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By E J. Hofmann, J E. Hofmann, A J. Hofmann-Fritz

"With its Head Quarters in Perth, global heavy engineering company Hofmann Engineering is one of the largest family owned engineering companies in Australia. The company has pioneered a number of new manufacturing processes and design improvements for components of large comminution equipment.Some of these innovations are: Innovative design improvements of high pressure grinding roll (HPGR) forged steel tyres. Hofmann Engineering has developed unique patented tungsten carbide stud and edge protection designs which improve wear life and introduce quick and cost effective replacement options to further extend the life of the tyre. Development of forged fabricated mill heads using rolled and welded high tensile steel plate as an alternative to cast conical mill heads. Establishment of Australian capability to manufacture and export up to 42 ft. (12.8 m) diameter SAG mill shells. Techniques for fast track, product improved replacements of cracked or damaged mill gears, including in situ profile & wear measurements of girth gears using portable coordinate measuring machine (CMM) technology, forged rim steel and induction hardening technology. Gear and pinion mechanical drive designs to 24 MW or higher for SAG mills of 38 ft. to 42 ft. (11.6 m - 12.8 m) diameter as reliable alternatives to gearless drives.The paper presents case studies from the Australian heavy manufacturing facilities of Hofmann Engineering on large, high powered equipment for both the domestic and export markets.CITATION:Hofmann, E J, Hofmann, J E and Hofmann-Fritz, A J, 2013. Australian innovations in high pressure grinding rolls and large grinding mill manufacture, in Proceedings MetPlant 2013, pp 141-151 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Jul 15, 2013

By French D

In presenting this paper may I preface my remarks by recognizing the presence here to-day of the many delegates from the overseas mining communities throughout the world. That is to say - those delegates not representative of Companies resident in Australia. This does not mean that my comments following are directed solely to the Australian exporter - far from it. The Company which I represent is internationally based. The experiences we have had in dealing and negotiating with our good friends the mineral cargo shippers vary very little in any operational area. However for the purposes of this exercise this address is based on some of our experiences within the Australian trade scene with the emphasis on the fact that we believe it has application to all trading areas.

Jan 1, 1989

By Ralph B. S

Bacterial leaching of low grade quartz felspar porphyry copper ore was studied in large-scale laboratory percolation leaching columns.Limitations in the release of soluble copper showed up before fifty per cent recovery, due to occluding precipitates of iron oxides and hydroxides. Precipitates were removed by increasing the acidity of irrigation feed four-fold with respect to sulphuric acid. However, irrigation at low pH (pH 1.5) inhibited copper leaching. Resumption of bacterial leaching at pH2 was achieved by introducing a period of non-irrigation. The results suggest a 'direct' attack by bacteria on the chalcopyrite substrate rather than an 'indirect' ferric-leach mechanism.

Jan 1, 1981

By Messenger A. J, Miles J. G

A thermal neutron irradiation technique using a mCf neutron source has been developed and applied to thp.simultaneous determination of iron and aluminium (expressed as AI2O3) in iron ore fines (-6 mm particle size) on a moving rubber conveyor belt.While the determination of iron with this technique is based on the use of a NaI(TI) detector to monitor the characteristic prompt gamma rays (7.64 MeV) emitted by thermal neutron capture reactions in the iron, the etermination of AI2O3 is based on the use of a second Nal(Tl) detector to monitor the characteristic gamma rays (1.78 MeV) emitted after thermal neutron activation of the aluminium. The second detector is located downstream from the first. Although the speed of the conveyor belt has no direct effect on the iron measurements, it must not exceed about 3 m/min if good accuracy is required for the AI2O3 measurements. Consequently an auxiliary conveyor belt is required in order to avoid interference with normal ore processing.Dynamic trials of the technique, using 1500 kg samples of ore on a 460 mm-wide rubber conveyor belt moving at 1.7 m/min, have demonstrated that the method can achieve accuracies of 0.7% Fe and 0.1% AI2O3. At the present stage of development, it is recommended that lump ore be crushed to a particle size of 6 mm before analysis.In addition to iron and AI2O3 determinations, measurements of total moisture content and bulk density are possible. The determination of Si02 is also feasible, but a separate fast neutron source (e.g., Am-Be) and a separate gamma ray detector are required.

Jan 1, 1980

By M Nagarajan

Orica Mining Services (Orica) in partnership with Coal and Allied’s Hunter Valley Operations (HVO) has developed a risk management process to maximise mining efficiency whilst controlling vibration and maintaining critical electricity continuity to New South Wales (NSW) electricity grid in the Riverview Pit. The issue is a high tension tower which supplies electricity located within 40 m of mining and blasting activities. The process involved developing an understanding of the relationship between vibration, explosives, geology and the location of the blasting in the geological horizon. From this an optimum methodology for blasting in each region was developed.

Nov 8, 2011

Six simulations by the Mpnte Carlo method employing both classical and geostatistical techniques are presented for the determination of the probability distribution of the in situ value of a coal seam. To avoid the problem of qualitative estimation of parameter variability in the calculation of an arbitrary seam value, only data values from borehole information were used to quantify the variation in four coai seam parameters.The method which is suggested as being the most appropriate is a particular geostatistical approach that employs the best linear unbiased estimate and the error of estimation for a number of two dimensional blocks. The results indicate that the variance of the coal seam unit value may be much higher than that indicated by the classical approach because of the spatial variability that is properly incorporated in the geostatistical approach.The model used in the Monte Carlo simulation to determine the economic value of a coal seam can be extended to incorporate all those parameters which are necessary for a true estimation of the probability distribution of the coal seam value. A time value concept for discounting can also be incorporated to optimize the economic return of a coal mining project.

Jan 1, 1983

By S P. Young, K R. Monro

Reducing metal prices have forced mining operations to become more efficient and innovate in order to do more with the existing base. Much of this effort has focused on improving the efficiency of load and haul operations. The key to this is to understand and quantify where delays and missed opportunities exist. Metrics such as utilisation of availability, efficiency utilisation and asset availability are helpful indicators of performance; however, uptime-based time usage models and performance analysis tools using productive operating time models help to identify additional improvement opportunities.Phu Kham is a copper-gold mine operated in the Lao People’s Democratic Republic (Laos) since 2008 by PanAust Limited. The mine is a single large open pit of 450 m depth, running a fleet of 51 100 t class rigid dump trucks and 300 t and 200 t shovels controlled with the aid of a fleet management system in order to achieve ex-pit material movements of 56 Mt/a.Commencing in late 2014, a range of initiatives were implemented in order to improve the efficiency of the mine haulage fleet. These include hot seating of all operator changeouts via changeout ramps, split shifting of crews to minimise queuing delays, maximising blast volumes and minimising blast event days to reduce blast exclusion delay events including opportune refuelling of equipment during blasting events, inspections of trucks during refuelling events, implementation of a dedicated haul road services team to help reduce wet weather related delays and infrastructure development for haul path efficiency improvements.These and other initiatives have allowed the mine haulage fleet utilisation of availability (UofA) to be sustainably increased from 85 per cent to 97 per cent (see Figure 1), efficiency utilisation to increase from 85 per cent to 90 per cent, and productive operating time (POT) to increase from 73 per cent to 84 per cent. The corresponding increases in efficiency of the haulage fleet has allowed an equivalent reduction of eight haul trucks from the fleet to meet continuing life-of-mine production requirements.CITATION:Monro, K R and Young, S P, 2016. Truck haulage improvements at the Phu Kham mine – the journey to 97 per cent utilisation of availability, in Proceedings International Mine Management Conference, pp 339-346 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jun 22, 2016

The area between Merrygoen and Digilah is located on a structural high that separates the Sydney Basin from the Great Artesian Basin, and hence the stratigraphic succession of younger rocks overlying the basement is relatively thin. The stratigraphy is briefly described and it is shown that fluvial sedimentation prevailed from Upper Permian through to Middle Jurassic times. Flint clays occur in the Permian, Triassic and Jurassic but only those in the Jurassic appear to have commercial value at present. The chemical, mineralogical, and physical properties of the flint clays are discussed.

Jan 1, 1973

Plant for the production of sulphuric acid from pyrites flotation concentrates was commissioned at Cockle Creek during 1956, to meet increasing demands for commercial acid and superphosphate. Pyrite was chosen as raw material because of the uncertain supplyposition of imported brimstone and the desirability of utilising domestic sulphur.Desulphurisation of the pyrite is performed by two 40-ton per day roasters of the Turbulent Layer type operated under licence from the Badische Analin and Soda Fabrik (B.A.S.F.) organisation. These units are the first of their kind commissioned in the southernhemisphere. Pyrite is fed to the roasters in the as-received un-dried condition. Waste heat steam production is coupled with electricity generation within the plant. Sulphur dioxide is produced at comparatively high strengths and cleaned by conventional cyclone and hot electro-filter equipment.The acid unit has a capacity of 100 mono tons of sulphuric acid per day and includes cooling and wash towers, mist precipitators, a single stage drying tower, 4-pass oxidation section and absorption system.INTRODUCTIONSulphuric acid has been manufactured at Cockle Creek Works since 1913, when the first chamber nitration plant was commissioned. The raw material was brimstone roasted in Herreschoff furnaces. Since that time three additional chamber units have been constructed and have produced acid from brimstone, zinc concentrates, pyrites and -spent oxide, according to changing economic and supply factors.Three chamber units are still in operation. Contact processes have become increasingly important since the first Schroder-Grillo unit was commissioned in 1923. Six of these 5-ton per day units were operating in the mid-thirties, but have since been demolished. Two 15 ton Chemico hot gas contact units commenced operation in 1937 and 1938, and although modified, are still in service.The increasing demand over recent years for sulphuric...

Jan 1, 1957

By D Zielinski-Nicolson

The emergence of affordable, portable and versatile wireless devices has enabled a new frontier in mine safety equipment. Existing solutions provide methods for tracking personnel and assets in underground mines but are not designed to optimally integrate into existing and emerging systems. Mine management are often required to coordinate primarily independent emergency, personal protective equipment (PPE), tracking and collision avoidance systems from multiple vendors. These systems involve a variety of wireless technologies that require separate integration projects that discourage adopting new services and policies.

May 5, 2022

THE choice of a pumping plant for the drainage of a mine is a matter of such importance that it is obvious that in a short paper it is impossible to go fully into the reasons governing the adoption of any particular type. The author, therefore, proposes to briefly discuss the methods.in vogue, and, as far as possible, to point out the advantages and disadvantages of the numerous systems. The probiem is of extreme importance to the mining engineer, and it appears that in the past sufficient thought has not been given to this branch, as shown by the numerous failures which are encountered.When water is met with in large quantities, the development of the mine depends upon the pumping plant to such a great extent that the most careful consideration should be given before deciding on any particular scheme for drainage. The pumpingplant in a mine should be looked. upon in the light of an insurance policy, and should be treated as such, care being taken that the premium is as low as possibl~, and to ensure this it is necessary that the most efficient plant be secured. Local conditions play such an important part ill the design of a plant that no hard and fast rules can be laid down. When the amount of water to be handled is small, and there is no possibility of any increase...

Jan 1, 1912

By M Thompson, N Vines, Z Hearne, S Lam, G A. Gomes-Sebastiaõ, D van der Spuy

Construction and commissioning of the Nova Copper-Nickel project of Independence Group was completed in late 2016. The plant is in the Fraser Range of Western Australia, about 120km east of Norseman and produces separate Copper and Nickel concentrates. Since the early feasibility phases of the project, the importance of automation and control was recognised and planned for to ensure the plant performance meets the design expectations. The site is well equipped with common as well as advanced instrumentation. It currently boasts the largest number of Blue Cube MQi (mineral quantifier inline) slurry grade analysers on a single plant worldwide. It was also decided that 25 Blue Cube TempoTracks would be installed on the flotation cells. The TempoTracks provide information on froth height and velocity, hence giving continuous, quantitative measurements of the froth that is pulled off each cell, rather than relying on infrequent, subjective visual inspections.The Nova concentrator consists of a differential flotation circuit whereby copper bearing mineral are selectively floated prior to nickel flotation. It is imperative that losses of copper to the nickel circuit, and vice versa, are minimised. The plant metallurgical team and Process IQ collaborated to develop and implement the advanced control strategy for the plant. This paper focusses on the optimisation of the copper concentrate that is pulled off the copper rougher and scavengers. This strategy was made possible by the additional measurements listed above. The control optimisation of the copper rougher and copper rougher scavenger circuit was implemented during August 2017 on the StarCSTM advanced control platform. It continuously optimises the level and air setpoints. The control philosophy incorporates several notable techniques which include: a variable mass pull target that is a function of the quantity and grade of material entering the circuit, integrated compensation to prevent inventory build-up in cells, balancing of the froth velocity over the lip of each cell to adaptive, modular system usage and advanced error handling. CITATION:Gomes-Sebastiaõ, G A, Hearne, Z, Lam, S, van der Spuy, D, Thompson, M and Vines, N, 2018. Nova copper-nickel project optimisation of the copper rougher-scavenger circuit through advanced measurement and control, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 77–92 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

By B Leisemann, M Watkinson

Coal augering is an ideal method for recovering coal from the highwalls of open cut coalmines. Coal augering is a simple process whereby additional flights are added to the auger cutting head and auger holes are drilled at 1.9 m diameter up to 200 metres deep. Traditional monitoring was located at the mouth of the hole and if methane was encountered above two per cent, inert gas was delivered into the mouth of the hole to deplete the oxygen content at the auger cutting head below 12 per cent. The auger operator was asked the question ‘how do you know that this is the case?’ Trials were undertaken to prove that the oxygen content at the cutting head did drop below 12 per cent (the lowest limit for methane to ignite, also known as the oxygen nose point). Initial trials showed that the oxygen content in the mouth of the hole did not drop below 12 per cent and modifications were made to hold the inert gases in the mouth of the hole so that the auger flights could take this inert gas into the hole. In-hole monitoring, after completion of mining and after extracting the auger flights, showed that the atmosphere quickly returned to fresh air. In-hole monitoring was also tried during the augering process and yielded valuable results. This paper will discuss the results of the monitoring, information on the gas results obtained and the methodologies used to optimise the oxygen content at the auger face.CITATION:Watkinson, M and Leisemann, B, 2017. Inertisation of coal augering holes, in Proceedings Australian Mine Vent Conference 2017, pp 293–298 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 28, 2017

By M Bellamy

The DeGrussa copper deposit was discovered by Sandfire Resources in April 2009. Construction of the 1.6 Mt/a concentrator, open pit and underground mining operations commenced in March 2011 with first concentrate production achieved in October 2012. Over the next ten years, DeGrussa grew to include both the DeGrussa and Monty underground mines, establishing itself as one of the world’s premier copper producers with total production of 663 000 t of contained copper by the time the mine closed. Final ore was trucked from Degrussa on 5 October 2022. This paper examines the mine closure experience from both a planning and operational perspective. The paper provides an overview of the site’s mine planning process including the factors involved in determining the end of the mine life and how this was tracked and communicated in the lead up to the end of mining operations. It will also look at some of the specific operational aspects involved in maintaining steady state production all the way through to the last day while facing increasingly challenging conditions. These factors, along with the external factors faced by most of the industry such as labour shortages and COVID related disruptions, contributed to making it an interesting journey to the end of operations at DeGrussa.

Mar 29, 2023

By G C. Bolton

Experiments were conducted to access the feasibility of removing zinc from lead slag by sulfation or chlorination or both. Gaseous sulfation with sulfur dioxide and oxygen released only 50 per cent of zinc even under the most severe conditions. Sulfation with concentrated sulfuric acid by a fast-leach process released 95 per cent of zinc while pug-roasting released a maximum of 78 per cent of zinc. Chloridization with NaCl in the presence of sulfating gas released 50 per cent of zinc, while direct chlorination with chlorine gas and oxygen released 85 per cent of zinc and 100 per cent of lead in a chloride condensate containing little impurities.

Jan 1, 1980

By R Winterberg

Concrete is a well established and reliable construction material for the permanent lining of tunnels, but shows some weak performance characteristics, which can be overcome by the addition of specialised fibre reinforcement. This paper addresses the particular performance design requirements of segmental linings, discussing the improvements of fi bres on concrete properties. Focus is made on the beneficial effects of fibre reinforcement on the cracking behaviour and the toughness performance, providing a safe and durable tunnel lining.Not only the mechanical performance of fibre reinforced concrete (FRC) for segmental linings, but also the durability of the linings has gained growing attention among the designers and consultants. Especially tunnel linings with exposure to media with corrosion potential, such as wastewater sewer tunnels or desalination plant outfall tunnels, have high requirements on their durability. The design of these structures must provide a comprehensive study of durability aspects. Fibre reinforcement can substantially improve the durability of concrete.Research has been carried out on the cracking behaviour of concrete. The beneficial effects of steel fibres on the cracking behaviour reduce the permeability by reducing the flow paths within the concrete. Crack bridging steel fibres create necking effects in bending cracks, leading to earlier closure of the cracks. Further, steel fibres create particular crack formations, which lead to a substantial reduction of the fl ow rates through separation cracks. The results also show that considerable cost savings can be achieved using FRC, as the thickness of the linings can be reduced.The durability design issues will be addressed and underlined by a case history on the Hobson Bay sewer tunnel in Auckland, New Zealand.

Mar 8, 2011

By Reid K. J, Restarick C. J

The breakage and flow characteristics of quartz, ground as a minor constituent with calcite in a continuous wet ball mill, have been determined by carefully controlled grinding tests.A mathematical model, combining the simple functions which describe these characteristics, has been used to predict both steady state and non steady state results.The calculated results are compared with experimental data.

Jan 1, 1966

By Met B. E

The increasing pace of modern mining makes constantly greater demands upon the several contributing departments of rock breaking and transport, and rock-drilling, as the spearhead of attack, has received a great deal of attention with respect to both machines and steels. By a series of mechanical improvements, combined with the application of selected heat-treated alloy steels, the rock-drill has now been developed into a machine capable of rapid drilling and long service under severe working conditions. As a factoryproduct made under strict metallurgical control it is as foolproof as, say, the modern automobile, and, like its prototype, it can be kept in efficient operation by a minor amount of attention during use and by periodical adjustments and replacements.The same cannot be said, unfortunately, of the drills with which the machine is supplied; in conventional mine-shop practice these are made of the best tool steel shaped and heat-treated under the poorest of metallurgical conditions.The crudities of steel-shop practice have, in fact, always prevented the full exploitation of the steels available at any time, and even at the present day the general standard of treatment offers a contrast with the quality of the steels which moves the metallurgist to amusement, despondency or outrage, according to his temperament. Nevertheless, the tendency persists to meet the increasing demands of the rock-drill primarily by the use of still better steels, and secondarily by improvement, of the steel-shop practice. Athird type of development is the introduction of factorymade tools in the form of detachable bits and rods. It is proposed in this paper to deal with these three aspects of the recent developments in rock-drilling.*Re-written from a lecturette given during the First Ordinary Meeting, 1936.

Jan 1, 1936

By R Wilson, S Luke, R Williams, B Freeburn

"In 2010, two McLanahan RSS14×50 scrubber screens were installed at Fortescue Metals Group’s (Fortescue) Christmas Creek site. By 2015, the trommel (screen) section had effectively reached the end of their serviceable life. This was determined by regular measurement of structural components over the previous 18 months that tracked wear life. At the same time, numerous trials and optimisations had taken place on screen panel design and material composition. During 2015, a new set of trommels were designed, manufactured and installed that incorporated many new features: increased open area to facilitate high throughput, improved wear protection for structural members, simplified trommel panels and realigned discharge ports to reduce wear on exit. Numerous other upgrades have taken place on the drive system, feed chutes, liner and weir configurations and park brake, to name a few. This paper will highlight how regular measurement drove design changes and how the site and the original equipment manufacturer (OEM) managed a replacement program that has delivered improved performance.Citation:Wilson, R, Luke, S, Freeburn, B and Williams, R, 2016. Regular Measurement Defines Upgrades on Scrubber Screens, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 285–290 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

Development on the North Kalgurli mine has established a major penetration of ore into calc schist. This is controlled by a system of east-dipping strike faults. Previously, most calc schist ore bodies were regarded as being confined to the quartz dolerite greenstonecak schist contact environment.INTRODUCTIONOne of the most interesting and economically important developments which has taken place in the Kalgoorlie Field over the past 20 years is the proved penetration of ore into calc schist on the North Kalgurli Mine. This is quite extensive, both laterally and in depth, and has occasioned some modification of geological thought in the search for additional ore sources.Ore has been mined in calc schist almost since the first major gold discoveries were made and the principal features of the various types of deposit are well covered in the literature of the field. However, occurrences in calc schist have not been characterised by the same degree of continuity or frequency as the innumerable lode formations in the more favourable quartz dolerite, and there has been a tendency to regard them as isolated and discontinuous ore bearing structures, occurring only under very special conditions.It is not intended to describe the whole range of calc schist ore occurrences but only major controlling structures, whose penetration therein has been definitely established and in which an appreciable amount of ore has been and is still being found. It is considered that similar structures may present a major objective for future exploratory work in other parts of the field.

Jan 1, 1964