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By Morrison RD, Peberdy NJ

Simulator training provides a cost effective method of training operators in both the process and control aspects of a metallurgical plant. The components and requirements of a training simulator are described along with the benefits to be gained from simulator training. A table summarizing some applications of metallurgical training simulators is Given.

Jan 1, 1991

This paper reviews the issues of mining machinery automation with special emphasis on underground applications. Automation is desirable because it offers the following advantages: ò increased safety by reducing human exposure to hazards of underground mining; ò higher productivity; and ò reduced wear of equipment. In spite of these advantages and in spite of numerous attempts over the past several decades, mining automation has been a difficult proposition, partly because no two mining operations are exactly alike and these operations are carried out in an unpredictable environment. This is the main difference between automation in factories and in mines and that is why mining automation has been lagging so far behind factory automation. Automation is possible only when the machine 'knows' its workspace. In a factory, this workspace can be 'described' to the machine because it is sufficiently controlled. In a mine, the environment undergoes continuous change and the only way the machine can 'know' its workspace is through real-time sensing.

Jan 1, 1995

By Blight P

There is today widespread concern about the future of the mining industry. In attempting to understand the underlying causes the paper probes in some detail, the long term structural changes affecting growth of metal demand and the development of excess mineral supply capacity. This examination reveals an industry characterised by an unfavourable combination of high barriers to exit and low entry barriers. While rising entry barriers are expected to herald some improvement in the profitability of mining over the next decade, this adjustment is likely to be slow and will require a more economically rational assessment of the industry by corporations and governments Alike.

Jan 1, 1986

Rheology is the science which deals with the deformation and flow of matter. Thus rheology is concerned with the flow of any material. The mining industry is concerned with digging things out of the ground, extracting the good stuff and throwing away the bad stuff. In the upgrading processes associated with mining, ie mineral processing, wet techniques are used where the primary material being handled is a particulate fluid, ie a suspension. After the processing operation, with the concentrates extracted, what is left behind generally is a wet material in suspension form, which may or may not contain reagents harmful to the environment. The amount of waste generated in any of the mining processes is large, in fact, the mining industry is the largest generator of solid waste in Australia. In order to minimise the waste generated within the industry it has become of interest to handle the particulate fluid wastes, or suspensions, at high concentrations, thus removing water and some of the reagents which may be harmful to the environment. The resultant highly concentrated suspension is a non-Newtonian fluid. Rheology deals with the flow of non-Newtonian fluids; therefore a combination of rheological understanding of high density suspensions, in conjunction with an understanding of the environmental problems being faced by the mining industry, can and has led to improved methods of waste disposal in the industry, ie waste minimisation. This paper describes the progress that has been made in the development of dry disposal technology in the mining and minerals industry in Australia.

Jan 1, 1998

By Kilgour I

The installation of a final cleaning column at Ok Tedi Mining Limited was carried out to increase final concentrate grade in order to reduce concentrate handling, shipping and treatment charges and to reduce penalty payments. To fast-track the project a decision was made to install a full-size column on one of the two parallel circuits, designed on information readily available and utilising the experience of mill staff and an engineering consultant, rather than delay installation while a pilot scale program was conducted. A 3.66 m diameter by 12.8 m high column was installed to produce 40 t/h of final concentrate from a combination of rougher concentrate and recleaner concentrate. The column design and sparger system were by Cominco Engineering Services Limited.

Jan 1, 1991

From the viewpoint of mechanical efficiency, charges should be fully coupled and, upon detonation, should just fail to break the rock in compression. But because mining thrives on its cost-effectiveness rather than its mechan- ical efficiency, the explosive which generates maximum energy per $ should generally be used, even though the mechanical efficiency of this explosive's detonation products may be sub- optimum. Wherever possible, each charge should have a length:diameter ratio of about 20 or more and should shoot to a concavely biplanar free face that is both parallel and reasonably close to the blasthole. Success in obtaining parallel effective faces often demands the drilling of angled blastholes and, hence, will require intensified research and development efforts by drilling manufacturers, especially where hard strong rocks are encountered. Blastholes should be drilled on equilateral triangular grids and fired in a Vl or shallower V-type sequence using inter-row delays which ensure that good pro- gressive relief of burden is achieved. The conventional method of calculating Se/Be values (on the basis of planar effective faces) is often invalid.

Jan 1, 1986

Conveyor belt haulage offers the advan tages of continuity of operation, minimum labour requirements, and the ability to handle large volumes of material over extended periods. However, breakdown of critical con- veyors in the system can cause undue and substantial losses in production output at the working faces, unless adequate surge bin capacity is incorporated in the haulage system. A conveyor belt simulation programme, code name 'Beltsim' was developed by Bucklen et al (1968) at the Virginia Polytechnic Institute in the U.S.A. and provides a quantitative measure of the performance of a conveyor belt network design. A limitation still exists with the computer programme and involves the inability of the programme to predict the necessary surge bin capacity to overcome conveyor belt downtime. The computer programme was modified to overcome this limitation, to simulate a con- veyor belt breakdown, and to provide a quantitative prediction of the surge bin capacity necessary to permit a modern mining system to operate effectively and continuously.

Jan 1, 1977

A review of ground control procedures in Western Australian underground mines is presented. Geotechnical input into initial mine design and methods of ground control is rare. As a result, the frequency of unexpected rockfalls is comparatively high, with over three quarters of the mines adopting non-specialist ground control designs experiencing unexpected falls-of-ground. In contrast, mines that provide some level of specialist input into initial ground control design experience decreased rockfall frequencies.

Jan 1, 1992

By Golab K, Partridge AC, Fletcher CAJ, Holtham P

Spiral concentrators are used globally in the fine coal processing industry to segregate particles, by gravitation, on the basis of density and size. Consisting of an open trough that twists vertically downwards about a central axis, a slurry mix of particles and water is fed to the top of the concentrator. Particles are then separated radially as they gravitate downward. Since their introduction to Australia in the 1940's, the generic design has evolved largely by laboratory trial-and-error investigations of different prototypes. However, this approach has proven expensive and optimal designs have not been necessarily developed. Accordingly, Computational Fluid Dynamics (CFD) analysis has been used recently as an alternative method of investigation, to assume as is envisaged, a role in the design process. To date, CFD models have progressed to simulations of turbulent fluid flow on current production spiral designs, and are continuing to be adapted for inclusion of particles at realistic feed concentrations. To be able to use the models confidently however, laboratory experiments must also be performed to validate the predictions during the development stage. This paper reports the current findings of an ongoing CFD and experimental program applied to one spiral unit. Satisfactory quantitative agreement has been achieved for the fluid and particulate flow characteristics, and although further validations are appropriate, the model already possesses significant potential for use as a reliable predictive design tool.

Jan 1, 1998

The effectiveness of three different types of longwall chock under the three different types of geological conditions worked recently is outlined. Some provisional analyses of the variation of chock load under the shale roof con- dition are briefly discussed and some problems and solutions of gateway and road- head support outlined.

Jan 1, 1974

MERLIN, the Queensland Department of Minerals and Energy's corporate geographic information system, provides ready access to all georeferenced data held by the department. Its aim is to provide a consistent, current, statewide coverage of timely information to assist in tenures management, exploration targeting and competing land use decision-making. Initially developed in 1988 and under continual enhancement since then, its functionality is the result of on-going close consultation with a wide range of departmental clients and potential users. A true geographic information system, MERLIN maintains both graphical data with linked textual information on a wide range of features of interest. The proprietary software products Arclnfo and Oracle are used to hold the graphics and attribute information respectively. Access to information is provided by a specially designed graphical user interface programed in-house. Hardcopy output of graphics displays including related attribute data as well as detailed reports of textual information can be retrieved at any departmental office. MERLIN is a network of computer systems which link each of the Department's regional offices and head office in Brisbane. The current state of exploration and mining is maintained by departmental officers processing tenure applications, transactions and dealings directly into the system. Data entered at regional offices are transferred overnight to head office to up-date central records and maintain a currency of data statewide as at the close of business the previous day. Through MERLIN the Department of Minerals and Energy now offers a much streamlined tenures management service as well as access to information about past exploration and mining, Queensland's mineral and energy occurrences and resources, and up-to-date information on the state's geology including maps, boreholes, geophysical surveys and field observations. In the future, this Geographic Information system will be invaluable to the mining industry in the development of mining projects.

Jan 1, 1995

By Savory P. J

Uranium mining operations commenced at Ranger mine site, Jabiru NT Australia in May 1980. The Ranger orebodies, totalling approximately 110 000 tonnes contained U305 had been indicated by airborne radiometric survey in 1969 and confirmed by drilling the following year. Both diamond and percussion drilling methods were used to define the mineralisation and samples were analysed using a combination of radiometric and neutron activation techniques. Ore reserve estimates were calculated from conventional and geostatistical methods, and following the mining of 15 million tonnes of ore, reconciliations with before mining estimates are well within acceptable industry standards. In-pit grade control employs radiometric techniques including a radiometric truck discriminator built in Australia to mine specification to meet production requirements and improve productivity. Environmental requirements associated with uranium mining are a daily consideration.

Jan 1, 1993

By Miles M. J, Sandy D. A

It has long been known that drilling and blasting operations have a direct influence over productivity and costs of subsequent operations. If mine management is to effectively optimise blasting operations, good information is required on the operating costs of each of the affected operations, together with knowledge of how they are influenced by blasting. In practice it is not possible to do enough repeats of a full scale production blasting experiment to make a statistically significant analysis of the results. By monitoring each blast and subsequent operations in as much detail as possible, enough data will be available to effectively measure the effect of blasting on costs. This gives management an insight into the blast performance and is the first step towards optimisation. An Integrated Blast-related Cost Reporting System has been developed at the Rossing Mine Open Pit, which calculates the total mining cost for each blast. In assessing the total mining cost for each blast, use was made of an.integrated planning and management information system to collect relevant production variables, current operating costs and survey data. An automatic image analysis system was employed to measure the fragmentation of the blasted material in the back of haul trucks. A shovel monitoring system is also under development for use in assessing the muckpile diggability and, in conjunction with an appraisal of shovel component reliability, to estimate the maintenance cost under various digging conditions.

Jan 1, 1990

By V Rajakumar, S Trang

Titanium has the potential to become the third wave of light metals used in high volume applications, following on from aluminium and magnesium. These light metals have functional attributes that can meet many of the goals needed for societyÆs transition to sustainable development. CSIRO has initiated a Light Metals Flagship to focus additional R&D efforts in support of the light metals industry. The vision of the Light Metal Flagship is for Australia to lead the Light Metals Age by reducing the costs and environmental impacts through innovative technologies for these metals. Life cycle principles will be used to identify novel technology pathways for metal production and product manufacture that are more energy efficient, less capital intensive and incorporating eco-efficient material flow chains.Under the auspices of the Light Metal Flagship, a Life Cycle Assessment (LCA) of titanium metal production was carried out with mineral sands mining of ilmenite as the starting point. Upgrading of the ilmenite to synthetic rutile by the Becher process and titanium metal production by the conventional Kroll process were the processing routes considered. Two alternative processes for titanium metal production, the FFC Cambridge process involving direct electrochemical deoxygenation of titanium dioxide, and a plasma process for producing titanium powder from titanium tetrachloride were also examined using LCA methodology and compared to the Kroll process. The environmental impacts included in the LCA were greenhouse gas emissions (Global Warming Potential, GWP) and acid rain gas emissions (Acidification Potential, AP). The Gross Energy Requirement (GER) of each process was also determined.These results for titanium, along with those from previous LCA studies by CSIRO on aluminium, magnesium, steel and stainless steel production, were used to show that despite the relatively large amounts of primary energy required for the production of these light metals, their special properties (eg corrosion resistance, strength and light weight) mean that these metals offer potential GER and GWP reductions compared to other competing materials in a number of applications, when viewed on a life cycle basis. Two applications considered in the paper are the lightweighting of motor vehicles and chemical plant equipment manufacture.

Jan 1, 2004

The Golden Plateau Mine is located at Cracow in central Queensland, 350 kilometres north west of Brisbane. The mine was operated by Golden Plateau NL as an underground mine from 1933 to 1976 with a total production of 18.5 tonnes of gold. Prod

Jan 1, 1994

Alcoa of Australia's Del Park mining op eration is centred 9 km. east of the Pinjarra alumina refinery, and is centrally locatedwith- in the 10, 000 sq. km. lease which the Company holds for bauxite in the Darling Ranges. An- other mining operation is situated near the township of Jarrahdale, and supplies bauxite to the Kwinana refinery. Definition of the bauxite ore, development works and mining to the ore haulage stage, are identical for both mining operations. Exper- ience, and production cost figures, obtained from the Jarrahdale mine, where 100 tonne trucks are used to haul ore to a fixed crushing plant, led to the development of the Del Park mining concept with increased mobility of op- erations. The crushing-conveying-stockpiling arrangement at Del Park consists of a 1200 t. p. h. mobile crusher feeding bauxite to an overland conveyor system which transports the ore approximately 6. 66 km. to the stockpile area in the refinery. In the refinery raw mat- erials area the bauxite is distributed into 200, 000 tonne stockpiles by means of a travel- ling boom stacker.

Jan 1, 1973

By Francis R. S, Campbell J. J

Aberfoyle's Hellyer Division has filtered very fine flotation concentrates using two different makes of pressure filter. At the Luina concentrator a Larox pressure filter was used to treat a combined Pb + Zn or bulk concentrate. At the Hellyer concentrator two Lasta pressure filters are being used to filter copper/silver, lead, zinc and bulk concentrates. Operating parameters and performance at both operations are described. In both concentrators it was found that correct cloth selection was critical and that cloth failures contributed significantly to downtime. Thorough preventative maintenance progammes were required to ensure adequate availability of both makes of filter.

Jan 1, 1989

The Ardlethan tin concentrator had dete riorated considerably in metallurgical per- formance, maintenance and plant availability. This problem was compounded by low tin prices and International Tin Council quotas. Mid- 1976 figures were: throughput - 1300 tonnes per day, availability 83% and metal recovery 537. Major problems existed throughout the circuit from crushing to tailings disposal and with morale, staffing, and housekeeping. With the lifting of the quotas in June 1976, management provided funds to implement a major rehabilitation programme and some fifteen major projects, at a cost of about $1.3 million have been completed to date. The change in performance has been dram- atic, and end of 1977 performance figures are: throughput - 1700 tonnes per day, availability 90% and metal recovery 65%.

Jan 1, 1978

By Baird G. R, Jurak R. N

In this study Dynamic Finite Element Modelling is used to investigate the distribution of peak particle accelerations (PPA) induced in a rock mass by a vertical decked column of explosives. The rock mass is assumed to be viscoelastic. The influence of the delay time between decking charges, the viscosity attenuation (quality factor Q), the decking configuration, and the velocity of detonation (VOD) on PPAs is examined. The results of this paper are relevant to fragmentation since the nature of the fragmentation is related to the stress magnitude and hence the PPAs. It was found that increasing the VOD, and increasing Q increases the PPAs in the neighbourhood of the blasthole. However, the VOD and rock quality factor Q have little influence upon the distribution of PPA. It was also found that an even distribution of PPAs, at a fixed distance from the blasthole, could only be obtained by increasing the ratio of charge length to stemming length. The study showed that the amplitudes and distribution of PPA surrounding the blasthole was approximately independent of the delay time between the decked charges. The modelling also shows that the particle accelerations at locations below the bottom of the charge are relatively small and so the model predicts no substantial damage below the bottom of the charge after blasting.

Jan 1, 1995

By Chamberlain A. C, Fisher N, Avraamides J

The thermal decomposition of sodium ethyl xanthate (SEX) adsorbed onto activated carbon was studied by coupled thermogravimetric analysis-Fourier transform infrared spectroscopy (TG-FTIR). Two discrete mass losses were observed, in the temperature ranges 100 - 230¦C and 200 - 340¦C. The same two gases, carbonyl sulphide (COS) and carbon disulphide (CS2), were the main gases evolved in each of the mass losses. Samples of activated carbon from two industrial plants were obtained and analysed by TG-FTIR. COS and CS2 were not detected in one of the samples. The other sample did show evidence of COS and CS2, which indicated that fouling of the carbon by SEX was still present. Other organic compounds were detected in the evolved gas stream of both samples, indicating the presence of organic reagents other than SEX.

Jan 1, 1996