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With the iron ore industry in Australia producing hundreds of millions of tonnes of ore per annum, the associated costs of these operations extend into the billions. It is no surprise in the current economic climate that more and more companies are looking into different ways of optimizing their costs to keep their sites operational. One way of improving operations is the use of electronic initiating systems like i-kon and Uni tronic detonators. These systems have been used around the world to improve current practices and optimize drill and blast costs. However, these systems have yet to make an impact upon the iron ore sector in Australia. Some of the potential improvements include:pattern expansion and a subsequent reduction in drilling and explosive costs;improved fragmentation and hence increased dig rates, thereby driving $/tonne down;embracing the 'mine-to-mill' concept by reducing the downstream costs of crushing and milling;improving the overall condition of pit walls and floors, leading to a safer working environment in which optimal haulage performance can be achieved; and improvements in vibration management around heritage sites and critical infrastructure, thereby saving the cost of relocation works. This paper introduces some of these concepts and the process of making the changes leading to potential savings from the improvements, using various examples as proof of the concepts.

Jan 1, 2009

By L Boczek

The term Engineer of Record (EoR) is commonly used in North America and South Africa to define the responsible person for the design, construction and operational phases of a tailings storage facility (TSF). Recently, this role has been elevated in prominence within Australia, but what does it really mean? Recent updates to international TSF guidelines suggests appointing an EoR is good practice, but where does the responsibilities of the EoR start and finish. Interestingly, both Samarco and Mount Polley failures had active EoR’s in place. This suggests that nominating an EoR alone, is not the full answer to mitigating the potential for a TSF failure. Appropriate construction and operational practices are key to the success of the design of TSFs, where all too often, operators ignore the operating plans developed by the designer. To be successful, a key consideration of the EoR role, is involvement in the operational phase of the TSF. This requires ‘buy-in’ from the mine managers and a change in the way TSFs are perceived by site. This paper explores how the roles and responsibilities of the EoR can assist in improving governance of TSFs if implemented effectively and what role the client has to ensure the success of the EoR.

Jul 1, 2021

By D A. Sims

This paper outlines the contributing factors to a series of erroneous Mineral Resource estimates which led to considerable loss, including significant reduction of mine life and consequently a large write-down of asset value. The error prompted divestment of the mineral asset in the short-term by the owners, a major mining company. There were multiple and complex contributions to the result: • The mine was undergoing a transition in the deposit geology with increasing depth that was not accommodated in the models. Early indications of the geological transition in initial drilling were generally unrecognised in resource modelling. The shortcomings of the models became apparent with increasing infill drilling and subsequent production reconciliation. • There was a lack of recognition of, and confidence in, site-based input and skills by corporate technical management. The site had a reputation internally for over-delivery to plan early in its life and that supported the anticipation of ongoing metal delivery into the mine plan by management. • A corporate lack of confidence in site being able to adequately domain the mineralisation led to the use of a CIK domaining process, rather than one which was geologically based. This domaining process led to gross over-statement of mineralisation trends reflected in the subsequent OK estimate. • Timelines on the outsourced estimation process were so short that validation was not possible. Obvious errors in the estimate versus data were not able to be used to correct the issues and the site’s Competent Person sign-off occurred without adequate checks. This case study is presented to reinforce the concept that Mineral Resource estimates are not solely based on the ability of the Competent Person to satisfactorily guide the process. There are usually multiple complex issues in the estimation process which need to be recognised and considered in judging reconciliations of model to actual.

May 24, 2023

By B Young

Variable bench heights, interaction with underground workings and a steeply dipping orebody are challenges faced daily by geologists at Xstrata Zinc’s Black Star Open Cut (BSOC) Zinc/Lead/Silver mine in Mount Isa, Queensland.BSOC has been in operation since late 2004 and was developed to extract the surface extents of the Zn/Pb/Ag mineralisation mined in the underground lead mine. To date many large scale stopes and extensive development drives have been intersected and successfully mined. The stratigraphically hosted orebodies strike in a north-north westerly direction, dipping ~75° west. Ore production from the pit is currently at 4.5 Mt/a.Historically, sampling was conducted using a multiple spear technique from blasthole cuttings. This method proved to be relatively reliable when blasting benches at a consistent height, but a requirement to vary bench heights to safely collapse and then mine through underground workings reduced sample representivity to unacceptable levels.The purchase and commissioning of a production rig which had been converted for reverse circulation (RC) has allowed for the flexibility of a small rig, with the capacity to easily drill 48 m holes while ensuring sample quality. Sample quality is not the only benefit of introducing RC grade control. By collecting grade control data well in advance, informed decisions can be made by planning, drill and blast and mining departments weeks beforehand, rather than hours before firing. Additionally, seeking operational value to offset higher drilling costs has proved positive with benefits including increased confidence in orebody wireframes, accurate tonnage and grade for proceeding five benches along with the ability to representatively test metallurgical response on a tight grid spacing.

Aug 22, 2011

By C Jones

Ridgeway Deeps is a block cave (BC) located down dip of the operating Ridgeway sublevel cave (SLC) mine. The BC is located approximately 210 m vertically below the lowest SLC level and approximately 1100 m below surface. Due to the mine layout containing a number of common pieces of key infrastructure the activities of both were interlinked.When investigating project construction options for the BC, a number of potential risks were identified including a conflict of priorities between operational and project deliverables and the varying safety and work methods between an owner mining approach in the SLC and a potential contractor workforce in the BC. This led to a review of the construction philosophy and the opportunity to utilise the existing SLC workforce as the basis of all activities in the mine. It was identified that a number of synergies existed with the current SLC operators and mine supervision including common work practices and the opportunity to build on the unique SLC skills of the operators and supervisors which could then be used at other Newcrest caving mines.With the commitment to this philosophy of building on the existing SLC crews and supervision the number of employees reporting through the superintendent underground operations grew from 95 to 245. This increase led to a restructuring of the reporting and work requirements of the superintendent, foremen and shift bosses. In order for the foreman and shift bosses to focus on running the larger crew numbers for the full 12 hour shift the mine superintendent became a pseudo human resources manager taking over all non-mine focused activities including overtime allocation and work and behavioural performance management. In simple terms, ensuring there were competent bums on seats when and where required. As the additional workers were recruited to top up the existing employee numbers, their employment history was used to place them in the most suitable roles. For example, those with building industry experience were placed on the civil construction crews and those with a farming background were used as truck drivers, nippers or on the service crews. To cope with the increased number of new starters a number of key personnel were seconded from the crews into the training group to act as on shift trainers. This initially caused a reduction in mine performance as the main operators were reassigned but it proved a valid move as the time for new operators to reach acceptable levels was significantly reduced with safe operating standards being maintained. This paper discusses how the Ridgeway Deeps Project was delivered on time and under budget whilst at the same time retaining its position globally as an operation to be benchmarked against.

Mar 21, 2011

By C Lutherborrow

The Sangdong Tungsten/Molybdenum Deposit is located in the Republic of Korea and was discovered in 1916. At this time Korea was a colony of Japan. It was mined for two years after discovery closing in 1918. Full production recommenced in 1933, and from that point until 1945, it was the major source of tungsten for armour plate for the Japanese military. After World War 2 the US government ran the mine until late 1946. The mine operation then passed to Korean ownership but production ceased during the Korean War and did not recommence until late 1953. The mine ceased operation in 1992 due to low metal prices. From the late 1960s to the time of closure, Sangdong was the largest tungsten mine in the world (Kim, 2002). An understanding of changing mining methods over time has been critical in assessing the potential of redeveloping the Sangdong Deposit.

Aug 22, 2011

By I Brandes de Roos

Water has played a key role in the Pilbara’s 60-year history of iron ore operations. In contrast to many of the current-day mining environments, iron ore mining was initially hosted by geological formations that were typically above the water table. Such mining operations required no dewatering or dewatering at rates that were less than mine and mining township requirements. The challenge for these operations was not pit dewatering but water supply for mining operations and municipal supply for nascent mining towns.The current industry sees new deposit styles being increasingly targeted, including channel iron and Marra Mamba Formation deposits. These deposits are often lower in the landscape and can require extensive dewatering. Furthermore, increased water demand for ore beneficiation has resulted in major programs of water-supply borefield development. Added to this is the emergence of magnetite projects and their significant levels of water use in ore beneficiation.The large volumes of water that are being extracted to support Pilbara iron ore mining is attracting attention. The Western Australian Department of Water has recently commissioned a study to assess the potential use of surplus mine water as a medium- to long-term supply for irrigated agriculture.This paper outlines the changing landscape of water management in Pilbara iron ore operations and explores strategies for maximising mining productivity. Water management is presented as an enabler for productivity improvements that can potentially provide long-lasting benefits post-closure.CITATION:Brandes de Roos, I, 2015. Shifting waters in the Pilbara’s iron ore industry, in Proceedings Iron Ore 2015, pp 507–510 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

Most new engineers in the mining industry do not realise the importance of legal obligations. During investigations the first question you are asked is: Do you have any proof or evidence? The smallest detail in an underground notebook or a diary entry is able to be used as your proof and/or evidence. The importance of a paper trail is often undervalued and overlooked when you first enter the industry. As a new engineer, all too often your legal obligations, including your duty of care are not given enough consideration. Whose job is it to inform you of what your legal obligations are and when do they end? Everyone has legal obligations at every level of the industry, from graduate to mine manager. The level of these responsibilities varies depending on the position that you hold. When you first start in the industry you need to understand what your responsibilities are and how you are expected to discharge them, whether they are memos, databases or senior sign-offs, etc. In order to fulfil your obligations you must first discharge your own obligation, which in turn discharges those of your department and ultimately those of the mine. As a graduate engineer in the mining industry what I have learnt about my own legal obligations has come directly from my own experience, which will form the basis of this paper.

Jan 1, 2007

By R Jia, J T. Waldram

"The Caijiaying lead zinc mine is located in China, north-west of Beijing, in Hebei Province. The region experiences severe winters, below -35°C, and warm summers, up to 30°C. The mine and concentrator commenced operations in the second half of 2005 with a conventional tailings disposal system consisting of a tailings dam with peripheral ring main discharge and central water recovery. A second similar dam sharing one common wall was added later. In view of the extreme winter conditions tailings lines and ring mains plus spigots, together with return water lines, require insulation and electrical trace heating. The volume of process water trapped as ice in the tailings dam ponds each winter is significant. This seasonal variation presents a major difficulty in the management of process water availability. Although Caijiaying is an underground mine there was no backfill plant at the start of operations. As plant throughput increased more quickly than originally anticipated, tailings storage capacity became a prime concern. The construction of a backfill plant in 2007 reduced the pressure on surface tailings storage area requirements, but as suitable land on which to construct further tailings storage was both expensive and difficult to acquire, a more efficient use of the available area was required. Dry tailings storage, where flotation tailings are filtered to provide an immediate return of process water plus ‘dry’ tailings filter cake for stacking, provided an answer to both the land area required, and the water management difficulties. The paper details the reasoning behind the change and the benefits obtained at Caijiaying by moving from ‘wet’ tailings storage to ‘dry’ tailings storage.Citation:Waldram, J T and Jia, R, 2016. Caijiaying Dry Tailings Storage, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 379–382 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By B W. Atkinson

Full-stream mechanised sampling apparatus, that collect a full cross-sectional increment from the complete screen discharge, will always be the preferred option for sampling screen overflows. However, the reality is that provisions for automated sampling are rarely, if ever, provided at the discharges of individual screens within beneficiation plants.Sampling from the discharge of high capacity vibrating screens, especially multi-slope screens, is subject to sampling bias, due to the stratification of the ore that occurs on the vibrating screen deck. The stratification in the vibrating bed translates to a stratified falling stream at the discharge end of the screen, typically with smaller particles at the back of the falling stream and large particles at the front of the falling stream (Figure 1).The chemical and physical characteristics of heterogeneous ore (mineral or coal) particles vary significantly with particle size. If samples do not correctly reflect the source material size distribution, they will be biased and the resulting analytical/assay data will not reflect the actual physical nor chemical characteristics of the source material.Prior published data for coal preparation research (Australian Coal Association Research Program) has demonstrated that a bias appears to exist for samples collected from high capacity multi-slope screens.A new form of sampling scoop has been developed with the aim of overcoming this issue.Bias was evaluated at a coal preparation plant by comparing the desliming screen overflow size distribution to that for æreferenceÆ coal preparation plant feed samples collected using the recognised stopped-belt technique. The study procured 20 sets of comparison samples in order to ensure statistical relevance.Two forms of sampling device were employed for the multislope screen discharge.A conventional square aperture scoop was demonstrated to exhibit a significant coarse bias, in that the resulting samples exhibited a significantly coarser size distribution compared to the reference samples. In other words it was evident that the conventional scoop æfavouredÆ material from the front of the falling stream.A new æcollapsibleÆ sample scoop was evaluated in parallel, and its samples were found to exhibit no relevant bias.CITATION:Atkinson, B W and Swanson, A R, 2012. A new method for sampling from high capacity screens, in Proceedings Sampling 2012 , pp 89-94 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 21, 2012

By M Parcell

"Ventilation risks in an underground mine have essentially remained the same for centuries, yet theevidence suggests that there are many coal mines that have failed to adequately control these risks.The conduit for the knowledge learned by previous generations exists in the mining legislation. In an ideal world, mines would not need legislation to tell them what to do; they would resolve the risks to an acceptable level so as to protect the safety of persons in the mines based on the acquired knowledge. There will be some who have been personally aff ected by a mining disaster but for the majority they will be remembered as a vague recollection of an event from long ago. The mining legislation is the repository for the knowledge and outcomes from inquiries of past disasters. The challenge for the current generation, and the generations to come is to appreciate the legislation that exists, so as to not ælearn the hard wayÆ. In reviewing most disasters there is comment or discussion on the adequacy of the legislation, which ultimately results in some amendment to the law. For each person, there is an increasing responsibility to ensure that the same mistakes are not repeated. Understanding the legislation, its history and its purpose is the fi rst step in ensuring thatventilation risks are eff ectively managed. Failing to do this will be disastrous. This paper discussesthe relevance, importance and potential pitfalls of coal mine ventilation regulation."

Jun 1, 2012

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 O Dominguez

Significant value can be added to ore supplied from the mine to the mill by measuring its quality in real time and performing grade control additional to that within the mine. Responsibility for ore quality between the mine and mill stockpiles is not always clear due to operational siloes so geologists and mining engineers need to be involved collaboratively with metallurgists to optimise ore value prior to processing. Sensors, such as the GEOSCAN-M which utilises high specification Prompt Gamma Neutron Activation Analysis (PGNAA), that measure conveyed ore flow representatively (continuous and fully penetrative) and in real time have been used in the minerals sector since 2003 and have been successfully applied in multiple commodities. Quality can be measured within the mine where material is conveyed underground or in-pit. Bulk ore sorting is used to divert increments of waste from the ore stream to upgrade material sent to the crushed ore stockpile (COS) as well as to create run-of-mine (ROM) stockpiles of different qualities to maximise blending opportunities and accommodate processing priorities, eg blending out deleterious content. The real time composition measurement can be combined with moisture and fragmentation analysis data for improved ore type characterisation, to control ore blending, for feedback to the mining schedule and block model reconciliation, and feed forward control for grinding and processing operations. The paper discusses various parameters measured and derived in existing operations that are used to maximise coarse waste rejection and metal recovery, optimise plant feed quality consistency, and reduce consumables; power, grinding media, water, reagents, and minimise fine tailings generation. Innovative geometallurgy applications are also discussed.

Mar 22, 2022

By H Kim, J Park, J Lee

Silico-ferrite of calcium and aluminium (SFCA) is a bonding phase in the iron ore sinter. The phase transition upon melting of SFCA was investigated with Differential Scanning Calorimetry and Confocal Laser Scanning Microscope. The initial melting of SFCA occurred at 1183.2°C and a massive melting was found at around 1351.1–1358.2°C. A phase transition-melting was investigated at 1476.5–1478.7°C. The liquid phase was composed of immiscible phases. The present results would be utilised to design a new iron ore sinter for better processing performance in a hydrogenenriched ironmaking process.

Jun 19, 2024

By D Woolmer

Since January 2019, BHP Olympic Dam have been trialling the use of a drone based LiDAR mapping system for the purpose for surveying stope voids. This new technology utilises Simultaneous Location and Mapping (SLAM) algorithm providing positioning, stability and collision avoidance in GPS denied environments. Implementation of this system utilised underground personnel trained in the equipment’s use. The study’s intention was to evaluate the effectiveness of this equipment versus traditional surveying methods in regards to quality, safety and productivity. The trial results showed a marked improvement in the quality, productivity and personnel safety when conducting surveys. The use of the drone and LiDAR system reduced personnel and equipment requirements for surveys, thus allowing these resources to be deployed elsewhere. The technology’s simple and rapid deployment allowed multiple surveys to be conducted during a 12 hour shift, including ad-hoc work with minimal disruption to underground operations. After the drone’s initial trial, further work was conducted to utilise the Hovermap LiDAR scanner on other platforms to increase utilisation. A mounting system was created allowing the LiDAR to be mounted on a remotely operated loader or vehicle. This enabled drawpoint scans to be taken directly after production completion, resulting in faster stope close outs and drive scans for convergence monitoring. Implementation of the LiDAR system has resulted in improvements in the stope production cycle by reducing delays previously associated with data capture. The increase in the volume and quality of data has also allowed in-depth back-analysis of stopes in new mining areas to be conducted, which have driven improvements in the design process.

Mar 15, 2021

By C Buchanan

For a long time there has been a known relationship between the northern Heavy Mineral (HM) deposits of the Murray Basin to the extensive north east trending ridges in the area. These ridges have been a targeting tool for exploration and have uncovered some significant discoveries, some of which have turned into mining projects. Bemax’s Ginkgo and Snapper deposits are good examples of how the faulting helped create an economic deposit but also result in significant planning issues in the exploitation of these deposits. Material balance, induration and pyrite issues have been made easier to manage through good geological understanding of the deposits.

Aug 22, 2011

Mr GEPP said: "He proposed at the outset to draw attention to figures dealing with the population of the countries adjacent to Australia for the purpose of comparison with the population of the Commonwealth. He would deal more particularly with the areas of land surrounding the Pacific and Indian Oceans. Korea and Japan had a population of 18,000,000 ; China, 437,000,000 ; Persia, 9,000,000 ; Arabia, 5,000,000; South Africa, 129,000,000; Madagascar, 3,500,000 ; India, 251,000,000; Siam, Indo-China, and so forth, 16,225,000; Federated Malay States, 3,225,000; and, very significantly, Java, only four and three quarter days from Fremantle, over 50,000,000. From the map displayed an idea of the comparative areas of the countries mentioned and Australia could be gained. It was rather amazing that Australia, with its great potentialities, had only about 5,150,000 people. New Guinea had over 750,000 people; Hawaii, a mere speck, 250,000; New Zealand, 1,300,000; North America, 130,000,000; Central America, over 15,500,000; and South America, over 65,000,000. Colombo was only six days from Fremantle, and it was only nine days from Capetown to Albany, and eight days from Albany to Hobart. Proceeding, Mr. Gepp said "It was in 1911 and 1912 that I had the good fortune to spend nearly twelve months in Europe, and during the course of my work in England and Germany to have the oppprtunity of studying both the economical and political systems in some detail... I was in Berlin at the time of the visit of Lord Haldane, when an effort was made by the British Government to arrive at some under...

Jan 1, 1923

By S Graskoski

The allocation of boggers and trucks at Telfer’s sublevel cave mine is currently assigned by manual techniques, with decision-making primarily dependant on the judgement of the operators and mine control. Field observations indicate that allocation decisions could be improved by establishing a systematic approach to dispatch. An investigation into the current state of technology determined that no currently available solution would provide a tool to make optimal decisions for the Telfer dispatch challenge.In an underground sublevel cave (SLC) environment, the destination decision is fixed and the source is variable, so open pit and block cave solutions are not relevant. Newcrest underwent a development venture with an external vendor to develop a novel production dispatch algorithm and user-friendly software program to make allocation decisions in a systematic way with consideration given for the true complexity of the operation.This new production software, nicknamed Dingo (for Dispatch ‘n’ Go), is a smart way to assist forepersons and mine control operators in their day-to-day roles of planning shifts and allocating trucks and loaders to optimal locations during shifts.CITATION:S Graskoski, 2017. Dingo – an optimisation tool to solve complex short interval control at Telfer underground mine, in Proceedings 13th AusIMM Underground Operators’ Conference 2017, pp 261–266 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Oct 16, 2017

By T D. H McGrath, R Byleveld, W P. Staunton, J J. Eksteen

"The Gold Technology Group at Curtin University through the AMIRA P420 series of projects has recently developed the integrated liberation leach model (ILLM) for optimisation of gold plants. The model encompasses recovery by both gravity (batch centrifugal concentrators or BCCs) and leach adsorption (CIP/CIL) circuits. The ILLM essentially combines the Group’s well-known standalone models (ie gravity and SIMCIL) to create a robust simulation package.The ILLM process model provides a tool for sites to determine optimum set points for operations to optimise recovery (eg target grind size). It can also be used to predict the effect on gravity recovery, leach recovery and overall recovery when changes are made to circuit design, either temporarily (eg a leach tank taken off-line for maintenance) or as part of a circuit expansion (eg expanded gravity circuit capacity, or addition of leach tank capacity).This paper discusses the capability of the ILLM process model by highlighting a recent case study. The paper also addresses the test work and plant data required as model inputs, as well as limitations and the application of the ILLM to greenfield projects.Citation:McGrath, T D H, Staunton, W P, Eksteen, J J and Byleveld, R, 2016. Application of an Integrated Liberation Leach Model for Process Optimisation, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 173–178 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By J Webb

"It is vitally important in projects where the cut-off grade is low that there is no contamination during the sampling and sample preparation process, both in the ore and the waste zones. Failure to identify contamination could have devastating financial consequences for a project. The use of a variety of blank types is essential for ensuring that contamination is identified and eliminated at every stage of the sampling and sample preparation process. This paper examines an instance where an effective assay quality assurance and quality control (QA/QC) program was able to identify and eliminate a source of significant multi-element contamination in the prefeasibility stages of an open pit project. This examination includes the: evidence for contamination findings of the investigation process of resolving the problem and correcting the data evidence for both addition of metal and dilution through contamination potential impact on the project had this issue not been dealt with. It was through the use of a combination of blank types that the QA/QC process at Mount Isa Mines (MIM) identified a contamination issue at the first crushing phase of sample preparation. Identification of the contamination allowed MIM to stop assaying activities and work with the laboratory to correct the problem. The sampling program could then be continued with no further doubts about the sample preparation process. Contaminated samples were resampled from retained core. With the continuous monitoring provided by the blanks program, it was possible to ensure that only clean results went into the resource modelling data set. CITATION:Webb, J, 2014. When nothing is what you need – the importance of using blanks at all stages of sample preparation, in Proceedings Sampling 2014 , pp 49–54 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Jul 29, 2014