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By A N. Parry, G van Wyk

"Sensor based automatic ore sorting technologies are used in the minerals industries to efficiently remove waste and submarginal grade material from crushed and screened run-of-mine (ROM) ore, producing a coarse (typically >10 mm) upgraded preconcentrate at an early stage in the mineral processing circuit. This avoids additional energy intensive downstream processing of this rejected component of the ROM feed, leading to lower unit operating costs and reduced tailings disposal volumes.Test work on bulk low-grade gold ore stockpile samples from Central Norseman Gold Proprietary Limited has been conducted, indicating high gold recoveries as well as high material rejection rates. A financial model, based on these results, evaluates grade sensitivity and identifies a minimum stockpile grade for adequate financial returns. The base case modelling estimates that the ex-stockpile grade (including the fines bypassed fraction) can be more than doubled through ore sorting and that the project will be highly viable with strong cash flow generation at stockpile grades as low as 0.7 g/t gold. The modelling will enable the company to benchmark ore sorting options against stockpile reclaim and screening operations currently employed. Citation:Parry, A N and van Wyk, G, 2016. Upgrading Low-grade Gold Ore Stockpiles by Preconcentration Using Ore Sorting - an Assessment of the Economic Impact and Viability, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 179–190 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By A P. Wilkinson

This paper reports on the implementation of the critical control concept to manage material risks in the mining and metals industries. The critical control management (CCM) approach assumes it is better to identify weaknesses in risk controls before an incident happens as opposed to discovering weaknesses from an investigation after an incident occurs. The first is sometimes referred to as active monitoring and the second as reactive monitoring (Health and Safety Executive and Chemical Industries Association, 2006). Both are needed. However, whilst methods for both active and reactive monitoring of risk controls are well established in many high hazard industries, such as oil and gas, petroleum and chemical industries, until the publication in 2015 of the International Council on Mining and Metals (ICMM) guides, (Good Practice Guide and the subsequent Implementation Guide) (ICMM, 2015), there was no specific mining and metals industry guidance on critical control management. This paper reports on progress in implementing the ICMM guidance drawing on two main sources. First, a benchmarking survey of a representative sample of coal and metalliferous mines, both underground and open cut/pit), sponsored jointly by the Queensland Resources Council and the Queensland Commissioner for Resources Safety and Health in the context of a recommendation that the Queensland mining industry adopts high reliability organisation (HRO) principals (Queensland Resources Council and Commissioner for Resources Safety and Health, 2022). Second, it draws on Noetic’s experience of implementing critical control management in mining and other high hazard industries in Australia, Africa, China and North America (Wilkinson, 2018). The paper describes good practices found and where significant improvements can be made, providing specific and actionable examples of both. From this it also identifies how future guidance on this topic could be improved.

Apr 16, 2024

Many young mining engineers do not consider consulting as a possible job, believing that many years of working on-site is required to achieve practical experience, develop expertise and acquire industry contacts. However, mining consultancies employ engineers with varying levels of experience, including part-time university students, graduates and engineers who are relatively new to the industry. This paper outlines the role of a young engineer in a large mining consultancy and the benefits to both the consultancy and the client of having a mix of consultants with a diverse range of experience. From the authorÆs perspective, the work experience, lifestyle and rewards of mine consulting are compared to site based work, including a discussion on whether consulting is able to offer the professional development that a young engineer needs.

Jan 1, 2009

By V Liebezeit

Data management is a significant, but perhaps unrecognised, consideration for any organisation embarking on a geometallurgy program. While resource geologists are accustomed to dealing with thousands or millions of samples and their associated assays, metallurgists and mineralogists have traditionally carried out only a few expensive and complicated tests and consequently tend to manage the resultant data in spreadsheets. The emerging discipline of geometallurgy arrives with significant challenges as a result of the sheer volume of data generated. As an example, the Olympic Dam geometallurgy program has generated more than:60 000 physical subsamples analysed for up to 30 analytes; 25 000 spreadsheet-based laboratory test results; 30 000 sized fractions analysed via QXRD, MLA and/or QEMSCAN;multiple external providers of data, and more than seven terabytes of data. Considerations for any geometallurgy data management system include storage space, data integrity, accessibility, traceability (sample provenance), maintenance and ease of use, integration with data providers and the ability to modify the system to adapt to changing requirements. Further, aspects of a geometallurgy program, such as conducting a range of tests on one sample, producing subsamples such as concentrates and tailings, compositing and routine QA/QC may not be well handled by existing software and providers geared to standard geochemistry, mineralogy or metallurgical test programs. The development of a geometallurgy database using existing software (AcQuire), and the associated file management system will be described for a large geometallurgy program at Olympic Dam. As with many aspects of geometallurgy there is no approach that meets the needs of every site or program. Recognition of data management as an issue, a structured approach in the program planning phase and commitment to executing the strategy will increase the chances of successfully mining the geometallurgical data.

Sep 5, 2011

By H Stedman

Integrating exploration and operational blastholes into one database significantly enhances geological modelling. Benefits include: improved coal predictions, stronger interpretation of structurally complex areas, detailed mapping of heat affected coal aureoles and additional roof accuracy for blast designs that deliver better coal protection.CITATION:Stedman, H, 2014. Integrating blastholes into exploration data to improve coal recovery and modelling, in Proceedings Ninth International Mining Geology Conference 2014 , pp 237–242 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 18, 2014

By D Piason

Newstan Mine commenced mining operations in 1887 and has since undertaken extensive mining within the Young Wallsend, Great Northern, Fassifern, Borehole and West Borehole coal seams using a range of mining methods including board and pillar mining and longwall mining.Newstan Mine is planning to extend the existing mine workings using longwall and miniwall mining methods to produce up to 4.5 Mt/a of run-of-mine (ROM) coal for at least 25 years. The planned extension in the Main East and South West sections will involve developing new longwall panels and related mains headings. The new area contains higher specific gas emissions (SGE) than previously experienced at Newstan Mine. To achieve the optimum ventilation requirements for the longwall operation in this new area, a new ventilation shaft was designed to be constructed using the blind boring method in the South West Headings section.This paper presents the shaft design parameters and selection criteria for the construction of the new ventilation shaft, including the construction phase and the holing process to connect the shaft to the underground workings. The paper also discusses future ventilation requirements for Newstan Mine.CITATION:Piason, D, 2015. South-west ventilation shaft project at Newstan Mine, in Proceedings The Australian Mine Ventilation Conference, pp 229–238 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 31, 2015

In May 2000, Kanowna Belle Gold Mines (KBGM) carried out a detailed Truck versus Shaft Haulage Study. The study showed that whilst the shaft option had many operating cost benefits the capital costs were too high, therefore the truck option was selected. In May 2001, the concept of achieving æshaft typeÆ benefits without the capital costs was floated. This is achieved by separating the hoisting of ore from other mining activities. The general concept is that material from underground is transported to a central location and then transported to the surface by a special truck fleet, thus removing the dependency between trucks and loaders, providing the mine with surge capacity and decreasing operating costs. At KBGM these advantages have been gained by installing an ore pass system with a plate feeder at its base that directly loads trucks. This provides the mine with a haulage system with enough surge capacity to remove the interdependency between trucks and loaders. The plate feeder is situated just off the decline which creates the opportunity to use larger more reliable, lower cost trucks. A number of truck types were considered for the truck loop including Elphinstone AD55Æs which are the truck type being used on site prior to the truck loop, CAT 775EÆs and power trailer road trains. This paper covers the philosophy behind the truck loop, the truck selection process, project installation and commissioning, people issues and the benefits expected by the operation. As of May 2002, the project is nearing completion, with decline haulage expected to commence in July 2002.

Jan 1, 2002

By A S. Derrington

This paper describes a hybrid ventilation system, which uses secondary fans that also act as de-facto primary fans to extract fresh airflow from the mine intake raise system. Also discussed are the associated problems such as uncontrolled recirculation, inadequate decline airflow, fire safety issues, prolonged blast fume clearance times, high air temperatures in main access routes, neutralisation of mine air cooling by heat from secondary distribution fans, increased ventilation system complexity, reduced flexibility and high pressure differentials (which cause safety issues with personnel access and reduce secondary ventilation system performance).Practical suggestions are provided on options to avoid these problems listed.CITATION:Derrington, A S, 2013. A critique of the push-pull hybrid ventilation system, in Proceedings The Australian Mine Ventilation Conference , pp 73-78 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 1, 2013

By Z Li, D Chalmers, J M. Tenney

This paper presents the findings and analysis of the investigation of effectiveness of thin spray-on liners (TSLs) as a gas management tool in underground coalmines. The project involves spraying TSL on the area surrounding gas drainage holes whereby the TSL acts as a thin membrane decreasing the permeability of the coal. This restricts air migrating through the coal seam and diluting gas from the drainage holes. There are a number of potential benefits from this technique but key points are that gas drainage holes produce gas with higher concentrations of methane. The design and execution of a field trial to investigate the effectiveness of a TSL on purity of in situ methane from gas drainage holes is presented in this report. For eight drainage holes, the results show an average increase in methane purity by 9.14 per cent and a reduction in air contamination by an average 7.93 per cent. Overall methane flow rate decreased by 27.6 L/s; however, flow rates were unreliable due to poor measuring equipment. For most holes, methane purity was not changed significantly; however, certain boreholes were responsible for most of the variation in methane purity. The boreholes showing a dramatic improvement in methane purity were likely those with intersecting cleats covered by the TSL. If the TSL was sprayed over more area, specifically in areas where the cleats are intersecting with holes, it is likely that purity of methane in the drainage holes will increase.CITATION:Tenney, J M, Chalmers, D and Li, Z, 2015. Thin spray-on liners potential in reducing dilution of in situ gas in underground coalmines, in Proceedings The Australian Mine Ventilation Conference, pp 323–328 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 31, 2015

The Bellambi Coal Company Limited com menced longwall mining at South Bulli Colliery in 1965. At present it operates three long- wall units in two seams. Although results to date have been less successful than planned, it is apparent that this type of mining has tremendous potential in the particular conditions at South Bulli. Massive sandstone strata above the Bulli seam is the controlling influence on face conditions. The earliest equipment proved to be inadequate and the Company has progress- ively replaced and upgraded the roof supports and ancillary equipment so that the present units are capable of producing high and consistent outputs.

Jan 1, 1976

By J Välivaara

The mining industry will face numerous challenges over the next 10–15 years as new deposits are likely to be more remote and lower grade and existing deposits will be mined deeper. As a result, mines and mining contractors operating in deep-mine conditions will need to focus on the quality of drilling and blasting to minimise unnecessary waste rock excavation to keep costs at an acceptable level. In addition, increased demand for improved safety and operator ergonomics will set greater demands on original equipment manufacturers of mining equipment. Finally, difficulties finding a skilled and experienced workforce, particularly in remote mine locations, have already negatively impacted mines’ ability to achieve high productivity and low operating costs.This paper introduces techniques and shares practical experiences in increasing productivity and reducing the costs of excavation in underground face drilling. The paper uses Sandvik’s new DD422i automated mining jumbo as an example of the type of equipment needed to deliver the features and corresponding benefits for future mine development. Case studies using this equipment are presented to illustrate the points made in this paper.CITATION:Välivaara, J, 2016. Automated drilling features for improving productivity and reducing costs in underground development, in Proceedings Seventh International Conference and Exhibition on Mass Mining (MassMin 2016), pp 723–730 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2016

By Minchinton A

CPeX is a non-ideal explosive performance prediction model. The model takes into account the rate of energy release, the extent of chemical reac- tion and the effect of confinement on energy release. The model resolves the explosive energy into `shock' and `heave' com- ponents as a function of explosive type, hole diameter and rock type. The predictions of the model are compared for a bulk emulsion, and a prill-doped bulk emulsion in soft rock. The predictions, based on calibra- tion of the model with simple unconfined detonation velocity measure- ments, show the significant effect of non-ideality on explosive Performance.

Jan 1, 1988

By J Fewings, T McCredden, S Seet, C Fitzmaurice

"Flotation of nickel sulfide ores are generally constrained by nickel grade and impurity concentrations (notably magnesium and arsenic) in the product delivered to smelters. Being a physical separation process, flotation recoveries and grades are limited by the grade recovery curve of a particular operation, where increasing product grades are invariably associated with lower recoveries. Impurities put further pressure on this relationship, as removal of impurities from the final concentrate is almost always associated with nickel losses.Western Areas Ltd are developing a proposed expansion to its Cosmic Boy concentrator to treat an impurity stream, that is high in nickel and would otherwise report to tails. Through the use of BioHeap® technology Western Areas aims to recover the nickel and discard the arsenic to tailings. This expansion will consist of a biohydrometallurgical plant that leaches the nickel arsenic minerals, removing the arsenic as a stable iron/arsenic hydroxide, while recovering the nickel as a high-grade nickel sulfide product (at approximately 50 per cent nickel). This can then be blended with final concentrate to improve nickel grades and recoveries, while simultaneously reducing impurity levels or used to produce high value products like nickel sulfate.The introduction of a small microbial leach plant may be beneficial to base metal concentrators constrained by impurities or grade.Citation:Fewings, J, Seet, S, McCredden, T and Fitzmaurice, C, 2016. BioHeap® - Breaking the Grade/Recovery Curve for Nickel Concentrators, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 361–368 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By L P. Gray

"From paving the way in gaining approval for the first metalliferous in-pit tailings storage facility (TSF) in Victoria, to developing a deposition methodology to optimise the storage capacity and provide a final rehabilitated surface which replicates the premining topography, in-pit tailings storage has proven not only to be a cost-effective means for tailings management at Fosterville Gold Mine, but also one which provides significant economic, social and environmental benefits. Coupled with ongoing raising of the existing above ground TSF and commissioning of a new above ground TSF, Fosterville Gold Mine have to date effectively used three open pits for in-pit tailings storage, with one of the pits currently progressing through the capping and vegetation establishment phases of closure.This paper presents the process adopted by Fosterville Gold Mine in their flotation tailings management, from design and operational phases through to rehabilitation implementation. Included within the paper are challenges which have arisen during the process, and a discussion on principals behind the designs and lessons learnt during operation of the facilities.Citation:Gray, L P, 2016. Full Cycle Tailings Management at Fosterville Gold Mine, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 369–378 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By H Mischo, M Ferber, M Donner, B Jung, S Grehl, A Dietze

Mobile robots have been making impressive inroads in a variety of domains. Within the Mining-RoX project, Technical University Bergakademie Freiberg is exploring a further frontier for mobile and autonomous robots: underground mines. The potential benefits of mobile robots in underground mining are plentiful as underground mines are strenuous and potentially dangerous working environments for humans. A higher degree of automation, with robots either acting as helpers for human miners or even replacing all human personnel deployed underground, could help to significantly reduce mining costs. In disaster cases, rescue robots could help to find missing personnel. Unmanned mines operated by robots alone would not endanger human lives at all. Further use cases, and a particular focus of the Mining-RoX project, are mobile robots that gather sensory information of the underground mine (eg for the purpose of creating detailed 2D and 3D maps) as well as monitoring environmental conditions such as air and water quality. This paper presents the design of a prototypical mobile robot for mapping and monitoring underground mines. A generic robotic platform was extended with various 2D and 3D imaging devices as well as other sensors. First results from test runs in an underground mine are reported. Maps of two sections of the mine enhanced with localised sensor measurements were successfully created.CITATION:Grehl, S, Donner, M, Ferber, M, Dietze, A, Mischo, H and Jung, B, 2015. Mining-RoX – mobile robots in underground mining, in Proceedings Third International Future Mining Conference, pp 57–64 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 4, 2015

By M Pomery

BHP’s Western Australian Iron Ore Operations (WAIO) move approximately 250 million tons of ore per annum. The magnitude of the constant changes to the terrain models along with the diverse output and presentation requirements of numerous stakeholders presents significant challenges for the geospatial team. This paper describes how the WAIO Survey team use a combination of technology and optimised workflows to capture, ingest, publish and access large data sets for diverse stakeholder requirements. Machine learning for processing of data and the use of web based systems to track and prioritise task allocation of resources will be discussed in detail, in addition to the changes to the traditional roles of surveyors from the use of automation and mobile technology.

Sep 18, 2023

By M Akop, G Phillips, L Elliott

An estimation geologist has many tools in their kit and using the correct one for the job is vital for creating a useful model. Reconciliation is a key step to monitor the performance of a resource model and to ensure the correct tools have been selected and appropriate parameters are set. This paper presents an example of refining the estimation methodology for a Channel Iron Deposit (CID), resulting in an improved model. Rio Tinto Iron Ore (RTIO) CIDs are unique iron ore deposits located in the Pilbara region of Western Australia and contribute a significant volume to the world’s seaborne iron ore market. A problematic feature of these deposits is the irregular dispersion of clay pods that cannot be delineated with confidence within the resolution of the exploration drilling. Resource to grade control reconciliation showed an over-prediction of high-grade material in the resource model. A fresh approach was required to improve grade and tonnage predictions. Historically, clay pods were delineated using traditional wireframing techniques and estimated using ordinary kriging with hard boundaries. The new method utilised indicator kriging to estimate the probability of clay. Probabilities generated from the indicator kriging estimate were used as an additional weighting following the ordinary kriging of grades. Results showed indicator kriging improved global high-grade tonnes reconciliation, however, as expected, it did not improve the spatial prediction of clay. Based on improved reconciliation results indicator kriging has now been adopted as a suitable alternative for analogous CIDs at RTIO. These improvements benefit the mine planning process, but do not replace grade control models.

Mar 22, 2022

By J Player, G Sweby, S Webber, E Jones

Seismic systems are a tool for the monitoring and forecasting the rock mass response to excavation. Common issues encountered at mine site audits and reviews are: how to design an effective seismic system, implementation of the design, interpretation of seismic source results and understanding the reliability of the seismic source. These issues are often a function of several items including: • Experience of site personnel in undertaking seismic system design. • Personnel not envisioning multiple phases of system expansion to understand system robustness issues. • System design/expansion occurring in response to damaging seismic activity rather than planned expansion of a system • The mine access development is often localised in comparison to the total orebody being mined hence, planning sensors in longholes in advance of development rather than in short holes close to development will improve the three-dimensional aspect of the network. • Limited site processing of the seismic event data, hence engineers do not see the uncertainty associated with event location, size, source and system layout. Mine site users require a framework to appreciate the challenges and limitations in locating large events. For example, event locations are given as precise measurements (to the nearest centimetre) whereas the volume of deformation resulting in the event often has dimensions of tens of metres or more (as defined by the source radius). A stronger awareness of the uncertainty of rock mass yield within large seismic sources will assist site users in the interpretation of rock mass damage. The encountered design and implementation errors are reviewed and discussed with a practical set of rules presented to provide a robust seismic system that provides consistent results and increases the user’s understanding of uncertainty in source location and size. The authors’ experience across multiple mine sites, seismic systems and damaging seismic events over a 30 year period has been summarised into practical rules for site personnel of all experience levels.

Nov 29, 2022

By M Darvall

Magnetite ore blending has yielded signifi cant performance improvements in OneSteel’s magnetite concentrator. The magnetite concentrator beneficiates magnetite ore from the Iron Magnet Deposit and produces concentrate, which is pelletised, then fed to the OneSteel Whyalla blast furnace. Concentrator feed variability severely detracts from the concentrator’s performance, affecting both concentrate yield and grade, which impacts on all downstream processing costs.A coordinated approach has integrated mine planning, geological modelling and grade control, to minimise concentrator feed variability, through effective ore blending throughout the mining and stockpiling process.Mine planning personnel design shots that extend the full width of the orebody and hence across the stratigraphic profi le. Based on geological information contained in block-outs and in consultation with Geology, the Grade Control team allocates material to each primary stockpile, potentially from every stratigraphic domane in the orebody. This ensures primary stockpiles are designed with maximum practical homogeneity and consistency.Using only primary movement, the allocated ore is stockpiled in a layer-cake fashion. The ore is pimple dumped across the width of the stockpile footprint and on completion of a layer, it is dozed flat with an access ramp that allows dumping to commence on the next lift. The primary stockpiles are reclaimed normal to build direction and the magnetite is crushed, all in, to a concentrator feed stockpile.The ore is sampled at the crusher from a falling stream cut. These assay data, are used for benchmarking and control charting the grade and variability of concentrator feed stockpiles. The concentrator feed stockpiles have demonstrated a statistically signifi cant reduction of within pile variation, between pile variation and pile to pile variation, primarily attributable to the development of ore blending. The concentrator has seen sustained, improved performance as a direct result, which translates into lower concentrate cost per tonne and improved yield and quality.

Jul 11, 2011

By C Hoffmann

Given that each year, 30–40 per cent of mining industry deaths are attributable to failures of vehicle interaction controls (EMESRT, 2023), the mining industry is now armed with a growing body of knowledge from EMESRT (Earth Moving Equipment Safety Round Table) and ICMM (International Council on Mining and Metals) global vehicle interaction initiatives over the past years, that enables mining companies, OEM’s and technology providers to work together to develop and implement more effective controls and drive the adoption of capable solutions. Leveraging 20 years of experience as a global technology provider of Proximity Detection System (PDS) and Collision Avoidance System (CAS) solutions for surface mining operations, Wabtec Digital Mine Technology shares key insights for ensuring the effective selection, implementation and integration of these technologies into existing mine site controls and mining operations for effectively reducing vehicle interaction risk enabling mines to drive towards ‘zero-harm’ objectives. Topics covered include: alignment with industry best practice for controlling vehicle interaction risk by EMESRT and ICMM, importance of the maturity of EMESRT levels 1–7 vehicle interaction (VI) control framework, managing expectations that PDS/CAS is a ‘silver bullet’, alignment with industry functional – performance – technical requirements, proximity detection versus collision avoidance, sensor performance and fusion and limitations, rules engine intelligence critical to mitigating nuisance alarms during normal operations, system health monitoring and reporting, human factors engineering and operator acceptance, implementation strategy, installation standards and quality control, change management program, training programs, reporting and data analytics with actionable insights and maintenance strategies. Insights will also be provided on the challenges moving from EMESRT levels 7 (operator awareness) and 8 (advisory controls) to level 9 (intervention controls) as it’s a journey not an out-of-box solution, the growing demand for coexistence of CAS and Autonomous Haulage Solutions (AHS), functional safety approach, value added systems integration and the applicability of new emerging technologies.

Apr 16, 2024