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Using Dynamic Simulation Throughout a Process Plant's Life Cycle

Sep 13, 2010

By R C. Cox

The Brukunga pyrite mine was operated from 1955 to 1972 to supply feedstock for sulfuric acid production in the South Australian fertilizer industry. Iron sulfide ore, mined by Nairne Pyrite Ltd, was finely crushed and concentrated onsite with the concentrates being sent by road and rail to Port Adelaide for roasting. Waste rock was dumped at two locations on the western side of Dawesley Creek and the tailings pumped to a valley-fill storage facility on the eastern side. Production of 1.5 Mt concentrate resulted in 3.5 Mt tailings and 8 Mt waste rock. The site has been administered by the South Australian Government since August 1977 and a lime treatment plant has been operated on the site since September 1980. Environmental issues arising from these operations included: diversion of Dawesley Creek to accommodate the waste rock dumps; dumping of low-grade sulfidic ore in waste rock dumps at the angle of repose immediately adjacent to Dawesley Creek; exposed fresh sulfide mineralisation in the quarry floor; tailings storage facility dam wall constructed by upstream up-lift using tailings and waste rock; an acid water pond sited on the tailings; and pollution of natural drainage. As a result, the minesite rapidly became a source of acid drainage and potential contaminants (sulfate, Al, Fe, Mn, Cd, Zn, and Ni). Various Government bodies have been responsible for considerable effort and expenditure in reducing the flow of acid seepage and contaminants into Dawesley Creek. Presently an estimated 60 per cent of seepage from the waste rock dumps, tailings storage facility and quarry is collected and neutralised prior to discharge into the creek. Tailings have been covered with waste rock, biosolids, neutralisation sludge and soil and planted with grasses, shrubs and trees to reduce rainfall infiltration. Monitoring of water flows, water quality and riparian ecosystems is on-going. Consultants have been engaged to develop cost-effective remediation techniques and a five-member Brukunga Mine Site Remediation Board was appointed to oversee remediation of the site and liaise with the community. Construction has commenced on the diversion of Dawesley Creek, and plans are being developed for the relocation of waste rock back to the quarry benches and upgrading of the neutralisation plant. The paper examines operations, environmental monitoring, remediation, research and community involvement with respect to current best practice.

Jan 1, 2003

By J Herd, J Rowe, M Cutbush, d F. Aziz

WearApp provides expertise for assessing the degradation of removable screening media panels on vibrating screens right in a user’s pocket. Through the WearApp application, users can simply take a picture of a panel using their mobile, enter some basic information and have the application assess the wear to provide a recommendation for whether the panel needs to be replaced. Where traditional mechanisms for assessing panel wear only measure a few points across the panel face and rely on having personnel with specialised knowledge available to perform the assessment, WearApp uses deep learning models to analyse the entire panel face and support the user to make an informed decision. The application works through analysing a panel image and using a model to automatically detect the corners of the panel. Given the known dimensions of the panel, this enables the application to calibrate the pixel size against a known reference. A second set of models then detect the apertures and measure their dimensions. With the aperture dimensions defined the application assesses the wear of the panel through referencing a stored 3D model of the aperture. Finally, the data from each aperture is collated and the wear of the entire panel face defined. Since WearApp performs measurement of the entire panel face, it also allows the user to perform a more detailed analysis of the panel’s wear profile. Where typically, the panel wear is only measured in a few locations, WearApp’s analysis enables users to visualise the panel wear across the entire panel face, identifying areas of high wear that could be leading to premature panel replacement. Additionally, because the entire panel face is measured the change in screening efficiency can be calculated accurately for the worn panel, even taking into account the impact of aperture pegging by small rocks.

Sep 1, 2024

"Geometallurgy is a discipline that seeks to improve the sustainability of the extraction of metals and minerals by promoting the smarter use of non-renewable resources, better energy efficiency and greater use of renewable energy. To achieve these goals, development of innovative technologies and approaches are being developed along the entire commodity value chain, starting with exploration and extraction and extending to reuse and recycling. This paper discusses the geometallurgy of industrial minerals with special emphasis on kaolin, a versatile industrial mineral applied in ceramics, paper, paint, plastics, rubber, pharmaceuticals, cosmetics, ink, sealants, adhesives, sanitary ware, glass fibre, toothpaste, animal feed etc. Aspects of kaolin extraction in south-west UK are analysed from a geometallurgical perspective. While geometallurgy already features in kaolin extraction, its role can be significantly expanded by combining advanced in-pit characterisation and orebody modelling with integrated planning and control of the refining and calcination process. This paper highlights the importance of innovation in realising the full potential of geometallurgy.CITATION:Glass, H J, 2016. Geometallurgy – Driving Innovation in the Mining Value Chain, in Proceedings The Third AusIMM International Geometallurgy Conference (GeoMet) 2016, pp 21–28 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Jun 15, 2016

By B L. Coulter, E Wightman, A S. Burrows

With their commitment to sustainable development in an increasingly carbon-constrained world, many resources companies are focused on reducing the energy required to create their final products. In particular, the comminution and smelting of metal-bearing ores are both highly energy-intensive processes. If resource companies can optimise the energy efficiency across these two processing stages, they can directly reduce their overall energy consumption per unit mass of metal produced and thus reduce their greenhouse gas footprint. Traditional grinding and flotation models seek to improve the efficiency of mineral processing, but they do not consider the energy used by downstream metal production, eg smelting and refining. Concentrators and smelters individually may be running efficiently, but are they optimising energy consumption of the overall system? A key step towards answering this question is to understand whether it takes less energy to remove an impurity in the concentrator or the smelter. Analysis of the complete concentrator û smelter process chain may show that there are times when the concentrator should use more energy to reduce the overall energy requirements across the mill and smelter. The new methodology discussed here will integrate downstream processing energy with mineral processing energy, to find the overall most energy efficient circuit design and operating strategy. The proposed methodology includes: determining what grade and recovery positions can be achieved in the concentrator by using different combinations and amounts of grinding and regrinding, thermodynamic calculations of the energy used to process the different concentrate grades to metal, and integrating the concentrating and smelting models to find the lowest total energy for the system. A case study which investigates the effect of increasing regrinding energy on the overall mineral processing û smelting energy consumption is presented. For the copper-nickel sulfide ore investigated the addition of regrinding results in 11 per cent less energy being used in the overall concentrator û smelter process chain per tonne of metal produced. Although regrinding is often seen as an energy-intensive process, in this case study the use of 1 kWh of energy for regrinding reduces the overall energy consumption by 12 kWh. The new mill to melt methodology will allow companies to model energy consumption from mill to smelter with a view to reducing the energy-intensity and greenhouse gas footprint of their processing and smelting operations.

Jan 1, 2009

By S R. Pecover

AustraliaÆs opal and sapphire mining industry has fallen from its peak in the 1980s and 1990s into a significant low today. This is not due to exhaustion of the resource, but instead an over-reliance of the Australian miner on achieving a fair price for the gemstone product from offshore middlemen dealers. Gemstone and geological research is also at a low as Federal higher education expenditure has fallen with research institutions relying increasingly on private funding in an environment of restricted autonomy and flexibility for researchers. What little remaining research skills the universities have is being bled into the private sector as a result of the mining boom and encouraged by lower than average academic salaries. Nevertheless, some highly innovative research has been taking place, often by self-funded individuals and retired academics simply with a desire to advance the understanding of the particular branch of science in which they are interested. New models for the formation of sapphire and opal are now beginning to be applied to the exploration for these gemstone commodities. This research, together with well thought out plans for managing the gemstone product through its value-adding steps to the jewellery retail level, has the potential to bring about a resurgence in the Australian gemstone industry.

Jan 1, 2008

By A McCallum, J Abols, G Patrick, G Johansen

The authors challenge the traditional thinking that whole ore cyanidation followed by Carbon in Pulp (CIP) or Carbon in Leach (CIL) should be applied as a standard process in the majority of gold processing flow sheets. The concept of whole ore leaching by using cyanide can result in unnecessary environmental and capital risk. Alternative, currently available technologies can be used to provide the desired level of gold recovery at a much lower installed cost and less impact on the environment. Gravity concentration, alone or in conjunction with flotation, can produce a gold bearing concentrate that can then be fed directly to a batch or continuous intensive cyanidation unit. The In-line Leach Reactor (ILR) is an intensive cyanidation unit developed by Gekko Systems of Australia. Advantages of this technology include significantly reduced capital outlays for greenfield plants or plant upgrades and increased investor returns. Reduction of onsite cyanide and carbon inventories improves plant safety, materials handling and site security. By using direct electrowinning to treat the gold bearing solutions produced by the ILR, the need for a conventional carbon stripping circuit is removed. Potential also exists to increase grind size û saving energy, further reducing capital and operating costs and decreasing the environmental impact of a mill. Detoxification of cyanide before the release of solution to the tailings dam can minimise tailings disposal and containment requirements. When used in the right application the proposed process will have little or no impact on gold recovery and may actually increase recovery for complex ores. Areas applicable to this type of treatment include: plants in environmentally sensitive regions, lower tonnage higher grade deposits, coarse gold deposits, and preg robbing ores û some of which may not currently be economically feasible using standard processes and flow sheets. We have provided two examples of such projects, where an alternative to whole ore leach and CIP or CIL has the potential to deliver these benefits.

Jan 1, 2004

For more than 15 years after the Northparkes orebodies were first discovered in 1976, the project was delayed by the need to find an economic way of mining the low-grade E26 deposit. The decision to use a low-cost block caving method to mine the orebody was made in the early-1990s; but the project's future did not solidify until 1993 when a radical new approach was adopted which sought to integrate business imperatives with technology and organisation strategies. The approach led to the establishment of a strategic vision which tied together all the components that could have a major impact on the project, to provide a framework for guiding strategic choices. The strategic vision strived to break away from the old rules of how mines are organised and operated; and involved finding imaginative new ways to radically redesign mining processes to achieve quantum leaps in performance.

Jan 1, 1997

By J Li, J Regan, D Payne

The Caval Ridge Mine is an open cut coalmine and located within the Bowen Basin region in Central Queensland, and commenced mining and processing operations in 2014. A number of geotechnical challenges for managing dragline bench and lowwall stabilities have been encountered in both southern and northern pits over the years. Southern Pits contain steep seam dips of up to 15° (27 per cent) whilst the northern pits also have shears below pit floors. Geotechnical guidelines to manage the risk of dragline bench failure and lowwall instability have been developed and improved since these geotechnical challenges were identified. The dragline guidelines include dragline tub offset distances from the 60° Line (SDL) or buttressing thickness for different seam dips greater than or equal to 8°. The low wall stabilisation guideline established floor disruption widths and depths depending on seam dips and presence of floor shears to known depths of up to 3 m. As mining operations advance, lowwalls have remained stable until floor disruptions were fired, then returned to stable soon after the shot. The maximum distance of lowwall cracking with blasting has been as far back as the second spoil peak (the prestrip truck dumps construction limit). These failures need to be eliminated to allow the operational flexibility and haulage benefit of constructing the prestrip truck dumps behind the first spoil peak, while maintaining no risk to personnel or equipment. The floor shear depth was verified by collaborating with the exploration teams and taking advantage of the already planned 8-inch coal quality core holes, drilling them an extra 5–10 m past the coal seam floor and locating the shear presence. With this continuous improvement effort, no lowwall failures have occurred during floor disruption firing from the second strip after the new floor disruption depth guidance have been applied. This paper documents the processes for developing these geotechnical guidelines, operational implementation, and outcomes. Operational applications over the years confirmed that these guidelines have effectively managed the dragline bench and lowwall failure risks related with the steep seam dips and floor shears in this open cut coalmine.

Nov 29, 2022

Beach sands on the Morobe coast of New Guinea contain significant amounts of chromite. This chromite, together with the more abundant associated minerals such as olivine, enstatite, tremolite, antigorite and feldspar has been de- rived from rocks of the Papuan Ultramafic Belt and transported to the beaches by three rivers, the Paiawa, the Saia and the Sesimbai. Of the hundreds of samples taken, 26 have been analysed mineralogically and chemically in some detail. On this basis, five groups of samples, four on- shore and one offshore, representing character- istic mineral assemblages, have been recognized. The chromite grains themselves have been exam- ined to determine variations in amount and in the Cr/Fe ratio, since this is of economic importance. Much of the chromite fails to reach a high Cr/Fe ratio as a result of magnetite rims around chromite grains. The precious metal content of the sands is negligible.

Jan 1, 1973

The basic make-up of the majority of currently produced bulk explosives has changed little in the last 20 years. These explosives would be described as mature in a life cycle analysis. Therefore these explosive products and the practical rules for their use are well understood and well established. In recent years there has been interest in low density explosives, predominantly due to ammonium nitrate shortages and the associated increase in the cost of explosives. In the use of low density explosives some of the practical rules for the more commonly used bulk explosives do not apply. Therefore a shift in the thinking among users is required. At a number of mines low density explosives have been trialled or are being used, utilising the practical rules that apply to bulk explosive products. This has led to poor blast results in many situations. These poor blast results have often then led to a reduction in the use of low density explosives at the mine. This reduction does not acknowledge the advantages that can be gained from this product in the area of reduced cost of mining. This paper looks at low density explosives and discusses how and why these products work. Included in the paper are some practical ideas and examples of how low density explosives can be effectively used at the mine site.

Jan 1, 2007

By S R. Williams

There is a sense of geometallurgy being new; a new methodology for mining project development and improved operational strategy. One of the main challenges that any ænewÆ technology faces is a validation of the value and the need to produce case studies. However, producing case studies can often be problematic particularly given the long cycle from mineral deposit project, through feasibility and construction to stabilised operation of a mine.However, the roots of geometallurgy go back quite some time. Successful practices with geometallurgy can be seen from as early as the 1980s. Many times those practices were not called geometallurgy but something else and, in other cases, what can be seen are various components of the geometallurgical ævalue chainÆ.This paper will analyse a selection of published past practices from a geometallurgical perspective to demonstrate the value realised from the application of this methodology. The paper will then make some general comments on where this history of work in geometallurgy has lead us to and what are the challenges today for the geometallurgical effort.CITATION:S R Williams, 2013. A historical perspective of the application and success of geometallurgical methodologies, in Proceedings The Second AusIMM International Geometallurgy Conference (GeoMet) 2013 , pp 37-48 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 29, 2013

Problems caused by water discharge from surface mine ventilation shafts can be significant and are usually unforseen. The discharged water is often hyper-saline or acidic and can cause environmental degradation over a wide radius. It can also lead to recurring power pole fires and primary fan breakdowns. A range of solutions to the water discharge problem has been implemented in many Australian mines. In most cases the solutions have been ad hoc, with the overall cost and effectiveness varying tremendously. This paper reviews and contrasts the practicality and effectiveness of the various available remedial options.

Jan 1, 2002

By A Querzoli, B Williams

In late 2014 the Flinders Power Management Team was executing business improvement plans to ensure continued electricity generation until 2028 and beyond. Six months later, in June 2015, the Board announced the closure of the Flinders Power South Australian business, including the Leigh Creek Coal Mine, the Northern and Playford Power Stations located at Port Augusta and the 250km railway line. The announcement was preceded by a brief period of internal planning. A date was soon set for ceasing coal mining operations, being November 2015. The mine is unique in many ways. Located approximately 550km north of Adelaide the site has over 100 years of history and was formerly operated by the South Australian Government. Privatisation in 2000 saw the mine continue operation under Perpetual Leases from the South Australian Government. The leases included exemptions from multiple sections of the Mining Act 1971, obliging primary regulation under the Mines and Works Inspection Act 1920. The coal, being a low rank sub-bituminous brown coal, is prone to self-heating and spontaneous combustion. The mine and company town Leigh Creek were the economic and cultural heartbeat of the community. Facilities at the mine were shared by the community and vice versa. While many mines across Australia and the world enter periods of care and maintenance, few have been actively closed to the point of relinquishment (Bennett and Lacy, 2016). A swift decision to close, followed by a short mining operations shutdown period, presented significant technical and regulatory challenges for both the mine operator and for Regulators. The subsequent joint risk mapping process employed by Flinders Power and South Australian Mining Regulators was a unique real-world example of collaborative mine closure planning and execution. Lessons learnt are valuable for all mines, production facilities and for Regulators, even for those who may wrongly assume that closure is many years away. CITATION:Williams, B and Querzoli, A, 2018. Risk management for minesite closure planning and execution – start now! Lessons from the closure of the Leigh Creek Coalfield, South Australia, in Proceedings Life-of-Mine 2018, pp 68–72 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 25, 2018

Teleseismic travel time residuals measured on 600-1000 km seismic arrays across the Rio Grande and East African rifts provide evidence for upper mantle low velocity zones beneath each rift of velocity contrast 6%-8%. Refraction studies show thinning of the crust below the rift axes. Regional uplift which extends hundreds of km either side of the axes, is isostatically compensated by negative density contrast at depth. Since the refraction argues against compensation by thickened crust, compensation in the upper mantle low velocity zones is suggested. Temperature effects alone can not explain the reduced velocities. Generation of a few percent of partial melt is the most probable source of the reduction. A passive extensional mechanism is investigated for the Rio Grande rift in which hot asthenosphere intrudes the lithosphere raising its temperature and generating moderate melting. It requires less than 1% extension to explain the melting but a prodigious 26% to raise the temperature from a pre-rifting continental geotherm to the solidus. Geological estimates find that extension is less than 10% over the uplift zone. Such a mechanism is possible only if the prerifting lower lithosphere geotherm lies closer to the solidus than that of stable continent. This is supported by the observed high heat flow in the Rio Grande rift uplift region which, given the long time constant for thermal diffusion, reflects elevated temperatures at depth well in advance of the onset of rifting.

Jan 1, 1987

By E C. Holloway

"The financial valuation of mining assets has a number of fundamental differences to the valuation of many other asset groupings. One such difference is that typically, the greater proportion of both the cost and revenue sides of the cash flow are inherently governed by systemic market forces.As a result, the range of outcomes for the valuation of each mining asset is more unpredictable, with higher levels of risk and uncertainty. In contrast, the management function of many other non-mining businesses or industry groups can control at least a portion of the cash flow by maintaining the margin or controlling the sales price. The management teams of mining businesses and operations typically have limited options, and are thus price-takers for both costs and revenues. As mining is an inherently cyclical industry, large, long-life operations can exist through several price cycles, making valuation both subjective and challenging.The outcomes of both static- and stochastic-based valuations, as well as the internal probabilities of the associated cash flow statements, are significantly impacted when the correlations between the appropriate parameters are quantified, modelled and incorporated into the valuation framework. The appropriate parameters for correlation modelling primarily include those that are governed by systemic market forces. Applying this process results in a different risk profile for the asset by allowing the risks resulting from systemic market movements to be more accurately quantified and then objectively minimised. This process also reduces the level of residual uncertainty in the valuation outcome.This paper presents a valuation methodology to pragmatically incorporate this level of valuation sophistication and statistically quantify the associated increase in the level of confidence of the valuation outcomes reported.CITATION:Holloway, E C, 2016. Correlated valuation methodology, in Proceedings Project Evaluation 2016, pp 181–200 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Mar 8, 2016

By B Lumsden

During periods of high metal prices and strong metal demand tailings retreatment can be economic. Most tailings retreatment operations are technically challenging, low margin operations, because the easily recovered mineral has already been removed, therefore, process improvements can potentially yield large economic benefits. The Hellyer tailings dam was owned by Intec Ltd and contained 10.9 million tonnes grading 2.8 per cent zinc, 3.0 per cent lead, 88 g/t of silver, 0.16 per cent copper and 2.6 g/t gold. In November 2006 the Polymetals Group, as operator, restarted the Hellyer plant to retreat these tailings. Within a few months the operation had stabilised and Polymetals was meeting budgeted targets of throughput, metal recovery and concentrate quality. Polymetals and Intec then investigated methods that would improve the metallurgical result for this difficult to treat tailings. Since the tailings are fine-grained with 80 per cent <45 ¦m, magnetic aggregation of the paramagnetic sphalerite was evaluated. Magnetic aggregation of an oxidised tailings feed has not been tested before, nor had the technology been available when Hellyer ore was originally processed. Extensive statistical test work showed magnetic aggregation of the sphalerite fines in the zinc cleaner circuit increased total zinc recovery. The increase in the mean zinc recovery with magnetic conditioning was 3.63 per cent, at a statistical level of confidence of 97.8 per cent, and at the same mean zinc concentrate grade.

Jan 1, 2009

By T Purvis, Z Liu

Ernest Henry mine (EHM) is an underground sublevel caving mine located in north-west Queensland with a production rate of 6.4 Mt/a. The mine has sublevels spaced with a 25 m vertical interval. The production process on each level starts with the drilling and firing of a blind uphole rise to start the slot extraction. These rises are fired as a single shot and routinely need to achieve a design height of 22 m to 30 m depending on the local mine geometry. If the rise fails to perform as designed then the production phase of the level is delayed with significant rework required to remedy the situation.This paper describes the process that the EHM team has followed to improve the first time performance of each rise. The improvement process commenced with a review of results from previous rises and resulted in the identification of a number of improvement opportunities. A revised holistic approach was established for the process, which included involvement from operators and engineers. Through continued measurement and review of rise performance, inputs to the process were improved to a point where reliable results can now be expected. The successful performance of subsequent rises has been verified through a comprehensive quality assurance quality control (QA/QC) program. Before quality control processes were implemented, the success rate of blind uphole rises was only 11 per cent (one out of nine rises) at EHM. In comparison, the success rates have been vastly improved to 25 per cent (one out of four) and 75 per cent (three out of four) respectively following two stages of improvements. This paper concludes with the ‘current’ series of best practices used at EHM and recommendations.CITATION:Purvis, T and Liu, Z, 2017. Improving the performance of blind uphole rises at Ernest Henry Mine – a case study, in Proceedings 13th AusIMM Underground Operators’ Conference 2017, pp 335–340 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Oct 16, 2017

By J Skousen, C E. Zipper

"Prior to the 1950s in the USA, surface coalmines were generally left without any reclamation. As government regulations advanced, mine operators were required to backfill the area and plant grasses or trees. After the federal Surface Mining Control and Reclamation Act (SMCRA) was passed in 1977 in the USA, mine operators were required to conduct pre-mining analyses of the site and to designate a land use that could be achieved after the mining. Common post-mining land uses in the USA are: agricultural uses such as prime farmland reclamation with crops, hayland and pasture, and biofuel crops forestry wildlife habitat building site development.Provisions and regulations for each post-mining land use were developed and practices to achieve successful and sustainable land uses were established. Post-mining conditions should provide ecosystem services and produce lands capable of supporting societal needs in the future.CITATION:Skousen, J and Zipper, C?E,?2014. Post-mining land use options in the Appalachian coal mining region of the USA, in Proceedings Life-of-Mine 2014, pp 153–164 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Jul 16, 2014

By Eggleton R. A, Taylor G

As the search for major orebodies continues, the regolith dominated areas of the Broken Hill region remain one of the major exploration frontiers. The past exploration philosophies emphasising bedrock related characteristics have been limited in their ability to effectively explore in the regolith dominated areas, that are a feature of most of the Broken Hill region (Figure 1). If mineral exploration is to be more effective across all of the Broken Hill region, particularly in the regolith dominated areas, an appreciation and increased understanding of the regolith and landscape features are a necessity. Ironically, there have been very few studies of the regional regolith and landscape features of this region. Owing to the previous lack of an established regolith-landform framework, this study initially concentrated on the general characterisation and variation in regolith types corresponding to the area of the Broken Hill Block, within NSW (Willis, 1989; Stevens, 1986). The approach has been to produce a regional regolith-landform map at 1:100 000 scale and conduct a complimentary program of regolith sampling and site descriptions. This was a basis to identify areas for more detailed regolith-landform mapping (1:25 000 scale) and for producing a regional stratigraphic framework and models for landscape and regolith evolution. This information can then be used to provide a basis for regional mineral exploration models and strategies. This paper highlights some of the regionally significant regolith-landform features and their general significance to mineral exploration. More detailed information on specific regolith-landform features and study sites may be found in Hill et al (1994; 1996; in press) and Hill (in prep).

Jan 1, 1997