Search Documents

By N Dube, K L. Sandvik, C Mutevhe

Trojan Nickel Mine is the largest producer of Ni, Cu and Co in Zimbabwe. The mine has operated a nickel flotation concentrator and base metal refinery continuously since 1969, creating 28 million tonnes of sulfide bearing tailings, five million tonnes of permanent waste rock and about seven million tonnes of smelter slag. Exposure of the sulfide bearing minerals renders them susceptible to oxidation in the presence of water and oxygen, resulting in acidic solutions with elevated concentrations of total dissolved solids, sulfate, metals and residual flotation chemicals in various waters draining from the mine site. These pollutants pose a direct threat to the environment and human health, and understanding their deportment and behaviour in the various waste streams is essential in the mineÆs environmental objectives to prevent or minimise adverse impacts arising from its operations. A geochemical assessment of the pollutants was carried out to compute a mass balance between the major sources of pollution and the distribution and fate of pollutants in waste streams from the mine site. Waste rock, tailings, surface water, ground water and sediments were sampled, tested and analysed. Mineral composition and water chemistry data show that geochemical reactions are responsible for the release of pollutants from waste rock, tailings and plant spills. Drainage from the mine area is near neutral due to buffering by magnesium carbonates in the fine fraction of the tailings. The natural wetlands that exist downstream of the waste rock and tailings dams are effective in reducing metal loadings to water courses. However, solutes and heavy metals are occasionally released to surface and ground water, when their concentrations peak during the dry season. The results demonstrate the necessity to understand the natural chemical processes that characterise the distribution of pollutants in nature and how such knowledge can be used to develop cost effective methods to remediate pollution in the natural environment.

Jan 1, 2006

By C A. Chaves

During most of its history, the metallurgical industry has been seen as a source of pollution for the environment. However, during the second half of the 20th century, as the world environmental legislation became more protective and the global environmental conscience consolidated, this landscape began to change. Metallurgical activities have become increasingly related to the social and environmental impacts caused by human activities. With the adoption of environmental management in steel plants, there has been a significant change in steel-related activities which have begun to introduce modern plants, managed with environmental, social and productive efficiency. More and more, steel companies search for a decrease in negative impacts of their industrial operations on the environment, fitting them to the current environmental legislation and even increasing productivity and profitability. The steel industry has started to become a clean and more efficient industry. This work presents a case study of a sustainable steel plant project, located in an environmental preservation area. The project includes treatment and reuse of industrial liquid effluents, air emissions control, noise control, recycling, recovery and adequate waste management. It also incorporates production processes using clean technologies, capable of coproducing energy resources which may be used in the plant showing how is it possible to produce steel with environmental and social responsibility and even increase the enterpriseÆs profitability.

Jan 1, 2009

By G Senanayake, K Hazarika

The demand for iron-ore is ever increasing with the industry directly employing 60 500 people in a range of highly skilled roles in Australia. In the year 2019, the global iron-ore production was 2.85 billion tonnes. It is estimated that each tonne of beneficiated iron ore produces 400 kg of tailings. The IOTs are fine, dense and stable crystalline material mainly composed of iron oxides, alumina and silica. The current and most applied method of iron-ore tailings (IOTs) disposal is using subaqueous disposal of tailings in dams. The footprint generated by a tailings dam is massive and requires constant monitoring due to the possibility of a failure making the operation and maintenance of tailings dam extremely expensive. This review briefly discusses the known causes of tailings dam failures, their impact to the environment and day-to-day human life and potential applications of IOTs. The increase in water content enhances the pressure on dam walls. This in turn increases the liquefaction potential of the tailings and reduces the overall strength of the dam making it more vulnerable to failure. Potential applications of IOTs are in paints, aggregates in construction materials and bricks. The reuse of IOTs reduce waste and generates further revenue facilitating a path towards a sustainable future for the industry.

Nov 8, 2021

By X Hu, Z Pokrajcic, R Embry, P C. Stewart, J Carpenter, E Jones

Whilst the value of Pit to Plant and Mine to Mill optimisation has been proven since the 1990s, sustaining the productivity and efficiency gains typically requires ongoing test work, blast trials, plant surveys, and model calibration services. In contrast, the input to digital twin Pit to Plant or Mine to Mill optimisation is tens to hundreds of millions of tonnes of standard mine operating data. This paper presents a series of digital twin case studies from across the mine value chain, including machine learning testing methodology, model accuracy statistics and the application of Shapley Additive Explanations (SHAP) for model interpretation. These case studies demonstrate how machine learning and data fusion ore tracking connects hundreds of millions of tonnes of downstream performance data to produce digital twin models (operating models that are continuously updated and integrated into the wider Mine to Mill/Pit to Plant ore tracking system). Digital twin modelling software has been used to add block model variables for dig-rate, crusher and mill throughput, recovery (tailings grade), lump yield, product grade and product quality, fines yield and fines in lump. Block-by-block predictions are added to the geological resource and grade control block models as new block model variables. These new block model variables are used across all mine planning time horizons from life-of-mine planning to daily schedules. In addition to the materials handling and geometallurgical prediction case studies, the paper also presents digital twin case studies for drill and blast simulation and plant set point optimisation. The case studies show how digital twin simulation enables drill and blast engineers to simulate the effect of different blast designs in different blast domains using the mines operating data. Plant set point optimisation applies mathematical optimisation algorithms to the machine learning model to provide live operational decision support to metallurgists and plant operators. The digital twin machine learning case studies demonstrate a digital and sustainable paradigm for Mine to Mill and Pit to Plant optimisation.

Jun 22, 2022

By H Bateman, I Cawrse, G Carnes, S Cawrse

In developing mineral resources, the focus typically centres on the management of identified social and environmental impacts and compliance with regulatory requirements. However, opportunities to protect and enhance the environment and communities are most effective in the planning and design phases. Achieving the objective of integrating sustainability considerations as an element of design decision making requires that the design criteria be technically sound, relevant to the project and applicable to desired design outcomes. This is particularly important for projects employing virtual teaming, where design engineers may be geographically dispersed and are unlikely to be familiar with site specific sustainability challenges and opportunities. This paper documents the approach taken by BHP Billiton to incorporate sustainability principles, objectives and guidelines in design criteria for the Olympic Dam Expansion (ODX) project. It describes the range of inputs used in defining sustainability objectives which interface in a framework that is dynamic and transferable to other mining projects and to engineering design in general. The Sustainability in Design Criteria document distils statutory requirements, corporate standards, lessons learned and leading industry practice into a single coherent framework that supports engineers to approach problem solving as a holistic and integrated exercise with a long term perspective. The framework also serves to improve linkages between internal stakeholders by fostering greater communication, collaboration and innovation to deliver more sustainable outcomes through the design process.

Jan 1, 2009

By Whiteman P. C, Stacey G. S, Hunter G. D

Processing of lead-zinc and copper ores by Mount Isa Mines Limited produces large quantit- ies of concentrator tailings waste which is pumped as a slurry to special dams where the solids are allowed to settle and dry out. These areas are unattractive and show no signs of encroachment by plant life even though the surfaces of some dams have remained undisturbed for more than a decade. During 1970 Mount Isa Mines Limited commenced a long term research program in conjunction with the Department of Agriculture, University of Queensland to deter- mine possible methods of establishing a plant cover on this material. Research has defined the major factors limiting plant growth in the tailings medium. Modification of the edaphic conditions through fertilizer inputs, particularly of phosphorus and nitrogen, and alteration of "soil" physical properties by incorporation of mulching mater- ials, provided conditions which allowed plant growth. The outstanding "soil" amendment treatment was incorporation of fly ash, a waste product of the company's coal fired power stations. A range of crop and pasture species have been selected which have grown well with adequate irrigation under the amended conditions in the field. Further research is assessing a range of native plant species and agronomic techniques to provide a stable plant cover on the tailings dams.

Jan 1, 1974

In August, 1975, North Broken Hill Limited announced that an intersection of 37.3 m of high grade lead-silver-zinc mineralisation, assaying 26.2 per cent Pb, 495 g/tonne Ag and 21.2 per cent Zn had been obtained at its Mine at Broken Hill, 520 m north-east of its No. 3 Shaft and slightly below the No. 36 level (1581 m). Subsequent drilling confirmed the presence of the extension of the Broken Hill Orebody on the north-western side of the Globe Vauxhall Retrograde Shear Zone and defined 1.8 million tonnes of high grade mineralisation. The area containing this mineralisation was subsequently named the Fitzpatrick Area in tribute to the late Mr. W.E. Fitzpatrick a former Member of the the Board and Manager of the Ccnpany's Broken Hill operations. This paper describes in brief the exploration programme leading up to the discovery, the general geology of the area and the proposed future exploration progranme for further extensions of the orebody within the mining leases of North Broken Hill Limited.

Jan 1, 1983

By Weber W

Methods of calculation of the reliability of process computers are getting more and more important. The paper presents long period observations of 21 process computers with online applications in the iron and steel industry. About 5000 failure events during 10 years have been systematically recorded and evaluated. On the basis of these long time observations it is possible to develop a probability model of the failure behaviour of process computers.This failure model is constructed with four different states of the process computer:Working phase, working phase with undetected reasons, repair phase, failure phase resulting from external influences.The model is defined by differential equations for the probability of one of these four phases. Long time observations show, that all of these four phases are closely correlated with the capa-city of a process computer, restarting without detection of failure reason, changes of programs and software, costs and time of repair. So the result of this analysis is a model of failure for process computers, which allows to predict breakdowns of process computers on the basis of external parameters.

Jan 1, 1985

By J Zhou, D M. Hunter, S M. Iveson, K P. Galvin

The recovery and concentration of ultra-fine iron ore can provide significant economic benefits. Presently, there are limited options available given the low settling rates achieved by conventional gravity separation and the relatively poor performance of reverse flotation. The Reflux Classifier is a new water-based gravity separation technology that consists of a set of parallel inclined channels positioned above a vertical fluidised section. This arrangement promotes a powerful throughput advantage compared to conventional fluidisation and a highly selective hydrodynamic basis for achieving sharp separations. A high shear rate develops within the inclined channels, which generates sufficient hydrodynamic lift to convey the lower-density particles (even if they are relatively coarse) to overflow while retaining the high-density particles (even those that are ultra-fine) for discharge to the underflow. The technology has previously been used around the world on particle sizes in excess of 0.1 mm. The present work, however, is concerned with density-based separations down to much finer particle sizes approaching 0.01 mm.A major advantage of the Reflux Classifier technology is the achievement of simultaneous gravity separation and desliming via a single-stage separation. A series of continuous experiments was conducted using an iron ore feed with head grade of 35 wt per cent FeT and nominal top size of 0.106 mm, with 59 wt per cent being below 0.038 mm in size. At a low throughput of 1.5 t/(m2 h), the Reflux Classifier produced high-grade products at a high recovery. For the entire feed, grades of 66.1 wt per cent FeT with Fe recoveries of 80 per cent were achieved in a single-stage separation. Within the 0.020–0.038 mm size fraction, grades of 68.8 per cent were achieved with iron recoveries of 94.7 per cent. Excellent recoveries of up to 57.0 per cent were achieved for the -0.020 mm size fraction. The ability of the inclined channels to retain the fine dense material further enhances the effectiveness of the Reflux Classifier by creating an autogenous dense medium effect within the vertical section. This helps to elevate large gangue particles up into the overflow.CITATION:Hunter, D M, Zhou, J, Iveson, S M and Galvin, K P, 2015. Gravity separation of ultra-fine iron ore in the reflux classifier, in Proceedings Iron Ore 2015, pp 143–148 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

This talk was delivered in Kalgoorlie in April this year, to the Kalgoorlie Branch of The Institution of Engineers, Australia. We believe it is of such interest to members of our Institute and readers of this publication we believe it important to extend the audience who have the opportunity to read it. An edited version follows:"Why should we be so concerned about Mining Related Education; after all is said and done, the mining industry is not a great employer of persons?"The mining industry is capital rather than labour intensive. It employs only 2.7 per cent of the national workforce. However; the minerals industry is Australia's major exporter accounting for over 40 per cent of the nation's total export of goods.In Western Australia the value of minerals production in 1985 was about $5,000 million and consequently mineral exports accounted for about 53 per cent of the total value of overseas exports from the State. The diversity of the mining industry is also worthy of mention and produces iron ore, alumina, gold, nickel and mineral sands. That apart, our potential to become a major producer of diamonds, rare earths and petroleum products is considerable, not to mention base metals (copper, lead and zinc) and uranium.Our mining industry is of national importance and contributes in excess of 30 per cent of the total value of Australian overseas trade. Although the mining ind ustry does not employ many people, the people it employs contribute very much more, per capita, to the wealth of the nation than do employees in any other sector of our economy.No-one would deny that during the 20th century Australians have depended on the export earnings from the sale of relatively unprocessed agricultural products and more recently the sale of relatively unprocessed minerals for their standard of living.Not surprisingly, therefore, our economy is highly vulnerable to unstable world commodity market prices.The slump in trade we are currently experiencing (in first quarter 1987-Edition) was brought about by the over supply of the raw materials we produce. However, the recent downturn in world market prices is more serious than previous slumps because in part it is due to technological advances 'in other countries which could have a permanent effect on the world trade of primary products.

Jan 1, 1987

By A Atkins

Six recent case studies were selected based on the eight main causes of mine disasters (Table 1; Quinlan, 2014) and where credible information sources, such as Royal Commission Reports, Coronial Investigations and textbooks, were available. The six case studies are listed below. Details are available via this link or the conference PowerPoint accompanying this paper. 1. Beaconsfield, Tasmania – 2006 Fall of Ground/Seismic Event (Chandler, 2009; Melick, 2007; Wright, 2012). 2. Bingham Canyon, USA – 2013 Manefay Slide (Ross, 2017). 3. Bronzewing, WA – 2000 Hydraulic Fill Inrush (Hope, 2002). 4. Brumadinho and Samarco, Brazil – 2015 and 2019 Tailings Storage Facility (TSF) failures (Bowker, 2019; Darlington et al, 2019; Demajorovic, Lopes and Santiago, 2019; Morgenstern, 2016). 5. Northparkes, NSW – 1999 Cave Air-blast (Bailey, 2003; Hebblewhite, 2003). 6. Pike River, NZ – 2010 Methane Gas Explosion (Macfie, 2013; Panckhurst, Bell and Henry, 2012.

May 5, 2022

The Black Star lead and zinc ore-bodies, situated in the western zone of mineralisation at Mount Isa occupy an area 2000 ft. long with varying widths from 100 ft. to 300 ft. The strike is N5°W, and the average dip 60° West.To test at depth the potentialities of this area, an extensive diamond drilling campaign was commenced on 16th October 1927. It was continued, with from one to six machines working, until the end of 1931. During this period, 26 inclined holes, with an average depth of 1224 ft, and a total footage of 31,828 ft. were completed. A vertical hole, 2452 ft. deep, for comparative purposes, has been omitted.These drilling operations came directly under the charge of G J Gray, General Superintendent of Mount Isa Mines, and, in the early stages were supervised by E. D. McDermott, of the Mining Trust, London. The foremen, who were in charge of various sections of the drilling operations, were: H Vale, F Bray, J Winston and A A Sanstedt.

Jan 1, 1932

The preamble to the mining Act sets out that such Act is to provide for the encouragement and regulation of mining within the State of Queensland. This paper will attempt to follow the legislative path of such aim and in particular to show what part Mining Wardens play in the administration of the Mining Act.The Mining Act empowers the Governor in Council to constitute Mining Districts and Mining Fields and to appoint any duly qualified officer of the Public Service of Queensland to be a Warden or a Mining Registrar. As a matter of practice Stipendiary Magistrates who hold office in the major centre within a Mining District are appointed Wardens and Clerks of the Court are appointed Mining Registrars. In some districts where there is no Stipendiary Magistrate the Clerk of the Court is appointed an Acting Warden with all the powers of a Warden. Every Warden so appointed is a Warden for the whole State.To achieve impartiality Section 74 of the Mining Act provides that a Warden shall not hold or be entitled (directly or indirectly) to the benefits of any share or interest in a mining tenement or mining venture and provides a penalty of $1000 or imprisonment for six months or both, for contravention of such section.

Jan 1, 1986

By B Stump

Reliable particle size analysis in minerals processing plants is a critical factor to the economic return of a plant. As recovery of valuable minerals is compromised for particles outside the optimal size range, effective and reliable particle size analysis is more crucial than ever, particularly in the current upswing of the global commodities market. Inefficient particle size analysis can lead to excessive over-grinding, thereby significantly increasing energy consumption and reagent costs, whilst negatively affecting process operation, thickening capacity, water recovery and tailings disposal.Australia’s first installation of a particle size analyser in Iron Ore has been monitored with great interest by the industry. Previously, manual size sampling at Rio Tinto’s Paraburdoo fines processing plant involved off-site sample analysis, with a turnaround measured in days. The Outotec PSI® 500 particle size indicator, commissioned in July 2009, takes approximately three minutes per line at site.The paper will include details on the following:• plant description,• sampling design,• PSI® 500 analyser functionality description, and• key learnings from site.

Jul 11, 2011

The Health Tracking project is one of five projects being undertaken as part of the Minerals Industry Cooperation Initiative (MICI) û a national initiative sponsored by the Minerals Council of Australia. The aim of the Health Tracking project is to assess the practicality of ways to demonstrate the monitoring of hazardous exposures and the occurrence of related occupational illness and disease and development of management systems and strategies at a national level. This second stage of the project will be completed in 2005 and will cover four areas: pilot development of a comprehensive job exposure matrix (JEM) for the minerals industry; development of both proactive and reactive occupational illness and disease metrics; recommendations regarding appropriate health tracking models; and provision of best practices guidelines for management of occupational health. The synergies between these areas will establish the path towards an effective national occupational health surveillance system and the development of effective prevention strategies and policies.

Jan 1, 2005

By C Claassen, R Balusu

Computational fluid dynamics (CFD) models have been developed based upon field data collected from a longwall mine in New South Wales, Australia to study the behaviour of goaf gas flow in both active and sealed goaf areas. A base CFD model was built to represent the goaf situations when the active longwall retreats near the finish-off line. Results from the base model were calibrated and compared against field goaf gas monitoring data. The base model was then used to carry out parametric studies to investigate a number of operational scenarios and their impact on goaf gas behaviour. CFD modelling results indicate that the overall goaf gas flow pattern changes as the operating longwall retreats towards finish-off line. In all cases, oxygen penetration into the active goaf remains high, reaching 15 per cent or higher, even at some 800 m behind the longwall face.The modelling results also indicated that it would be difficult for early detection of an active goaf heating (on the maingate side) based upon CO readings in the return airflow, as the main stream of the gaseous product will be flowing into the sealed deep goafs in adjacent longwall (LW) panels. Monitoring points (such as tube bundles and bag sampling points) should be selected at deep seated seals along the active goaf so that abnormal CO or C2H6 readings can be picked up for early detection and location of potential heating spots; goaf inertisation can be better achieved by injecting inert gas such as nitrogen at deeper points (>200 m) behind the operating longwall; the injection of in-seam drainage methane into the goaf areas will only have a limited impact on goaf inertisation as much of the injected methane will migrate towards deep and higher parts of the goaf due to its buoyancy effect.

Sep 26, 2011

By L Neindorf

The development and application of paste fill, cement slurry aggregate fill and shotcrete bulkheads at Mount Isa Mines is described. The progressive changes in filling style in the Mount Isa copper mines from a dry fill based cemented rock fill to tailings based paste fill and slurry fills is explained. The development of shotcrete arched bulkheads and engineered drainage system is described. Details on how Mount Isa Mines has achieved approximately 30 per cent cost reduction in backfill operations through innovations are given. The development of a rocky paste fill is explained.

Jan 1, 2005

By P Hatherly, H Gurgenci

With the depletion of the mineral reserves that can be mined by surface mining, demand for highly productive and safe underground mines will increase. Underground drill and blast techniques continue to be refined but true æmass productionÆ is difficult to achieve. As is evidenced by the longwall mining of coal, alternative mining methods based on mechanised mining can meet the expectations but the issues of how to effectively cut strong rocks, how to define the orebody and how the mechanised miners can be automated and maintained all need to be addressed. CMTE is working in all of these areas. We believe that the oscillating disc cutter may provide the long sought-after breakthrough in mechanised rock cutting. Disc cutters are one of the most robust designs of cutting tool and the cutters attack the rock in a manner which effects direct tensile breakage. The internal cutter drive and the inertial damping mean that the already low cutter forces are not all transmitted back to the machine, making it possible to design lightweight, flexible mining systems. For orebody delineation drill monitoring, drillhole logging and geophysical imaging are key procedures being developed at CMTE. To automate mining machines, work is progressing well in the development of systems for autonomous vehicle navigation and mining robotics. A strategic contribution to maintenance issues is being made through the development of procedures for automatic analysis of used oils, monitoring the strength of mechanical structures, and operating point optimisation.

Jan 1, 1998

By Canterford J. H, Sparrow G. J, Dyson N. F

Pressure leaching of a bulk flotation concentrate prepared from a complex Cu-Pb-Zn sulphide ore was carried out at 150 and 190¦C under 1050 kPa oxygen overpressure in 1 L and 4 L titanium autoclaves to extract zinc, and to obtain residues for smelting tests and leach liquors for purification and recovery of the zinc by electrowinning. Dissolution of 95% of the zinc was achieved at both temperatures. Copper and iron dissolution and the degree of oxidation of the sulphide sulphur to elemental sulphur or sulphate depended on the temperature of the leach. At 190¦C, a jarosite (a basic iron sulphate) was the major iron-containing material in a residue that contained 17% total sulphur. Its formation was associated with dissolution of 18% of the iron. At 150¦C, oxidation of the sulphide sulphur and dissolution of the iron were significantly less. Only 7% of the iron was dissolved and a residue containing 25% total sulphur, present as a lead jarosite, lead sulphate, and elemental sulphur, was obtained. The formation of small pellets of unreacted sulphides coated with elemental sulphur caused problems during the leaching at 150¦C, and also during scale-up from the 1 L to the 4 L autoclave at 190¦C. At 150¦C the concentrate required two stages of leaching to achieve dissolution of over 90% of the zinc. These problems are discussed.

Jan 1, 1989

By C Munro, S Emery, M Flynn, K Tan

"AEROPHINE® 3418A Promoter is a well-known and widely used collector and is an industry standard for its excellent selectivity and efficacy in the processing of complex polymetallic sulfide ores, particularly those containing silver. Until now, however, it has not found widespread use in primary nickel flotation.In an effort to increase nickel recovery without compromising selectivity over iron sulfides, Western Areas Forrestania Nickel operation trialled the use of AEROPHINE® 3418A as a secondary collector at low dosage. A series of ON/OFF trials were conducted, with the finding that a very low dose of AEROPHINE® 3418A increased nickel recovery by 0.6 per cent compared to using xanthate alone.This paper provides a brief operational history and overview of the Forrestania operations, a description of the trial and an analysis of the results.Citation:Emery, S, Flynn, M, Tan, K and Munro, C, 2016. Aerophine® 3418A Promoter as a Secondary Collector to Boost Nickel Recovery at Forrestania Nickel Operations, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 145–148 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016