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The comminution process indicates that the most energy-efficient comminution system would be one where the particles leave the breakage field as soon as they reach product size. Contrary to the free falling gravitational (vertical) flow in crushers, the grinding millÆs energy efficiency essentially depends on ore characteristics and the discharge rate of broken particles, which in turn depends on how efficiently the discharge pump (grate and pulp lifters) operates. The essential function of a pulp lifter is to transport the broken material and slurry from the discharge grate out of the mill. Hence, the design optimisation of pulp lifters affects not only the energy efficiency and throughput of autogenous grinding/semi-autogenous (AG/SAG) grinding mills, but also contributes other process benefits such as improved wear life and operator-friendly steady and smooth mill operation. Following its introduction in 2006, OutotecÆs patented Turbo Pulp Lifter (TPLÖ) design has been retrofitted at existing sites and also installed in some new ones around the world. This paper will provide operational experience and data on how the TPLÖ design has allowed AG and SAG mills to operate efficiently.

Jan 1, 2009

By R Dimitrakopoulos

Optimisation and mathematical formulations for open pit design and long-term production scheduling have been available since the 1960s. There are two main concerns in the application of existing mixed integer programming (MIP) models in open pit mines: a. the feasibility of generating both optimal solutions and practically mineable scheduling patterns and b. the inability to deal with in situ variability in orebodies and account for uncertainty. In dealing with these issues, a general open pit production scheduling method for multi-element deposits is presented and subsequently used to optimise the long-term production schedule in a nickel laterite deposit. The application shows the weaknesses of MIP formulations in terms of generating optimal solutions as well as practically feasible mining patterns. The application of the same formulation in the presence of in situ orebody variability and uncertainty uncovers a major reason for deviations of scheduled production from actual production, and outlines additional limits of traditional optimisation formulations as well as future needs.

Jan 1, 2003

By R Balusu

This paper provides an overview of computational fluid dynamics (CFD) modelling capability developed by CSIRO with the aim of improving the knowledge of flow migration dynamics within longwall goaf areas. The CFD models can be used to study the ingress of oxygen into the goaf in different ventilation scenarios and goaf drainage arrangements. This approach not only helps the design of effective gas control strategies but also the management of spontaneous combustion risk in the goaf. Innovative goaf inertisation strategies have been developed and implemented during longwall sealing operations. Work is continuing to develop general guidelines of proactive goaf inertisation strategies to suppress the development of spontaneous heating behind active longwall faces.

Jan 1, 2005

Chemicals derived from petroleum raw materials satisfy so much of our industrial needs today that it is good to pause and realise two things -ò the petroleum chemical industry is so new, and the use of chemicals is a very old one.Petroleum is such an'abundant and convenient source of raw material that in little more than 30 years it has become the major source of supplyfor chemical rdanuf ctiree This paperw~l'l 'disc'uss t1.e main 'r`easons' for this rapid development by considering the : sub jest -under tkzree headings ea. Source of Raw Materials.b. The Impact of Petroleum Chemicals on Plant Design and Processes. ce Scme of the Major Chemicals Used Today.

Jan 1, 1962

During conventional eddy current separation, a repulsive force is applied to metallic particles by placing them in a rapidly changing magnetic field generated by a spinning magnetic rotor carrying an arrangement of alternate magnetic poles. This method works effectively for larger non-ferrous metallic objects, such as aluminium cans, but as the metallic particles become smaller, the bulk repulsive force on the particles is increasingly replaced by a rotational torque. Therefore, for small metallic particles it makes sense to use particle rotation, rather than particle repulsion, to effect a separation. Eddy current separators using particle rotation are similar in construction to present separators, but are designed to produce a rotating field of essentially constant angular velocity and field strength. Practical and economic particle rotation eddy current separations are possible down to particle sizes of about 200 ¦m, but separations, at probably uneconomic rates, can be carried out on particles as small as 50 ¦m.

Jan 1, 2000

By Weller KR

Completely dry or completely wet materials are comparatively easy to screen, but materials with moisture contents between these two extremes can present varying degrees of difficulty. The presence of moisture can impair the performance of a dry screening plant in a number of ways: ò agglomeration of fine undersize particles onto larger oversize particles, resulting in the fine particles being misplaced to the oversize; ò increasing attractive forces between particles that hinder stratification and particle presentation to the screen; and ò blinding of the screen apertures caused by fine moist particles clinging to the screen which reduces the effective aperture size and the open area of the screen. Test work on full-scale screens has shown that the agglomeration of fine particles onto larger particles only occurs once the equilibrium moisture content of the ore is exceeded, and that the quantity of adhering fines present is proportional to the surface area of the larger particles. An -adhering fines screen model has been developed from this work, and by using relationships derived between the model parameters and feed moisture content, the effect of changes in feed moisture on both product quality and operation of iron ore dry screening plants is predicted.

Jan 1, 1993

By G Harbort, T Georgiev, M Phillips

Phu Bia Mining Ltd, a subsidiary of Pan Australian Resources Ltd owns and operates the Phu Kham copper concentrator located in the Xaysomboun District, Lao PeopleÆs Democratic Republic. Construction and commissioning of the 12 Mt/a copper concentrator and associated facilities was undertaken by Ausenco Ltd and handed over to Phu Bia Mining Ltd in April, 2008. The first copper concentrate was produced in April 2008 and the ship carrying the first shipment of copper concentrate set sail 27 July 2008. Nameplate mill throughput was reached in August, 2008 when 1 020 000 dmt of ore was treated in the milling and flotation circuit. The Cu-Au mineralisation is contained in skarn and stockwork mineralisation and is interpreted as a distal expression of a conventional porphyry copper-gold system. Copper mineralisation is principally in the form of chalcopyrite with lesser bornite. Gold occurs as small grains, typically associated with copper minerals. In the upper portions of the orebody, oxidation and water table movements have resulted in near surface leaching of the copper and below the leached zone, supergene enrichment resulted in chalcocite mineralisation. The circuit operates with a semi-autogenous grinding (SAG) û ball mill circuit, feeding a bank of OK200 rougher cells. Rougher concentrate is reground in an IsaMill prior to entering a cleaner circuit consisting of three stages of cleaning and one stage of cleaner scavenging. The concentrate typically assaying 24 per cent Cu and 6 - 7 g/t Au is hauled for over 1000 km across the border to the Port of Sriracha in Thailand, and stocked in sheds at the wharf from which it is shipped to various Asian smelters. This paper discusses the successful commissioning and ramp up to design tonnage and metallurgical performance. In addition, a program to optimise both the comminution and flotation circuit is detailed with reference to grinding efficiency, flotation residence time and size by size mineral recovery.

Jan 1, 2009

By S Blackburn, T Veasey

The physical and mechanical properties of rock can be measured by a variety of standard tests, and studies have shown that there should be a fundamental connection between breakage in comminution and rock æstrengthÆ. The current study aims to develop the ring-loaded strength test, used as an industry standard for the characterisation of brittle ceramics, for determination of comminution behaviour from exploration borehole core samples. The test procedure is simple, reproducible and can yield 250 separate measurements from a one metre length of drill core. The effects of material grain size and fabric on the degree of scatter of results have been investigated with respect to the ring-loaded strength test. This study has also compared the ring loaded strength to the chevron bend test used to determine the Mode I fracture toughness. A wide range of rock materials have been studied and with further work it is conceivable that an operational work index could be obtained directly from exploration drill cores tested via the ring-loaded disc test.

Jan 1, 2000

By Mortensen JK, Lang JR

The Canadian Cordillera contains numerous classic porphyry deposits and several unusual subtypes, including the alkaline suite of porphyry Cu-Au deposits and the Tombstone magmatic suite and associated Au¦W deposits. The alkaline suite formed in collisional settings in island arcs whereas the Tombstone suite was emplaced in an active fold and thrust belt in a continental arc. In addtion to different regional settings, these suites differ in the type of underlying basement, metallogeny, and the styles of mineralization. Both magmatic suites were emplaced over short intervals, probably in response to specific tectonic events. In the case of the alkaline suite, the tectonic event promoted magmatic processes suitable for the formation of porphyry Cu-Au deposits. The tectonic environment is less well constrained for the Tombstone suite, but the result was the formation of distinctive porphyry and intrusion-related Au¦W deposits.

Jan 1, 1995

By J Player, K Braddon

High productivity mining is the key to the financial success and stability of modern mines. This can be achieved through the use of new technologies, the development of innovative work practices and optimisation of the mining method to suit the mining environment. Big Bell Mine is a 1.7 Mtpa longitudinal sublevel caving operation at a head grade of 3.14 g/t. Annual production is 170 000 ounces of gold. The selection and implementation of bulk emulsion explosives was seen as the logical progression from blow loaded ANFO for the high tonnage rate required from the longitudinal sublevel cave. Prior to the implementation of bulk emulsions an investigation was required to examine the technical and financial benefits available with the introduction of bulk emulsion. This paper examines the review process and the successful implementation of bulk emulsion explosives at Big Bell.

Jan 1, 1999

By S M. C Verryn

Through the application of the Rietveld method, X-ray diffraction analysis has developed into a fully quantitative method for phase analysis of metallurgical products. The Rietveld method itself has progressed from an unstable method that required constant operator intervention to a stable and robust method suited even for routine process control. Knowledge of the crystal structures of the major phases is essential for Rietveld analysis, and these are well known for most minerals and major phases in metallurgical products. It provides the basic structural information necessary for the determination of mineral stoichiometry and for elucidating solid solution behaviour. Modern methods, such as simulated annealing and charge flipping, permits the determination of crystal structures from powder data. Unit cell data can be used where conventional microchemical analysis is unable to provide an answer to the extent of solid solution in ilmenite roasting. Unit cell data (by XRD) is used to determine the amount of roasting necessary for the development of magnetisation to be able to separate chromite from an ilmenite concentrate. Phase quantification is probably the most widely used application of XRD analysis. It is used for materials balance in the minerals and cement industries, and it is finding novel applications in the iron and steel industry. Applications of XRD in high-temperature metallurgical processes are increasing. In this paper the phase chemistry of iron ore sinters, the evaluation of subsolidus reactions in titania slags and the identification of furnace accretions are discussed. Despite the success of the Rietveld method in phase quantification, the method still needs further development in the quantification of closely related or polytypic phases. The quantification of pyrrhotite phases using various Rietveld programs still gives ambiguous results. This is also true for the different SFCA phases in iron ore sinters. Clearly the analysis of similar phases, differing only in the presence of weak superlattice reflections is still problematic.

Jan 1, 2008

By A Cooper

The current financial climate has given rise to fears that falling mineral prices and tight credit will force mining companies to cut back on production and new project development in a bid to cut costs and conserve cash. However, a prolonged squeeze on global supply can have only one result: a massive and potentially explosive demand for metals in the not-too-distant future. A resurgent global economy will also generate dramatic new demand for oil and energy, with a return to higher oil prices likely. How then should the mining industry plan for the future? In-pit crushing and conveying (IPCC) could lead the way as a partial or complete substitute for trucks. In 13 of 15 studies undertaken by Sandvik and Snowden, comparing IPCC with truck-optimised pit designs, IPCC generated operating savings ranging from US$0.18 to US$0.82 per tonne moved, compared to trucks. Trucks have higher operating, maintenance and energy costs than conveyors. New emission standards on diesel engines may make them more emission friendly but less efficient in terms of energy usage. With far more efficient energy use and cheaper operating costs per tonne moved than trucks, conveying offers an attractive alternative for the bad times ahead and into the apparent energy depleted future. When evaluating alternatives, a reasonable first step would be to conduct a scoping level study which analyses the differences in capital and operating costs between a truck and shovel operation and an IPCC solution. The study can also determine what type of IPCC is best suited to the particular mining application. The results can then be used to decide whether a more detailed study is justifiable. IPCC is a proven process that, with a fresh mindset, can make a significant improvement to mining operations. Sandvik (as an OEM with a full suite of IPCC equipment) can undertake these studies in ten working days in conjunction with Snowden or any other independent mine planner who knows how to schedule for IPCC. Because most mining industry personnel have been æborn and bredÆ on trucks and shovels û this paper focuses on some of the practical considerations necessary to make IPCC systems work that the Sandvik Technical Services Group has encountered during these studies.

Jan 1, 2009

By J C. Furness, F S. Cannon

Metal casting operations are a significant source of hazardous air pollutants. In particular, high production iron foundries emit significant quantities of volatile organic compounds (VOCs) during pouring, cooling and shakeout of iron castings made in green sand molds. End-of-the-pipeline capture and destruction methods to reduce VOC emissions add crippling costs to foundries. Alternately, the incorporation of advanced oxidants (AO) into metal casting green sand systems has been shown to reduce emissions from high production iron foundries in the US, and at the same time reduce operating costs. Cost savings are driven by the benefits of AO in clay recovery systems. Emissions reductions are the direct result of cascading AO-based reactions taking place in green sand molds. This sustainable greening of the metal casting process is a prototype for the development of other AO and non-AO process-based solutions for sustainable high temperature processing of materials. Fundamentals of AO technologies will be discussed along with the performance characteristics of AO processing systems in the metal casting industry and the breadth of other processing and remediation applications for which AO technologies have the potential to be successfully employed.

Jan 1, 2002

George Fisher Mine, near Mount Isa in northwest Queensland, has been producing Pb-Zn-Ag ore since the late 1980s. It consists of two separate underground deposits, George Fisher South and George Fisher North. These two deposits are drilled and modelled separately but are crushed and hoisted as a single stream. The Pb-Zn concentrator in Mount Isa processes ore from George Fisher Mine and Black Star Open Cut, with production also from the Isa Lead Mine until January 2006. This paper outlines the steps involved in setting up a robust reconciliation system for George Fisher Mine, in conjunction with requirements of the Pb-Zn concentrator, Black Star Open Cut Mine and the Mount Isa Lead Mine. Good quality input data and commitment to training have contributed to establishing a robust and effective reconciliation system. Reconciliation data has highlighted several other continuous improvement opportunities.

Jan 1, 2006

By A Thompson, E Villaescusa

The Western Australian School of Mines (WASM), Kalgoorlie, has been performing dynamic testing of reinforcement systems as part of the Minerals and Energy Research Institute of Western Australia (MERIWA) Projects M349 and M349A sponsored by WASM, the Western Australian State Government and the mining industry. These projects have resulted in the construction and commissioning of the WASM Dynamic Test Facility and a program of reinforcement system testing. The primary purpose of the WASM projects is to evaluate the performance of complete reinforcement systems when subjected to an axial dynamic load. The test procedure, monitoring and associated analysis enable assessments for each component (ie the element, the internal fixing mechanism and the surface hardware) of the reinforcement system. The performance of a reinforcement system is usually defined by a static force-displacement response to axial loading. However, this static response may not be applicable to dynamic loadings associated with violent failure of rock due to overstressing as mines progress to greater depths. It was therefore appropriate that the responses of reinforcement systems subjected to dynamic loading be defined and evaluated. The key findings from the tests on a number of reinforcement systems are presented and recommendations made regarding their application for dynamic loading.

Jan 1, 2008

By A Richmond

"In some lode-style gold deposits the geological (lithological) uncertainty may have similar economic significance as the grade uncertainty. In the absence of precise knowledge of the deposit geology, geological models of these types of deposits that are used to constrain spatially the estimated (or simulated) grade values may influence significantly the contained metal. Methods for assessing geological uncertainty quantitatively are rarely considered due to their perceived inability to consider exhaustive geological interpretations, and resulting models that often appear geologically unrealistic. Furthermore, should the lodes have been subjected to folding, or where the mineralisation continuity does not follow a planar orientation along strike or down dip, standard methods of variography and interpolation using linear vectors in space often do not provide a good representation of continuity. An alternative approach is to relate spatial samples from adjacent drill holes using an unfolding plane.The paper demonstrates conditional simulation of the geometry and gold grades of a folded lode-style deposit where:simulation of lode geometry considers explicitly the geologistÆs interpretation, andsimulation of gold grade values that consider explicitly the folded nature of the lodes.The results are contrasted to the traditional approach of linear vectors in real space for a single lode interpretation.CITATION:Richmond, A, 2012. Conditional simulation of a folded lode-style gold deposit, in Proceedings Narrow Vein Mining 2012 , pp 149-154 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Mar 26, 2012

Anyone who has driven backwards using only their rear view mirrors knows how difficult it is to avoid spinning the steering wheel the wrong way. So why run your mine that way? Traditionally Reconciliation has focused on the past performance of the mine. In this paper we make a case for Prognostication û the act of forecasting or predicting something in the future from present indications or signs. Reconciliation is a common activity carried out at most mines around the world. Countless geologists and engineers spend hours poised in front of spreadsheets diligently comparing how their resource/reserve model, grade control, and survey pick ups compare to what was actually produced. The result is usually a group of factors, which are applied to future estimates in an attempt to better predict how the operation may perform. Unfortunately, if the road ahead isnÆt the same as what you have just been down, youÆll be æoff-roadingÆ in no time! An alternative is to constantly collect and analyse key measurements that are used to calibrate critical estimates in an iterative process. When variations occur, they are analysed and corrective action is taken to ensure the estimates and measurements realign. In this way the estimates become forecasts and can then form the basis for decision making to ensure that what does happen in the future will match the plan or schedule. By automating this process, some mines have been able to be proactive on a daily basis in order to improve the overall performance of the operation. This paper outlines the key estimates and measurements used for reconciliation, details the characteristics of an automated web based information management system to facilitate the process and provides some insights about how mining operations might move beyond reconciliation.

Jan 1, 2003

Virtual reality (VR) simulators represent a powerful tool for training humans to perform tasks which are otherwise expensive or dangerous to duplicate in the real world. The idea is not new. Flight simulators have been used for decades to train pilots for both commercial and military aviation. These systems have advanced to a point that they are integral to both the design and the operation of modern aircraft (Adams, Klowden and Hannaford, 2001; Mastaglio and Callahan, 1995). This technology has been successfully extended and utilised in the mining industry in a range of successful applications (Bise, 1997; Denby and Schofield, 1999a; Schofield, 2005; Henning et al, 2002; Kaiser, Vasak and Suorineni, 2005). There are a number of lessons that can be learned from other industries that have successfully utilised virtual technology for a number of years. Specific rules of thumb regarding the specification, development, application and operation of these simulators can be garnered from other industrial training systems and examined in a minerals industry context (Tromp and Schofield, 2004; Schofield, 2006). This paper intends to discuss some of these generic rules in the context of a number of recently developed virtual reality mining applications.

Jan 1, 2008

By R Castroviejo, F Segundo, C Brea, J-C Catalina, H-J Bernhardt

Optical microscopy is a basic but still indispensable tool for examining mineral parageneses in ores. The design and concepts behind the reflected light ore microscope have obviously not been subject to spectacular technical evolutions in the last decades. However, digital imaging capabilities have opened new and stimulating perspectives for automated mineral identification. Recent works in developing multispectral image analysis (Pirard, 2004) have demonstrated its superior potential with respect to conventional colour imaging, but at the same time reconciliation with spectroscopic databases such as the Quantitative Data File III (Criddle and Stanley, 1993) still needs a more in-depth investigation as well as the possibility to extend both imaging and spectroscopy into the near infrared domain. In this paper, the authors present results gained from multispectral imaging in the range between 400 and 1000 nm together with spectrophotometric data from the QDFIII database, with an emphasis on minerals that cannot be easily distinguished in the visible spectrum.

Jan 1, 2008

This paper reviews hydrometallurgical processing technology for refractory gold ores, which form an increasing resource stock for gold. The reasons fQr ore refractoriness and pressure, chemical and biooxidation process options are briefly listed. Electrochemical technology, suitable for processing refractory ore is reviewed and some preliminary results for the electrochemical oxidation of slurried arsenopyrite are given.

Jan 1, 1992