ore products of medium quality variation as defined in ISO 3082 (ISO, 2009). The CLB system is required to sample at shiploading rates from 6000 t/h to 13 440 t/h and provide full load-port analysis. The sampling approach is to proportionally extend primary increments (of varying mass relative to shiploading rate) to a standard length using variable speed aero-belt conveyor systems. This enables a fixed number of secondary cuts to be achieved for all primary increment masses and to be delivered to the automated cell. The cell is required to be capable of concurrently processing four individual shipments, each containing multiple cargoes.Achieving the target sampling precision for all export cargo sizes has culminated in the planning, design and construction of the largest automated iron ore port laboratory in the world. The CLB sampling and analysis cell was commissioned in Q3 and Q4 2013. This paper discusses the sampling philosophy and commissioning outcomes.CITATION:Brunning, R, Andringa-Bate, C, Graham, M and Westergren, S, 2014. Cape Lambert Port B shiploading, sampling and analysis, in Proceedings Sampling 2014 , pp 79–90 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 29, 2014

By M J. Thurley, M Wimmer

To assess the present-day functionality of large-scale sublevel caving at LKAB Kiruna a comprehensive measurement program was undertaken involving blast function, fragmentation and gravity flow. As part of this assessment, a fragmentation measurement trial was performed based on 3D imaging of the drawpoint and corresponding bucket load of the underground load-haul-dump (LHD) excavator. 3D image data from stereo photogrammetry was collected and an automated image analysis strategy developed. A number of data sets were collected for each of the drawpoint and LHD bucket, along with sieving results for four of the LHD bucket loads (totally about 70 t). Two of the sieving results were used to inform the automated image analysis strategy, and two were held back as a comparison. Large variations in the visible particles are apparent when comparing corresponding drawpoints and LHD buckets highlighting the impact of sampling location and the need to measure large quantities of data in order to avoid bias from small samples. The results show that 3D imaging and analysis can produce fully automated measurement and analysis of the visible particle size distribution. Although this is not the same as the sieve-size distribution it provides useful estimation of both the larger size classes and a bulk estimate of fine material below approximately 60 mm. The 3D stereo photogrammetry measurement system used produced very high 3D point density but this was achieved using a custom up-sampling technique which significantly smoothed the data, removing small particles, smoothing edges, and this negatively affected the particle delineation algorithms.CITATION:Thurley, M J, Wimmer, M and Nordqvist, A, 2015. Blast fragmentation measurement based on three-dimensional imaging in sublevel caving drawpoints and underground excavator buckets at LKAB Kiruna, in Proceedings 11th International Symposium on Rock Fragmentation by Blasting, pp 763–774 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 24, 2015

By L Bertoss, D Carvalho

In the last decade, the use of advanced implicit modelling software/algorithms in mineral resource workflows has become a best practice in the mining industry. In most cases, these workflows can easily replicate the level of detail of explicitly modelled geometries, even for very complex deposits. These techniques are flexible and can produce fast results since software is responsible for generating 3D surfaces and solids based on geological and interpretation data. Nevertheless, depending on how unique and complex some deposits are, intense manual editing and input are required to honour the geological context and produce the desired outcome. The current geological modelling workflow at George Fisher Mine (GFM) is based on the semi-automatic built-in tool that generates stratigraphic sequences (stacked lithology layers) based on logging and mapping data. This tool (stratigraphic sequence from Leapfrog Geo™) works for the majority of areas in the mine but fails to capture observed mineralisation pinch-outs in operational areas and at extrapolated boundaries of the deposit. These pinch-outs have the potential to negatively impact grade forecasts if not resolved manually. Using built-in software tools only, the alternative for a more accurate model is to generate each individual layer and adding tens of thousands of manual interpretation points to honour pinch-outs (based on the amount of existing drilling in the mine and number of layers). This approach would require an estimated minimum of two to four years of a full-time employee (FTE) to be exhaustively completed. This study presents an automated approach to generate pinch-out points using a set of Python scripts that only take a few minutes to run. The newly generated points are then combined into the commercial software workflow as interpretation points, honouring observed pinch-outs. The remarkable time difference between approaches removes chance of manual errors and allows mine geologists to spend valuable time in validation and testing of scenarios, ensuring they are more representative of the deposit’s geology.

May 24, 2023

By R Bradford, W Gift-Agbey, T Vorster, P Morgan, E Grobler

The Asanko Gold Mine in Ghana started processing ore from the Nkran pit in January 2016 at a production nameplate of 3 Mt/a. The flowsheet is a conventional SAG, ball mill and pebble crusher (SABC) with gravity-gold and carbon-in-leach (CIL) recovery. The nameplate production was comfortably achieved within 3 months, so much so, that it was clear the SABC circuit was capable of processing more than the downstream section of the plant. Consequently, a program of de-bottlenecking was initiated to rectify volumetric capacity constraints. This program was later referred to as ‘Project 5 Million’ (t/a) or P5M. Having completed the de-bottlenecking exercise, it became evident that the SABC circuit could not reach 5 Mt/a solely on hard rock from Nkran. The new challenge was therefore to increase the capacity of the milling circuit through a focused comminution initiative that would address the following: geometallurgical treatment plan; upfront fragmentation requirements; installation of feed and mill monitoring equipment; and integration of a knowledge-based control strategy. This paper takes the reader through the various measures implemented to increase the milling rates and to create a stable/ sustainable control philosophy. As a result of the implementation of advanced mill performance monitoring technology (MillSlicer) and the collaboration between a team of experts in comminution, control and operations, the Asanko Gold Mine process plant feed tonnage has successfully increased from 3 Mt/a to 5 Mt/a.CITATION:Bradford, R, Gift-Agbey, W, Grobler, E, Morgan, P and Vorster, T, 2018. Optimisation of Asanko’s Obotan SABC circuit to achieve ‘Project 5 Million’, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 477–484 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

By S Grimsey, E Janetzki, J Emery

Floor failure on the longwall face is a complex problem due to the dynamic interaction between the surrounding strata and powered roof supports involving multiple variables. It can also be highly problematic and costly when not well understood as there are significantly less remedies available post event. This was the early experience at the case study mine where significant lost time was incurred due to unplanned delays in the first two panels. To detect and prevent such occurrences is clearly the best approach, hence a tool to predict both floor failure occurrence and magnitude prior to mining was developed. Several parameters were determined as the key drivers for the failure events that had been experienced at this site. These parameters were, in list of influence from highest to lowest, material strength, retreat rate and the presence of water. The parameters were evaluated using a semi quantitative risk rating system ‘Heave Risk’ and given a weighting per their apparent influence. This ‘expert system’ methodology was selected as the use of risk rating systems in underground coal mining is well established. The heave risk model was first applied to previously mined panels. It accurately identified all areas of known major floor heave, with clearly defined areas of low and high risk apparent. The heave risk model was then used prior to mining and evaluated post mining based on observed conditions. It was found to also be highly accurate for prediction. The variability of each parameter and its influence on the overall risk rating is illustrated and discussed.

Nov 29, 2022

By L Gobbo

X-ray diffraction (XRD) provides useful information about the composition of an ore sample in terms of quantification of crystalline phases and amorphous content. The use of new, fast detection systems implemented in CubiX FAST industrial diffractometers creates the opportunity to use this technique in exploration and modern process control. Besides the chemical composition of iron ores, their phase composition is also an important factor for exploration, quality control and processing. In the analysis of iron ore, XRD can identify the phases containing iron, such as haematite Fe2O3, magnetite Fe3O4, and goethite FeO(OH), and any other mineral phases present, especially silicas. Quantitative analysis is possible by various classical methods such as straight line or polynomial calibration with standards, but modern quantification analysis techniques such as Rietveld analysis or full pattern autoscale analysis are attractive alternatives, as they do not require any standards. These methods offer impressive accuracy and speed of analysis. Another analysis technique offering great benefit to ore exploration and process control is cluster analysis. This technique greatly simplifies the analysis of a large amount of data, eg from drill core samplings, and automatically sorts closely related scans of an experiment into separate clusters and marks the most representative scan of each cluster as well as outlying patterns. This can facilitate multi-dimensional compositional mapping of ore deposits, identifying regions of favourable mineral composition and allows fast and reliable tracking of the process. It is the most economic procedure to have automatic data evaluation without involving any dedicated personnel in the process. Details of the techniques used, sample optimisation methodologies, results, data precision and limitations will be discussed. The approaches have enormous potential as an inexpensive, reliable tool, useful in the characterisation of iron ore materials in an industrial environment.

Jan 1, 2009

By Ward M

The current and future requirements for an underground mine information management system are being met with a flexible, value-engineered approach to mine information/communication infrastructures. El-Equip has developed and delivered to over fifty mines around the world an integrated, high capacity, radio-based leaky feeder communication system called MultiCOM. To meet the requirements of recently developed advanced information management technologies, such as production and ventilation management, the system has evolved to support simultaneous mobile and fixed information delivery services over an integrated single cable system. The following paper will review how MultiCOM is enabling information/communications technology to cost-effectively implement mine monitoring and control applications. Applications described in this paper include mobile vehicle production tracking, vehicle location, ventilation system monitoring and control with integrated ventilation system simulation. The techniques described are leading the world in terms of flexible and value-engineered applications of technology in the underground mine.

Jan 1, 1995

By X T. Nguyen

Western AustraliaÆs Mining Act 1978 was amended in 2010 to provide for the requirement of a mine closure plan to be submitted to the Department of Mines and Petroleum (DMP) for approval, as part of a mining proposal application. The mine closure plan must be prepared in accordance with approved guidelines. Guidelines for mine closure plans were developed to assist the mining industry in Western Australia to plan and implement effective closure of mines. The guidelines focus on the application of integrated mine closure principles and industry best practice information on mine closure. This, includes stakeholder consultation, risk based approach, data collection and monitoring, development of completion criteria and financial provision.Due to the potential high level of public interest in the guidelines, extensive consultation with stakeholders was conducted. The purpose of this paper is to share experiences from the consultation process.CITATION:Nguyen, X T, 2012. Mine closure guidelines for Western Australia and consultation process, in Proceedings Life-of-Mine 2012 , pp 43-46 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 10, 2012

By M M. Pande, M Ishfaq

The effect of aluminium on nitrogen solubility was investigated by equilibrating melt comprising master alloy of Fe-Al with pure electrolytic iron in a controlled atmosphere (pure argon) at 1873 K. Nitrogen in the samples was measured by sampling technique using inert gas fusion absorptiometry. It was found that nitrogen content decreases steadily with aluminium concentration and gradually, becomes close to 1 ppm for very high aluminium steels. Wagner’s second order interaction parameter formalism has been used to estimate the equilibrium constant and interaction parameters. Scanning electron microscopy (SEM) investigation showed, dual-phase inclusions comprising AlN phase surrounding alumina core. The 3D morphology of inclusions was studied by extracting the sample from the top and the central bottom portion of the solidified ingot. A sparse distribution of nitrogen was found for most of the inclusions which manifested the presence of almost pure alumina inclusions with different morphologies and sizes.

Jun 19, 2024

By C K. Boafo, J Visser

Obuasi Mine in Ghana, with more than 100 years of mining history, developed from a surface operation into a deep >2000 m underground gold mine. The challenge is to extract value from narrow veins left after extensive mining in the wider ore zones of the mine. Since the merger of AngloGold and Ashanti Goldfields in 2004 the mine strives to achieve optimum extraction through an integrated Mineral Resource management process from geological modelling, resource evaluation to mine design and scheduling. The shear hosted gold deposit displays complex secondary shears of variable thickness and continuity. There is an ongoing process of changes taking place in the way that geological modelling and resource estimation is done. Recent developments include the use of computerised systems that support the whole resource management chain from resource modelling to reserve optimisation. The change in thought and technology now allows for targeting narrow veins previously ignored in optimisation and mine design since moving into mechanised mining. The increased knowledge and confidence in the resource models now allows for flexibility in mine design, selection of mining method and scheduling and extraction of the reserves. The focus area for change is the way the orebody is evaluated and extraction designed. Since 2005 major changes were made to the process. This paper considers the historical approach of resource management. It looks at the individual process changes and qualifying the way ahead.

Jan 1, 2008

By T Y. Dube

In this paper current net present value (NPV) based mine valuation techniques that take into account market and private risk are discussed and analysed. Potential pitfalls that arise from the application of a portfolio, market or commodity based risk metric to a mining project are identified. An alternative non-simulative framework for quantifying and factoring market and private risk in NPV calculations is proposed and then applied to a hypothetical case study in an attempt to overcome identified pitfalls. Mathematical proof that a static discounted cash flow (DCF) calculation can underestimate or overestimate mine NPV is presented, the conditions for each are outlined and the degree of underestimation defined.CITATION:Dube, T Y, 2012. How the use of market-based risk metrics can undervalue good mining projects and overvalue poor ones, in Proceedings Project Evaluation 2012 , pp 29-34 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 24, 2012

By R Peiffer, L van Wyk

The Port of Port Hedland is the largest bulk export terminal in the world and is one of Australia’s most important pieces of economic infrastructure. BHP is the largest Port user to support the export of iron ore products from mines located within the Pilbara region of Western Australia (WA). BHP’s priority is the safety and well-being of its workforce and the communities where it operates. In a recent regulatory application to increase export capacity, BHP committed to the deployment of wind fences to reduce wind erosion from stockpiled ore. Wind erosion from stockpiles was identified through inverse modelling as the most significant dust source compared to other sources such as stackers, reclaimers, shiploaders and transfer stations. The primary cause of dust emissions from stockpiles is dust lift-off during high wind conditions. BHP proposed the installation of wind fences across its Port Hedland operations, targeted at reducing emissions from wind dependent sources, primarily stockpiles, by reducing the wind speed downwind of the wind fence. Modelling predicts that installation of the wind fence will significantly reduce emissions from stockpiles, particularly at BHP’s western operations (Finucane Island). To be effective in shielding stockyards and reducing wind speeds, the wind fences are located upwind and as close as practical to the open stockyards. BHP’s wind fence design incorporates learnings from other existing installations and has been tailored for Port Hedland’s cyclonic conditions. The wind fence will be higher than the stockpile height, with a mesh porosity of approximately 50 per cent. The mesh porosity allows some of the wind to pass through the mesh. This reduces the wind turbulence downstream of the wind fence, as opposed to a solid wind fence, which increases downwind turbulence, resulting in increased dust.

Sep 18, 2023

By C N. Hatton, K Ward

Tailings operations are inherently reactive as operations personnel continuously contend with a concentrator reject feed (tailings) transient in physical and engineering properties, which places a constant constraint on capital and operational spending. It requires a unique skill set to manage the prescribed distribution of tailings under unenviable conditions. Enter the tailings operator, an oftenundervalued commodity and untapped resource that can provide benefits beyond the rigors of dayto- day operational support. Experience consistently demonstrates that skilled and committed operators can serve a vital function in the safe construction of a tailings storage facility. It takes a village to raise a tailings dam. An important part of this process is establishing a culture of operational accountability and ownership. Operator development training is nothing new. However, we find that many of the intrinsic operator skills are left unexploited, and an operator's experiential knowledge base and creativity are commonly overlooked and underutilized. With proper training and guidance, these skills can be harnessed, contributing to safe dam operations. Operator engagement, when properly facilitated, provides tangible benefits ranging from improved tailings engineering properties to reduced closure costs. One important benefit is helping transitioning tailings management from reactive to proactive. There are many processes involved in the reactive to proactive transition process. One element of that process includes engaging operators in the tailings management process and facilitating legacy ownership. The core of operational legacy ownership is measured and described using five-stage operator engagement rubrics. Levels of operator engagement are presented with a description of the incremental benefits of each stage. An important part of legacy engagement is providing the tools to operators necessary for managing the tailings. Therefore, the approach identifies specific methods used by operations personnel to control tailings distribution and in-place properties. The end goal of leveraging operator engagement is to facilitate committed ownership and transition tailings management from an inefficient, reactive process to an improved, cost-effective, proactive practice.

Jul 1, 2021

By A Jakowetz

OxianaÆs Sepon Copper Operation (part of the combined Sepon Gold and Copper Operation) is located in Savannaket Province, in southern central Lao PDR. The site is relatively remote, being some five hours inland from the Laos/Thailand border crossing on the Mekong River. The copper processing plant was designed to treat 1.3 Mtpa ROM ore to produce 60 000 tpa of copper cathode. Commissioning of the processing plant was completed in mid March 2005 with ramp up completed in January 2006 with 5260 tonnes of cathode harvested in this month. The focus of this paper is on SeponÆs unique grinding circuit. The entire grinding circuit is operated at highly acidic conditions, adding a number of different operational issues over and above those normally associated with grinding circuits. It became evident early in the ramp up, that reaching design mill throughput of 170 dry tonnes per hour with the original design would be challenging, coupled with the realisation that ceramic grinding media consumption had been underestimated. In order to lift the overall throughput of the processing plant, a significant continuous improvement process has been implemented within the grinding circuit to lift this key unitÆs production capacity. This presentation will focus on the key areas that have been addressed in the 12 month ramp up period and highlight areas for future work. Results to date have shown this improvement process to be very successful, with throughput rates in excess of 200 tph regularly achieved.

Jan 1, 2006