Search Documents

By Shanahorn C

During the last decade the proper training of operating and maintenance staff has been recognised as directly contributing to the successful startup and continuing operations of a metallurgical project. During this period Bechtel has assisted clients in the design, development and implementation of such training. The clients have been located in Australia, Papua New Guinea, Africa, China and North America. The programmes have addressed mobile and fixed plant operations and maintenance in coal, copper, gold, borax and other mining environments. The level of sophistication has varied from highly structured and documented instruction to less formal, yet controlled efforts to reorient and enhance the skills of experienced workers to training personnel with no previous work experience. Many lessons have been learned, some easier than others. This presentation will recount the elements of various projects which enhanced and detracted from the cost-effective achievement of the goals which training was

Jan 1, 1986

By Young JA, Rogers G, Bannister S, Edwards SA

Many coal mine operators have responded to economic pressures by massive investment in machinery to reduce unit costs. To sustain the increased production which must justify the expenditure it is essential to know the resource in great detail months or even years in advance of its extraction. The required detail includes variations in composition and any lateral disruptions to the seam which night affect production. As Wilson (1985) has pointed out, a day's production loss can mean half a million dollars income forgone, and an unexpected major fault can mean a shutdown of weeks. Traditionally, seams were probed by surface drilling on (typically) 250 or 500m centres, and by horizontal drilling from sithin'the seam. Core was analysed chemically. The new generation machinery cannot tolerate the risk attendant on such widely spaced sampling, but the costs of much closer sampling rapidly become prohibitive.

Jan 1, 1987

By D M. Weedon

This paper introduces a novel roll crusher design, which incorporates non-cylindrical crushing rolls. The use of non-cylindrical rolls enables the crusher to achieve a greater reduction ratio than is possible with conventional roll crushers. Referred to as the NCRC (non-cylindrical roll crusher), the new crusher incorporates two rolls comprised of an alternating arrangement of plane and convex or concave surfaces. The two rolls are complementary and arranged so that when they rotate the convex and concave surfaces of each roll are substantially opposed. With the rolls rotating in opposite directions at the same speed, this arrangement produces a gap between the rolls that remains approximately constant. Discontinuities on the roll surfaces provide improved angles of nip, which increase the probability of larger particles being drawn into the crusher. Initial tests on a scale prototype of the NCRC have indicated that reduction ratios exceeding 10:1 are achievable.

Jan 1, 2000

By R O. Laidlaw, J L. Mauk

The Coeur d'Alene mining district in northern Idaho, USA is the second largest producer of silver in the world. Mesothermal silver-lead-zinc veins occur in the metasedimentary rocks of the Belt Supergroup with five main types of associated hydrothermal alteration: 1) feldspar destruction, 2) hydrothermal bleaching, 3) carbonatisation, 4) sulfidation, and 5) silicification. Hydrothermal bleaching is characterised by hematite destruction with associated siderite and quartz veins and veinlets, coarse euhedral pyrite and magnetite. Bleached zones envelop both mineralised and barren veins and extend for metres to tens of metres into the wall rocks. Carbonatisation consists of addition of siderite, which occurs as veins, veinlets, stockwork, irregular blebs or spots, and coarsely disseminated grains, depending on the relative distance from the main vein structure. Siderite envelops nearly all mineralised veins, relates to all other alteration types and extends from several metres to tens of metres into the wall rocks. Pyrite and galena alteration dominate sulfidation and are associated with some mineralised veins. Pyrite alteration strongly correlates with siderite alteration and exists in three main forms: a) very fine-grained pyrite flooding, which can extend for metres to tens of metres into wall rocks; b) coarse-grained, euhedral pyrite, which is sporadic and associated with the redox boundary in hydrothermally bleached zones; and c) small isolated zones (6 - 15 cm) of medium-grained, subhedral to euhedral pyrite associated with pervasive siderite alteration. Where present, disseminated galena extends for metres to tens of metres into the wall rocks. Silicification is characterised by veins, veinlets, stringers, irregular patches and variable hardness in siltites and commonly appears in association with hydrothermal bleaching and siderite alteration. Although related to mineralisation, silicification is sporadic and in most places a clear envelope around mineralised veins cannot be identified.

Jan 1, 2001

By S Bluhm, R Funnell

Creative mine-designs are constantly being applied in the deep platinum mining industry in South Africa. Recently, this has resulted in deep hot mine-designs including room and pillar, bord and pillar or stall and pillar layouts and the use of in-stope trackless mechanisation. In these mines, the ventilation systems use refrigerated air and high fan pressures and as a result ventilation leakage can have a huge impact. Leakage is a serious impediment to cost-effective operation and potential leakage in future projects is a major factor in judging project viability. This paper describes certain mine layouts and quantifies the extent of the leakage. Based on typical field data, a range of seals from ævery poorÆ to ævery goodÆ was defined and used to estimate overall leakage. Within these mine networks the ventilation pressure, temperature and density all vary significantly and with the multiplicity of leakage paths it was necessary to make use of the VUMA-network simulation package. For the examples examined, the leakage was found to be up to 85 per cent for æpoorÆ category seals and up to 50 per cent for ægoodÆ category seals. The total air flow (and refrigeration) requirements grow exponentially with strike distance due to the compounding effects of higher pressure and more leakage paths. It is shown that beyond certain depths and strike distances the leakage will become so great that it will be impossible to operate cost-effectively û even with ægoodÆ seals. Indeed, in these examples the projects were not considered viable in their original format because of the high ventilation-cooling costs and the mine-designs were modified to include footwall drive systems û the cost of which was justified by the reduced strategic risk to operating ineffectiveness due to leakage.

Jan 1, 2005

By J O. Watson, V S. Vutukuri

This paper presents results of an investigation on acoustic emission characteristics of granite, sandstone and rock-like material in the unconfined compression and tensile tests. Both the acoustic emission signature and stress-stain curve are analysed in the experiments.The experimental results show that different acoustic emission characteristics are observed at different stress and deformation stages in unconfined compression and tensile testing. Extensive and unstable acoustic emission changes may be interpreted as indicating failure of the rock.

Jan 1, 1999

By C Hall, K Williams, B Keogh, S Wong

Cannington mine is a silver lead zinc operation located in north west Queensland. The operation has been in production since 1997. Ore is primarily moved through an underground material handling system comprising of a crusher, conveyor and hoist. The underground crusher and conveyor system were sited in lower grade ore when the mine was first commissioned. As Cannington is now a mature operation, this ore is considered run of mine and stoping progressed into the crusher exclusion zone. As the stoping fronts advanced there was increased damage on the crusher chamber and infrastructure. In response to monitoring data, the crusher monitoring system was significantly upgraded in 2016. The monitoring system included rock mass and infrastructure instrumentation. It improved the understanding of stress impacts and mechanisms driving the damage within the chamber. It allowed the site geotechnical team to respond to changes utilising ground support, mining sequences and increased levels of monitoring. As stoping and damage to the rock mass continued, so did the process of responding to monitoring data. Ultimately, the monitoring system enabled a safe and controlled closure of the chamber. CITATION:Williams, K, Keogh, B, Hall, C and Wong, S, 2018. Monitoring as an input to support and sequence design, in Proceedings The Fourth Australasian Ground Control in Mining Conference (AusRock), pp 446–452 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 30, 2018

By S Latchireddi

Close circuiting autogenous and semi-autogenous mills is an energy efficient way of grinding and a number of operations have utilised this in the design of their comminution circuits. Owing to the large flow of slurry through the mill that results from operating this way the grates and pulp lifters have to be designed to cope. However, the literature has little or no information on how grate and pulp lifter size and design are related to their ability to remove slurry from the mill. Over the last few years the JKMRC has been researching this area and has developed relationships between grate/pulp lifter design and flowrate capacity. At the same time it has determined the major causes of pulp lifter inefficiency and a solution to preventing this inefficiency (the Twin Chamber Pulp Lifter). This paper describes the models that have been developed through this program and uses industrial scale data to illustrate their accuracy. Results from the industrial trials of the Twin Chamber Pulp Lifter are also presented.

Jan 1, 2000

DCF Valuations are very important to individuals and companies involved in the mining industry. Such valuations are critical to investment decisions in relation to new and existing projects. In particular they provide fundamental information to shareholders in the event of a capital raising or takeover and to financiers supporting mining companies and projects. Also, DCF Valuations are often used to support asset carrying values in the financial statements of mining companies. This paper presents a Chartered Accountant's (CA's) perspective on the main issues to be considered in preparing, analysing and relying upon DCF methods in mineral valuations and provides some practical examples relating to key issues. The paper makes the important point that DCF methods involve making assumptions about future events and circumstances that inherently contain uncertainty which results in a valuation prepared on a DCF basis providing a range of values that are not perfect or accurate. In order that DCF valuations provide meaningful information the underlying methodology used and assumptions made must be consistent, sound and well supported. Credibility of those involved in preparing mineral valuations is vital and this paper supports the adoption of sound practices by all concerned.

Jan 1, 1994

Over the last 15 years working in the mining, construction and extractive industries, one of the areas that has always concerned and at the same time drawn the author to it is the application of drilling and blasting in the underground development mining and civil construction tunnelling fields. In that time, the author has come across many drives and tunnels that are larger than design or badly damaged in the perimeter or both. When the question is asked as to why this is the case, the reply is generally æthatÆs the way it is and always has beenÆ. Sometimes it is blamed on bad ground, bad drilling, bad explosives, bad initiation or just plain bad. Most operators build a dilution factor into development and tunneling costs as an acceptance of overbreak and similarly pattern bolt everything to overcome excessive perimeter damage. This paper will attempt to unravel some of the mysteries behind perimeter drilling and blasting in underground drives and tunnels and discuss methods to reduce overbreak and therefore reduce costly dilution and to minimise perimeter damage which in turn will allow more cost-effective ground support. It should not be assumed that better drilling and blasting alone would automatically allow an operation to reduce ground support. The operator must still æreadÆ the ground and its characteristics in order to ensure sufficient ground support is placed to allow the operation to progress safely. This paper will not go into the intricacies of bolting, meshing, shotcreting, concreting and other ground support, but it will use indicative costs for the primary areas of drilling, explosives, excavation and labor to show the magnitude of cost-efficiencies which can be obtained through improved drilling and blasting applications. Drill and blast remains the most flexible and cost-effective method of underground excavation as long as it is applied safely and effectively.

Jan 1, 1999

By P J Savory

Ranger is a uranium mining operation located within one of the most environmentally sensitive regions of Australia. Geology has played an important role in mine planning, operations and rehabilitation since discovery of the deposits 25 years ago. The Ranger orebodies have a reserve total of 166 300 tonnes of U308 including 90 400 tonnes of U308 at North Ranger. At current milling rates these reserves give a mine life greater than 40 years. The uranium is hosted in Lower Proterozoic rocks of the Cahill I ormation and is associated with strong chlorite alteration. In pit grade control involves the use of calibrated probes and a radiometric truck discriminator allowing fast, accurate grade determination of material. Ore is defined at a cut-off grade of 0.2 per cent U308. Mineralised material is defined by the Uranium Mining (Environmental Control) Act 1979 (UMEC Act) at a grade of 0.02 per cent U30s. Natural water levels in the #1 Pit area vary as much as 7.5 metres between wet and dry seasons. Ground water inflow into the pit during the dry season is 600 m3/day. No significant slope failures have occurred in the pit. The environmental impact of mining operations is constantly monitored. Rehabilitation of non-mineralised stockpiles is ongoing. This paper discusses the interaction between geology, hydrogeology, rock mechanics and grade control with the present mining operation.

Jan 1, 1994

By G J. Harbort, V Lawson, L Reemeyer

The Jameson Cell is a high intensity flotation device, which utilises induced air from the atmosphere. It was developed jointly by Mount Isa Mines and Professor Graeme Jameson of the University of Newcastle in the 1980s. It is proven to generate fine bubbles, in the order of 300 to 500 ¦m, in a high intensity, high shear and compact zone contained in the downcomer. This aerated mixture exits the downcomer into the pulp zone, which is the quiescent mineral and gangue separation zone. A number of Australian base metal flotation circuits feature a reverse flotation stage at the head of the circuit. Testwork and plant operating data has shown that the use of a Jameson Cell in the prefloat cleaner application has further improved prefloat gangue recovery and selectivity. Operation of a Jameson Cell in a carbonaceous/pyrite prefloat cleaner duty at the Mt Isa copper concentrator increased copper recovery and reduced pyrite in the copper concentrate. Testwork at Zinifex Century Zinc Mine showed a decrease in zinc losses by the utilisation of Jameson Cell prefloat cleaner. Appraisal of a Jameson Cell in a scalping role within the Mt Isa Copper Concentrator indicated significant benefits could be achieved.

Jan 1, 2005

By P R. Lock

The Silver Swan nickel mine is located at the Black Swan Nickel Project, 53 km north east of Kalgoorlie, Western Australia. The Silver Swan orebody is a massive sulphide nickel deposit dipping 70¦ east with an average in situ grade of 14 per cent. Mining of the massive orebody is by Mechanised Ramp Cut and Fill (MRCF). A mining recovery of 98 per cent and minimising dilution are primary goals in extracting the high-grade ore. Placing a distinguishable marker bed (working platform) on rock fill was identified as a key method to achieving these goals. Gravel from a pit located onsite was considered the most suitable material for the marker beds. Research undertaken to design the marker beds using the gravel revealed conventional methods used in mining would not suffice, but that road stabilisation methods could be a viable alternative. Trials used a road recycler to mix cement and gravel in situ and several test beds were constructed on the surface to determine the final design. The trials attempted to replicate a marker bedÆs life cycle of construction and placement and mucking of ore from the marker bed. Testing the marker bed for strength for use as a working platform was completed using a Clegg Hammer; good correlation to a Clegg Impact Value and the compressive strength of the stabilised gravel was found. This paper describes the use of a road stabilisation machine, tests conducted, monitoring and marker bed design and discusses underground placement of the marker bed and its performance.

Jan 1, 1998

By Morrison R. S, Doennilan N

Recent mapping (1989-1992) by the Northern Territory Geological Survey in the Tennant Creek 1:250 000 map sheet area has resulted in substantial revision of the lithostratigraphy of the Tennant Creek Block (Donnellan, Hussey, and Morrison, in press). Briefly, the former Warramunga Group (Dunnet and Harding, 1967; Dodson and Gardener, 1978) is divided into the Warramunga Formation, and an overlying less deformed volcano-sedimentary succession, the Flynn Subgroup. The latter is conformably overlain by the Tomkinson Creek Subgroup of the Tomkinson Creek province in the north of the Tennant Creek Inlier. These two Subgroups constitute the Churchills Head Group which is essentially equivalent to the Hatches Creek Group of the Davenport province to the south of the Inlier.

Jan 1, 1994

By McMahon D

The approach to valuations at the Normandy Poseidon Group is a measured and methodical process that utilises skills sourced from a number of different disciplines. Whilst being subject to a strict set of guidelines, it is also sufficiently flexible to be able to cope with the considerable variety across the resources industry. The group uses Discounted Cash-Flow (DCF) techniques extensively in order to develop a base valuation. Other external factors (eg the market) are, however, also taken into account when forming a view on value. Other methods of valuation are used in tandem or as alternatives depending on the task. DCF techniques are an important tool but would never be used in isolation. Considerable care must be given to developing the DCF analysis as its components (eg discount rate) are prone to misuse. Whilst the valuation process is quite detailed and scientific, it is really only as good as the inputs or assumptions (technical, financial, etc) that are used. The methodology used remains consistent whether the group is undertaking the corporate planning process or making an acquisition.

Jan 1, 1994

Mining the Carpathia orebody at the Ardlethan tin mine in the late 1970s involved an innovative approach to underground mining which stretched the limits of drilling and blasting techniques. Holes of up to 95 m in length were drilled and blasted from the surface to extract an orebody which extended from 45 m to approximately 95 m below surface. This approach resulted in the elimination of an underground drilling sublevel, thus minimising the costs and hazards associated with underground drilling and blasting. Now, almost 30 years on, this method would probably still be the most appropriate choice.

Jan 1, 2008

By M Yahyaei, M S. Powell

Mineral processing plants have become large and complex, generally through progressive expansions. Addition of a pre-crushing stage to conventional Semi-Autogenous-Grinding (SAG) and ball mill - crushing (SABC) circuits has introduced a complex materials handling system coping with +200 mm particles. Application of High Pressure Grinding Rolls (HPGRs) and implementing hybrid comminution circuits (ie, HPGR-SAG mill) requires proactive control of the feed size distribution to each unit. Application of Vertical Tower Mills (VTMs) and other fine grinding equipment to achieve a finer grind size, while maintaining the throughput, requires splitting the feed evenly between parallel units. Many of the conventional comminution circuits (ie, staged crushing and screening followed by staged ball milling) must deal with the transition from open pit ore, which is generally altered and soft, to underground ore, which is intact and hard, requiring existing crushers to produce a finer product to unload the ball mills.This paper presents common process improvement opportunities which have been identified during a number plant process reviews conducted by the authors in Australian and international operations. The operation of comminution circuits to known and accepted standards, which is explained in this paper, could improve the performance of circuits by between 5 and 10 per cent, generally at no capital cost and often at a lower operating cost. The performance improvement can be realised as throughput increase, a finer product size, or reduced operating costs (ie, energy saving, low maintenance, less consumables).Process optimisation opportunities presented in this paper include: enhancing materials handling and storage to avoid segregation; standard operation of screens to reduce misplaced materials; proper feeding arrangement and control of crushers to increase their utilisation; preparing proper feed for SAG mills to reduce grind size; splitting the feed evenly between parallel equipment to improve utilisation, and controlling operation of classification units to improve energy utilisation.CITATION:Yahyaei, M and Powell, M S, 2018. Production improvement opportunities in comminution circuits, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 233–248 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

By V A. Diemar

The Chatree Gold Project represents a greenfields discovery of metallurgically clean shallow gold mineralisation in a logistically simple terrain. Total Measured, Indicated and Inferred Resources are currently 31 tonnes of gold and 160 tonnes of silver. Gold occurs in an adularia-sericite epithermal system within quartz-calcite-adularia veins, breccias and stockworks. Host rocks are volcanic arc porphyritic latite-trachyte flows, their pyroclastic equivalents and volcaniclastics of upper Permian to upper Triassic age. The mineralisation was deposited in dilated zones during repeated reactivation of pre-existing structures. To-date five mineralised prospects have been defined by drilling with three reaching JORC Code Mineral Resources status. The project is in its definitive feasibility stage and is anticipated to be in construction during 2000.

Jan 1, 1999

By Jiaxin Zhou

Acid mine drainage is a serious and chronic environmental problem of mining. This paper discusses the factors affecting the rate of acid generation by mine rocks and illustrates the relevance of these factors to the mines of the Northern Territory, Australia. The factors may be divided into two groups: internal factors and external factors. The first group covers characteristics of ores, mine waste rocks, tailings, etc and the second group covers surrounding conditions. The latter is further divided into four sub-groups, viz surrounding temperature and pressure, chemical conditions (ferrous/ferric adsorption ratio, total iron concentration, oxygen concentration and pH), surrounding biological conditions and mechanical conditions. Special attention is given to the surrounding P-T conditions, especially water partial pressure, and its relevance to the Northern Territory mines.

Jan 1, 1994

The Graham Farmer Freeway Project in Perth, Western Australia, is the largest urban infrastructure project ever carried out in the State. At a project cost of over $360 million, it also ranks as one of the largest in Australia and is even large by world class standards. The project provides a much needed east-west freeway bypass around the CBD of Perth, linking the Great Eastern Highway in the east with the Kwinana and Mitchell Freeway system in the west. The Bypass will have 6.5 kilometres of freeway, a major bridge over the Swan River, several pedestrian overpasses and underpasses, dual use paths, interchanges and flyover bridges and a rail tunnel. The whole project is being carried out over a four-year time frame, due to be complete and open to traffic in June 2000. The project has been divided into two stages, with Stage 1 including the 1.63 kilometre long Northbridge Tunnel, the subject of this paper.

Jan 1, 1999