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By M Spagnolo, M Ashley, D, L Reemeyer

PasmincoÆs Century Concentrator in North West Queensland commenced operations in November 1999. The nameplate production capacity of 500 000 tpa of zinc metal production in concentrate was achieved in August 2002. Completion of the production ramp up was successful due to the culmination of a number of initiatives throughout 2001 and 2002. Mine to mill interaction to understand and eliminate head grade related bottlenecks affecting Concentrator production and reduce feed variation. Grinding circuit process development û operating and process control strategies to improve stability and reduce grind size to support zinc recovery. Pumping upgrades to control spillage in ultrafine zinc flotation Low density zinc flotation strategy û to improve silica-sphalerite separation to improve zinc recovery while maintaining acceptable silica in final concentrate. Flotation circuit process development û froth crowders, froth cameras and reagent control strategies to improve primary zinc flotation performance. Review and implementation of longer campaigns between planned shutdowns to improve availability. Team reorganisation û to improve setting and implementation of metallurgical strategies. This paper describes these initiatives and their contribution in achieving the production target. It also notes the ball mill motor failures that delayed the successful achievement of the ramp up, and CenturyÆs response to minimise the production impact. The paper also outlines the capital improvement program that was implemented to improve zinc recovery to design 82.5 per cent recovery once the production rate had been achieved.

Jan 1, 2003

By I C. Carrasco, V G. Mirada, J F. D Domingo, F S. Leite

This paper investigates ore loss and dilution produced by rock movement in bench blasting. A total of four blasts, in which electronic detonators have been used, were monitored in Cobre Las Cruces Open Pit Mine (FQM Ltd) in Gerena (Sevilla, Spain). Rock motion has been obtained in 137 points of the free face and 6 points inside the block. Multiple liner regression has been applied to predict rock motion and estimate ore dilution as a function of hole coordinates, rock contacts, powder factor/hole, amount of explosive per blasthole, burden, spacing, hole length, stemming length, explosive energy, hole row, subdrilling, blast sequence, stiffness ratio, blasthole distance to free face, rock density and Young’s modulus. The model is statistically significant with a determination coefficient over 0.8. Rock motion measurements in 31 more points have been used to validate the model and to show a reduction in ore dilution.CITATION:Domingo, J F D, Leite, F S, Mirada, V G and Carrasco, I C, 2015. Dilution, ore grade and blast movement calculation model, in Proceedings 11th International Symposium on Rock Fragmentation by Blasting, pp 71–78 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 24, 2015

By J Folwell, G Phillips, F Gassner

Geomembranes selected for various applications often start with considering target properties developed by industry organisations such as Geosynthetic Research Institute (GRI), and test methods developed by ASTM and other Standards organisations The geomembrane types are typically, initially selected based on manufacturers recommendations and chemical resistance data from the manufacturer or industry knowledge. Geomembranes considered for this project included materials with material properties that exceeded the minimum target values of various test methods. The difficulty is in selecting which parameters are most important for a particular application and also what service life can be expected for the geomembrane under various chemical and environmental exposure conditions. Accelerated aging testing of candidate geomembranes in simulated exposure conditions can be useful to select the preferred geomembrane and predict the service life of the geomembrane under different exposure conditions. The exposure conditions of immersion in acidic tailings liquor, splash zone and freeboard zone were considered for evaporation ponds on a site with significant heat and UV radiation. Candidate geomembranes considered a range of different types of polyethylene liners. The results of the accelerated aging testing have allowed the selection of the geomembrane for the range of exposure conditions and evaluation of the expected service life of the geomembrane.

Jul 1, 2021

By G Brooks

The control of phosphorus in steelmaking is one of the famous challenges of pyrometallurgy. It is well established that highly basic slags, the presence of FeO in the slag and lower temperatures (less than 1650°C) are favourable for phosphorous removal. The thermodynamics of this reaction have been extensively studied under laboratory conditions and the general trends confirmed through industrial trials. However, in general, phosphorus slag/metal distributions measured in industry are far from equilibrium and quite specific to the oxygen steelmaking technology being used. This variability was quantified by Urban, Weinberg and Cappel (2015), who found that the phosphorus partition ratio measured in plants varied with blowing practice, stirring intensity and even converter life. Some recent kinetic studies by Gu, Dogan and Coley (2017) have shown how the kinetics of these reactions vary with FeO content and dissolved sulfur at the droplet scale. A global kinetic model by Rout et al (2018) provides meaningful predictions of where dephosphorisation occurs in an industrial basic oxygen furnace (BOF) and some recent heat transfer modelling by Madhavan et al (2021, 2022) implies that temperature difference between droplets and slag has a role to play in explaining why equilibrium is not achieved. This paper will review the current state of knowledge and provide suggestions on predicting phosphorous removal for industrial operations and how greater removal could be achieved.

Jun 19, 2024

During 2009 the technical services staff at Barrick Gold Corporation's Australian Business Unit conducted a review of their five underground mines that utilise pastefill as the backfill component for these operations. Of the five mines reviewed three use dry tailings and two use wet tailings plants. The primary aim for these reviews was to determine whether pastefill was the right option to be used, and if not, what where the alternatives. The reviews undertaken focus on several areas including, paste plant operation, reticulation and barricade techniques, the geotechnical requirements for pastefill in regards to the current mining methods, the consideration of alternative methods, capital and operating cost histories compared to initial estimates, and a cost benefit analysis of pastefill against other mining methods. The main benefits from the use of pastefill is increasing the extraction of the resource, reducing or eliminating the need to leave pillars. In some mines the use of pastefill is geotechnically driven, to manage high stress environments or mining induced seismicity. A third benefit of using pastefill in some circumstances is that it reduces dilution, however it is considered that this is not a valid argument for most of the mines reviewed. At two mines no alternative to pastefill was determined, whilst differing extraction and filling strategies were potentially identified at the other three mines. The reviews developed cost benefit curves for those sites that had alternative mining methods to assist in determining whether pastefill is the right option to use for any particular stope. At the grades typically mined in each operation, pastefill was the preferred option to use. In all mines, pastefill was determined to be the best option at this time.

Nov 25, 2010

By P Bartlett, K Naidoo

Premier Diamond Mine is planning a new, mechanised, block cave, with a production level approximately 1000 m below surface. A high degree of tunnel damage is expected, due to stress and the relatively low in situ strength of kimberlite. An evaluation of the timing of tunnel excavation, tunnel size and spacing has been carried out to define critical parameters for planning layouts and development schedules. Extensive use has been made of three-dimensional FLAC3D numerical models, calibrated against known rock mass behaviour at 650 m depth, to examine the influence of undercut advance on production level excavations. These were able to represent the effect of stress rotation on tunnels during undercut advance and the effect of an inclined undercut. The analysis has provided guidelines that are possibly applicable to any deep block cave layout. The choice of drawpoint layout is of considerably less significance than the proportion of ground extracted on the production level elevation prior to advancing the undercut. The analysis shows that damage to production development will be potentially severe if it is all excavated prior to advancing the undercut, or is mined directly beneath the undercut face. The development of the main production tunnels alone ahead of the undercut may be feasible, but no breakaways should be put in as they appear to trigger a rapid increase in the severity of damage. The optimal sequence is when all production tunnels are developed at least 10 m in plan behind the undercut, where the induced peak field stress is less than 20 MPa and a maximum support pressure of 100 to 500 kN/m2 is require to contain movement. The assessment showed that the conditions are not significantly improved by increasing drawpoint spacing from 15 m to 18 m. The vertical spacing between the undercut and production level beneath is investigated. Provided production level development is carried out beneath the undercut, there would appear to be little benefit in increasing the vertical spacing between the undercut and production level beyond the current 15 m to 18 m.

Jan 1, 2000

By P J. Terbrugge

Many ore deposits have considerable vertical extent which is not always known at the time of commencement of mining. In many of these cases, initial mining is by opencast methods, and as ore reserves are proved to greater depths, the pits are often planned to go deeper than had been originally envisaged. In such cases, surface plants and critical underground facilities such as conveyer tunnels, access ramps, ore passes, hoisting shafts and ventilation shafts are often located much closer to the pit rim and the orebody than is desirable for the deeper mining situation. This usually raises the question of the stability of such underground excavations, which may be critical for the viable longer-term mass underground operation of the mine. In this paper the key considerations in the evaluation of the stability of the overall mining environment for ædeepened minesÆ are defined. Aspects which are dealt with are: open pit stability, shaft stability, dilution, mudrushes and airblasts, and selection of mining method. The necessary stability evaluations are put into the appropriate context by considering two case histories. Critical parameters and considerations which need to be addressed during the evaluation of excavation interaction are also discussed.

Jan 1, 2000

Our modern cities are almost incapable of sustaining themselves without subsurface infrastructure, which is not identifiable at first glance. This very soon becomes evident when the chaotic conditions prevailing in some cases in the multi-million cities on the African, Asian and South American continents are taken into consideration. This does not simply apply to the hopelessly congested streets in the downtown areas. If anything, it is shown here too that a subsurface infrastructure represents an important prerequisite for public health right up to banishing the danger of disease. Even during the 1990s, this has been clearly underlined through examples of cholera and plague epidemics in parts of Central and South America as well as on the Indian subcontinent. The overriding significance of an inner urban subsurface infrastructure in order to create decent conditions in the major built-up areas was once again emphasised not all that long ago at the United Nations HABITAT-II Conference in Istanbul, Turkey, in June 1996. More than 15 000 delegates from all over the world mulled over and discussed the prerequisites for humane living conditions in human settlements taking the varying climatic, topographical and cultural marginal conditions in different regions of the globe into account. Apart from the built-up areas themselves, the utilisation of underground space is experiencing high and ever increasing significance in less densely populated regions. Attractive and fast transport links between industrial centres call for high- performance transport arteries for the economic, speedy and unhampered carriage of people and goods. Important impulses for the economic power of a region or nation are provided by transport development and links. As a consequence, tunnels for roads and railways are being built or planned to a great degree for crossing mountain ranges, rivers and straits.

Jan 1, 1999

By C J. Carr

The Ernest Henry Mine (EHM) is owned and operated by Xstrata Copper and is located in North-West Queensland, Australia. The mine is currently undergoing a transition from an 11 Mtpa open pit mine to a large sublevel cave underground mine producing 6 Mtpa. Due to a number of factors, including geometry of the pit and crusher depth, the decision has been taken to develop a hoisting shaft rather than inclined conveyors.During the feasibility study the strip and line shaft sinking methodology was preferred over blind sinking due to scheduling opportunities and interactions with level development. Other methods of sinking considered included large-diameter raise boring, which was rejected due to concerns relating to centreline accuracy. The strip and line decision was reviewed during the tender process where better than anticipated blind sink advance rates and costs were presented. This in turn enabled the higher cost of the blind sinking method to be justified by a combination of reduced risks including schedule and ground water management. This paper discusses the pros and cons of both strip and line and blind sinking methodologies in the Ernest Henry context including sinking rates and total schedule impacts of the two methods, the key risks associated with each method, cost implications of blind sinking and safety implications of the work methods in general. The paper then concludes with the reasoning behind the decision to change to blind sinking for the EHM shaft.

Mar 21, 2011

By M Boyd

The University of Wollongong was named University of the Year 2000, for its work in preparing students for the e-world. Computer facilitated learning is being introduced into subjects throughout the engineering course. First year mining engineering students are introduced to computers, e-communication, using the UniversityÆs web based information system, and web based subject delivery. Mining engineering students in the mid-years of the course use programming languages and numerical computation software such as MATLAB, while students in the final years use a range of commercially available professional engineering software such as TALPAC. Most of these subjects are offered as part of the UniversityÆs Learning Online program, co-ordinated by its Centre for Educational Development and Interactive Resources (CEDIR). Learning Online subjects are delivered using the Web Course Tools (WebCT) environment. WebCT allows all resources to be accessed through the web, allows email communication between lecturer and student, and allows discussion groups for the exchange of ideas. Students can submit their assignments through WebCT and receive immediate feedback. This paper describes how WebCT has been used to deliver a first year engineering computing subject, mid-year numerical computation subjects, a mining economics subject and mine planning subjects.

Jan 1, 2002

By Askew JE

The large, massive low grade gold orebody at Mount Charlotte has demanded an innovative approach to mining engineering. In the last five years several advances occurred in the areas of rock mechanics, mass blasting, blasthole drilling and truck haulage.Successive crown pillar failures throughout the life of the mine had resulted in a continuous geotechnical program, mostly utilisingconsultants. The culmination of this workwas the development of a successful crown pillar support system. Several stopes have incorporated the technique and the most notable success has been the relatively large F3 crown pillar.In hole hammer drilling was introduced to the mine in 1979, but little work had been done to develop a blasting system to suit the 165mm diameter holes. A non-electric sequential blasting system was adapted for use at themine and up to 600,000 tonnes have been fired successfully in an individual blast. Problems with ground vibration were addressed although this work remains incomplete.

Jan 1, 1984

By A Marton

Concerns with crest losses have seen changes to a number of design and operating parameters to retain the integrity of the wall and the berms of the Kidston Gold MinesÆ Eldridge Pit. Until trials began in 1999 most final wall designs utilised large diameter blastholes up to the presplit row to achieve the wall angle. The berm crests were being lost, wall support requirements were increasing and affecting mining schedules and several fault areas were putting pit access at risk. Standard designs had been determined during the early mining years and while periodic modifications had been made there was a need for major blast pattern revision. This paper traces the development of wall control blasting programs over the years, relating designs to the geology and the evidence in the walls with the theories of the day and includes the recent trials that were conducted in what is a most unforgiving geology. Trials and improvements to ensure the walls were safe were conducted even as the mine neared its economic life. Instrumented monitoring of trials blasts has greatly increased the understanding of the damage criteria and enabled rapid revision of designs. Recent changes included reduction in presplit energy, charge redistribution and use of smaller blast holes for the trim patterns. Determination of a minimum proximity-to-final wall limit for production blastholes, establishment of the correct standoff to berm crests and walls and selective use of presplitting techniques for protecting crests have resulted in cost effectiveness, improved bench crest retention and an overall reduction in visible wall damage.

Jan 1, 2001

By P Standish

Qualitative risk assessment methods are not well suited to considering complex systems and potential interactions of new technology. As part of supporting tier one mining organisations and international industry groups, the author and colleagues have innovated processes to help provide better solutions to sites/companies considering a move to implementing proximity detection and collision avoidance systems. The process identifies required operating states for the system. By applying a combination of research and team-based analyses, a rigorous identification of credible failure modes which could cause these states to be lost, is identified. Finally, required business inputs, expressed in practical terms are distilled from regulator, industry, organisation and site in a way which clearly addresses the failure modes and so retain the required operating states. These business inputs identify improvements for site arrangements (EMESRT levels 1 to 7) before identifying functional requirements for technological collision avoidance solutions (levels 8 for advisory and 9 for autonomous). The paper presents a case study synthesised from multiple sites analyses and will provide guidance on where to find additional resources to assist in making the best possible transition to better equipment and road network solutions.

Jun 22, 2022

By R Klepper

Separation of leach residue suspended solids from pregnant liquor solution is an important step in hydrometallurgy flowsheets. Alternative flowsheet options are counter-current decantation (CCD) thickeners or counter current washing (CCW) horizontal belt vacuum filters. Extensive sedimentation and vacuum filtration simulations have been completed by FLSmidth on leach discharge slurries to indentify equipment capacity and performance. These data were used to compare Capex and Opex for CCD versus CCW alternatives. In addition, Capex and Opex for large horizontal belt vacuum filters with filtration areas greater than 250m2 are compared to current state of the art sizes of 150m2. This paper presents this information and discusses various advantages and disadvantages.

Aug 8, 2011

By Cloutier JY, Quinn P, LeClerc A, Dube G, Agar GE

Gold dissolution by cyanide requires the presence of oxygen which is usually supplied by sparging compressed air into the gold containing slurry. For those ores that contain certain obnoxious substances that consume oxygen, maintaining the required minimum level of dissolved oxygen can be troublesome. One of the most economical solutions to the problem of low dissolved oxygen, especially in plants that have air compressors installed, is to enhance the rate of oxygen mass transfer. The oxygen mass transfer rate was measured in a two phase system using two different sparger arrangements, and with addition of a frother that is known to reduce the bubble size produced by the sparger. The common sparger system was shown to be inefficient compared with a readily available but under utilised method of gas dispersion which introduces air directly below the reactor turbine. Transfer of this technology to an operating plant confirmed the beneficial effect of the improved sparger system. The addition of the frother did decrease the bubble size, but it also reduced the oxygen mass transfer rate.

Jan 1, 1993

By C Tonkin, S D. Howell, P V. Johnson, J Moriarty, P W. Duck

This paper presents the scientific framework underpinning the resource valuation and optimisation model (RVOM). The RVOM is a partial differential equation based real options software package, which helps mine owners optimally plan their operations, understand their project risks, and make defensible valuations. This is achieved in the presence of both financial and physical uncertainty, as well as processing capacity constraints. The RVOM can be applied to any multi-ore mine, open pit or otherwise, where the block-order of extraction has already been planned using existing software tools such as the Gemcom WhittleÖ strategic mine planning package. The RVOM can also take account of multiple commodities within a single mine, and multiple forms of price behaviour. The three key outputs from the RVOM are: valuation, optimal decision and probability of decision. A decision takes account of upfront costs, and can include an unlimited number of transitions between: normal operation, expanded operation, care and maintenance and abandonment (and variants thereof). The RVOM then employs stochastic process theory to determine the probability of reaching these decisions. This gives the mine operators clear indications as to where their risks lie, aiding their mine planning. A clear example of the RVOMs usage to a case-study gold mine is presented, demonstrating its broad applicability, the added value it can create and how users can easily make use of the RVOMÆs state-of-the-art algorithmic engine.

Sep 26, 2011

By H Kurth, L Balzan

The potential for bulk diversion was identified and quickly implemented following the development of bulk sensing technologies applied to conveyed flows. In the early 1980s real time analysis of ash in coal was intended to improve the understanding and control of quality variability. By the end of the 1980s approximately 5% of coal analysers installed were being utilised for bulk sorting; diverting flows to create stockpiles to improve blending flexibility and boiler feed consistency, diverting waste material, or bypassing the beneficiation process when the coal met product quality criteria. In the 1990s bulk sensing and sorting utilising natural gamma detection was applied to conveyed waste in gold-uranium mineralisation and allowed ore to be recovered and processed that would otherwise have been discarded. Further applications developed in the iron ore sector where product quality ore could be diverted to bypass beneficiation and save significant unnecessary processing costs and improve recovery by avoiding process inefficiency losses. Plant capacity was freed up to be utilised by material that required processing. Similar benefits became evident in the phosphate industry and in base metals where multi-elemental analysis using Prompt Gamma Neutron Activation Analysis provides ideal opportunities to representatively measure 30 second conveyed increments at high accuracies. This has been successfully adopted in copper, nickel, platinum and lead-zinc to improve waste removal after primary crushing to eliminate unnecessary expense and improve plant efficiency. The benefits include increased output from existing operating capacity, significant reductions in consumable costs and generation of fewer detrimental waste streams. The paper outlines the technologies and discusses case studies covering the above commodities, demonstrating the immense value that representative real time measurement of conveyed flows can create. Measurement data concurrently provides multiple benefits in operational performance besides sorting, through ore reconciliation, ore blending, feedforward control and metal accounting, adding further value.

Nov 10, 2020

By R Bourcier, T Rafferty

Following an underground coal mine explosion, it is important that ventilation is quickly restored to ventilate the mine and affect a mine rescue. To achieve this, surface ventilation fans must be suitably protected from explosion damage, but still able to be quickly restored.A review of all Australian coal mine regulations was carried out, revealing that Australia has no prescriptive regulations that specify the design of explosion relief panels and the protection of ventilation fans in the event of an underground explosion.To better define the level of protection required, this paper reviews and extracts details from relevant major international regulations and standards on the subject.A suitable design methodology for the protection of ventilation fans is presented that could be applied in Australia, using a combination of explosion relief panels, appropriate isolation of the fan, and ventilation shaft/mine design.CITATION:Rafferty, T and Bourcier, R, 2013. The protection of surface ventilation fan installations from underground explosions, in Proceedings The Australian Mine Ventilation Conference , pp 169-173 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 1, 2013

A hidden asset in most exploration and mining activities is data. Common practice involves the spending of large amounts of money to discover, define and prove the viability of a mining project. Some organisations have used operations research analysis and internal costing methods to allocate a value to their data and to compare the costs of data maintenance to other more tangible activities like plant and equipment maintenance. Those organisations, which do not undertake such an analysis often, have little knowledge or understanding of the extent and the worth of their data. Often the organisations lack of knowledge and understanding of the data is indicated by their failure to fully exploit or realise their opportunities. The focus of this paper is to discuss new technologies that optimise the management and security of collected and derived data. The technologies discussed are components of the software systems acQuire and MineSight.

Jan 1, 1999

By J Moffatt, T Payten, N Spooner, L Teixeira, L A. Balzan, G Wilkie, G Tsiminis

Fluorine is a penalty element due to its reactive nature. In acidic environments many fluorine minerals dissolve to form hydrofluoric acid (HF), changing processing conditions. When smelted HF can be released, causing negative effects to nearby people and the environment, as well as potentially damaging the smelter. Sale of ore with high fluorine levels elicit a financial penalty or are banned outright. Real-time sensors create the opportunity for instantaneous decisions on ore processing due to changing conditions. A fluorine sensor would allow rises in fluorine concentration in a processing stream to be flagged, and decisions on processing conditions or diversion to stockpile before processing could be undertaken. As fluorine is a light element, it is difficult to detect with in-field XRF devices and does not work well with PGNAA. There are currently no existing sensors to quantify the presence of fluorine in real-time, and thus decisions based on fluorine grade cannot be made at minute- or even hour-scales. Sensors designed to measure the presence of minerals that contain fluorine are a possible avenue to enable the real-time detection of this element. Mineral-based sensing may also give an added advantage of additional information about how the fluorine will react under different processing steps. The authors were given a grant under CRC ORE II (project number P1–005) to search for mineralspecific signatures suitable for real-time analysis. The work focused on novel regimes and applications of fluorescence as a means to detect specific minerals. The aim was to exploit fluorescence responses unique to minerals of interest in mining systems in order to produce sensors that address gaps in existing capability. After the successful discovery of signatures specific to two major fluorine minerals an additional grant (P1–014) was funded to develop the research into a prototype on-belt sensor, in partnership with Scantech International Pty Ltd. This paper details the development of a sensor package through multiple Technology Readiness Levels (TRLs) through collaboration with government/industry grant schemes, academics from university, and a sensor-focused Mining Equipment and Technology Services (METS) company. We give a brief description of the new sensor technique and provide a case study of multi-disciplinary collaboration.

Aug 24, 2022