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By P Mulvey

"Currently mine process studies and geochemical waste characterisation are considered as two interdependent studies, necessary for the development of the mine and inclusion in the environmental impact statement (EIS). Geochemical waste characterisation will utilise the simulated tailings produced by the mine process studies team to understand the behaviour of the tailings, but the two teams rarely integrate these to develop a coherent and agreed final design.Thorough mine waste geochemical assessments can develop processes to minimise environmental harm, resulting in substantial savings in the decommissioning, closure and rehabilitation phases, and may also be able to address changes in mineral processing methods that can result in substantial savings in process inputs, or even recovery of metal concentrates.Based on geochemical waste characterisation, the full cost of waste management can be calculated and incorporated into the costing of milling.  This allows for a more effective evaluation of the metallurgy.  A number of examples are presented in which substantial improvements have been made from the collaboration of both the metallurgical and geochemical teams during planning and the metallurgical team and environmental team during operations.*This paper is only available for individual download. It is not included in the conference proceedings*CITATION:Mulvey, P, 2013. Optimising metallurgy at the planning stage to minimise environmental impact - a feedback loop from geochemical waste characterisation, presented to MetPlant 2013 Conference (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Jul 15, 2013

By Whitham M

Prior to exploitation, the feasibility of mining and recovering ore can usually be determined to a satisfactory level of uncertainty by the consideration of conceptual scenarios, using a range of reasonable parameter values. Such values are selected on experience, knowledge of other mining operations, and the characteristics of the particular deposit being considered. Having established such feasibility, it is usually considerably more demanding to determine what the optimum set of parameters might be. Yet many decisions taken at the feasibility stage represent commitments extending at least into the medium term.

Jan 1, 1991

By L O. Filippov, Q Dehaine

Variographic analysis, a classical tool from the Theory of Sampling (TOS), can address practical situations with multiple variables; however, its application has very often been limited to one variable at a time. Recent developments have shown the benefits of using multivariate approaches for variographic characterisation of a set of variables instead of considering individual variables sequentially. Among these approaches, the multivariogram has been revealed itself to be a powerful tool when the overall time-variability of a process must be summarised in terms of a large set of properties (variables) to assess its true global variability. However, even when choosing the properties of interest carefully, the resulting global variance obtained with this approach may be very high. In particular, some variables that contribute to a major proportion of the global (multivariate) variability could be less important for the process performance than others having a lower variability. To address this issue, a new approach is proposed, combining the multivariogram with process modelling and multivariate data analysis methods such as partial least squares (PLS) regression from chemometrics. An example from the mineral processing industry is presented, for which the process performance could be linked to key process variables (sensor data) using the PLS regression. Once introduced in the multivariogram equation, PLS model parameters (loading-weights or regression coefficients) can be used to weigh the variables according to their relevance for the process. In addition, this also permits characterisation of process performance variability with time using only the process input variables and a weighted metric according to the PLS regression model. Ultimately, this method helps to find an optimised sampling procedure in terms of frequency, sampling mode and number of increments according to the actual overall process performance. This approach has potentially many applications in the mining, feed and food, pharmaceutical or any other industry for which it can be used to reduce risks and ensure a better use and management of resources.CITATION:Dehaine, Q, Filippov, L O and Glass, H J, 2017. Optimising multivariate variographic analysis with information from multivariate process data modelling (partial least squares regression), in Proceedings Eighth World Conference on Sampling and Blending , pp 381–390 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2017

By H Kurth

Geoscan is used for multi-elemental analysis of conveyed bulk materials in real time. It has been used for coal analysis since the 1990s, in the cement industry, and since 2003 for measuring mineral ore quality. Geoscan-M has proven performance and demonstrated paybacks of weeks or months, in iron ore, manganese, copper, zinc-lead and phosphate industries. Geoscan-M measures continuously through the full bed depth and is unaffected by belt speed, particle size, layering and dust levels. Increments of two minutes (typically one to five minutes) are accurately measured and provide the plant operators with tonnage weighted results of each element within seconds.A Geoscan installed after crushing is able to measure quality shortly after mining. The analysis results can be used to divert the increments based on composition, such as diverting waste for disposal and diverting marginal material to a stockpile for processing at a later date. The bulk sorting process allows different qualities to be placed into relevant stockpiles for subsequent blending. Material meeting product DSO (Direct Shipping Ore) quality can bypass a beneficiation circuit to prevent unnecessary treatment costs. An analyser in a blending application enables proportioning of different quality feed materials from multiple stockpiles to achieve a desired compositional consistency for process feed. The parameter used for decisions may be; a) primary metal content, e.g. Cu, Fe, P, etc. b) deleterious component content, e.g. Mg as an indicator of talc content, c) process parameter content, or a combination of these. Process parameter content may be the elemental ratio between critical components, e.g. Cu:S ratio, Fe:Si ratio, basicity, Lime Saturation Factor, etc. or the content of an “indicator” element, e.g. Si as an indicator of material hardness or grindability.Measurement of the composition in real time enables prompt feedback to the mining operators and also feed forward to the process operators. Compositional variability can be critical in the process and advance warning enables appropriate reactions prior to processing. This may include modifying the feed rate, changing the feed blend (through additives), or modifying reagent dosing in anticipation of a change in feed quality. Benefits include, but are not limited to; reducing waste processing, improved feed grade stability, reducing energy, water and grinding media consumption, producing less tailings, increasing process efficiency, higher metal recovery, better plant utilisation, reducing plant downtime, better utilising mined material, all achieved using the same process plant throughput capacity.CITATION:Kurth, H, 2015. Optimising plant feed quality and process performance using Geoscan elemental analysis, in Proceedings MetPlant 2015, pp 373–380 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 7, 2015

"Geoscan is used for multi-elemental analysis of conveyed bulk materials in the minerals industry with proven performance and demonstrated paybacks of weeks or months in iron ore, manganese, copper, zinc-lead and phosphate industries. Geoscan-M measures continuously through the full bed depth and is unaffected by belt speed, particle size, layering, mineralogy and dust levels. Increments of typically two minutes are accurately measured and provide the plant operators with tonnage weighted results of contained elements. Measurement of the composition in real time enables prompt feedback to the mining operators and also feed forward to the process operators. Crushed ore increments can be diverted based on composition, such as diverting waste for disposal or marginal material to a stockpile for separate processing. Bulk sorting allows material to be placed into relevant stockpiles for subsequent blending to achieve consistency for process feed. Parameters used for decisions may be primary metal content, deleterious component content, other process parameter, or a combination of these. Process parameter may be the elemental ratio between critical components, e.g. Cu:S ratio, basicity, or the content of an “indicator” element (such as Si indicating material hardness). Benefits will be discussed based on case studies in copper and iron ore.IntroductionAs operators of process plants strive to remain competitive as capital and operating costs increase and commodity prices fluctuate, more focus has been directed at incremental performance improvements at incremental cost rather than major expansions to increase output. The philosophy of working smarter allows plants to adopt technologies proven in other industry sectors to minimise risk. This paper discusses one such technology that the minerals sector is adopting and has found to be safe, reliable and accurate with paybacks of weeks in most applications. New applications continue to be found and major benefits realised at various stages in the processing and handling of ores and products."

Jan 1, 2016

By André van Wageningen

Long-term mine scheduling is one of the most difficult optimization problems. The problem is said to be NP-complete in that the best possible solution cannot be found any quicker than checking all possible permutations and combinations. Although a number of techniques have been used in the past, many include significant simplifications or fail to produce acceptable results within the required timeframe. Genetic Algorithms (GAs) are among the most promising optimisation techniques within operations research. They are based on natural selection and evolution of solutions to complex problems. They have been known to quickly converge within a few percent of the optimal solution by examining only a fraction of the solution search space. The GA itself contains very little problem specific information and as such, has been linked to a discrete-event simulation (DES). The DES feeds information regarding the feasibility and quality of the solutions back to the GA during the optimisation process. In this paper, GAs and DES are described and the coupling of the two methods is outlined. The GA coupled DES is then used to ?optimise? a problem and the results are discussed.

May 1, 2004

By Andrew J. Brennan, Jonathan A. Knappett, Lewis Hamilton, Michael J. Brown

"Abstract This paper investigates the compressive behaviour of screw piles in sands and the key design parameters which control this. These types of foundation elements have typically been used as screw anchors onshore (i.e. for their tensile capacity), but there is increasing interest in their potential use as compression piles for supporting offshore marine renewable energy (MRE) devices (e.g. wind and tidal turbines) in deeper water. For such foundation applications, the compressive capacity is as important as the tensile capacity and is not well understood, particularly in cohesionless soils which are a likely seabed condition in MRE applications. A 1-g laboratory study was initially conducted on small scale model screw piles in sand beds of various relative density between 25 – 88%. These experiments were used to validate a Finite Element (FE) model having a stress-dependent constitutive model, making it useful for future up-scaling of the pile size for field applications. Following validation, the FE model was used to conduct a parametric study on the effects of flange spacing ratio (s/Dflange) and flange to shaft diameter ratio (Dflange/Dshaft). By using a validated FE model for this study, it was possible to observe the failure mechanisms (through the shear strain distribution) within the soil and correlate these with the pile capacity. This information was then used to comment on the most optimal (cost-effective) pile design for supporting compressive loads. This study represents a key step towards producing design tools appropriate for the design of screw piles in MREapplications.IntroductionAs defined in this paper, screw piles consist of a central small diameter hollow steel shaft, around which thin circular steel flanges run. Their principle of operation is that the flanges are spaced so as to trap the soil between them, thereby acting as an equivalent solid pile of the outer flange diameter, with a fully-rough ‘shaft’ interface (as shearing is soil-soil). One of the most important design decisions relates to the spacing of the flanges – if the flanges are spaced too far apart, then the soil will not be effectively trapped and the pile have a lower axial capacity and stiffness (controlled by the shaft friction along the central shaft and the bearing resistance arising from the individual flanges; If the flanges are spaced too close together, then there are potentially flanges which are not contributing to the pile capacity, therefore making the pile more expensive than it needs to be."

Jan 1, 2014

By A. M. Hearn, J. G. Roos

Energy consumption, being a large proportion of the input of the ferroalloy production process, can be measured in terms of the efficiency with which the energy is utilized and the effectiveness with which it is used. The efficiency of the usage of energy revolves around the specific consumption of the energy for the production of the alloy, which encompasses the thermodynamic aspects of the process and is more of a metallurgical function that will not be addressed further in this paper. The effectiveness with which the energy is utilized is determined by the optimisation of the electricity supply from the utility (in this case Eskom). The South African electricity supply industry is on the brink of considerable restructuring, implying changes in ownership, structure and regulation. In other countries, however, restructuring has often seen higher prices. Owing to the diversity of growth prospects in South African markets, Eskom is turning to new market management and generation strategies. In future, Eskom will develop pricing strategies to increase demand from attractive customer segments such as paper & pulp, iron & steel, aluminium, and other metallurgical industries. There will be a broader spectrum of product offerings, including dynamic pricing options and demand-side management incentives. In a future electricity market that will become more dynamic and demanding, it will become increasingly important for electricity consumers to optimise their electricity supply. There are many facets in optimising the electricity supply, which include optimal utilisation of the tariff, integrating energy cost management into the production planning process, implementation of demand-side management actions, modelling, scenario planning (.what-ifs?.), optimisation, maintenance scheduling coordinated with the tariff periods, etc. This paper gives consideration to the status of the development of technology at the manganese alloy works of Samancor at Meyerton, South Africa in order to increase the effectiveness with which energy is utilized.

Jan 1, 2004

Consolidated Rutile Limited (CRL) was one of the best performing mining stocks of the turbulent 1980s, having a very high payout of franked dividends. In contrast to some other mining groups, it was not highly involved in the speculative lead-up to the 1987 sharemarket crash. Its base was firmly laid through a succession of decisions that were taken in the period 1982-1985. These decisions and the rationale behind them are outlined in this paper. CRL began the 1980s in a highly favourable position. It had successfully pioneered the transition to high-throughput mining of the high dunes on North Stradbroke Island (NSI), commissioning its 2100 tph cutter suction dredge at the Bayside reserves in 1978 at the time of rising prices, such that it was able to pay off its modest bank loan within 18 months. The June 1980 results showed a record after-tax profit of $5.6M, from total assets fo $26.5M and sales tonnages of rutile and zircon of around 50,000 tonnes each.

Jan 1, 1991

By Y Li, S Ramazan, E Topal

A mine waste dump progression plan can provide a clear outlook of the mining operation. To produce such an output requires detailed placement schedule of the mined material, including the volume (or tonnage) and the allocated dumping location. However, current practise mainly focuses on the ore production, over-simplifying the waste material scheduling. As a result, a rock dump is often treated as a single point in long-term planning, making it difficult to predict the waste dump progression pattern over the life-of-mine. Without such a guidance, it is almost impossible to carry out progressive rehabilitation on the waste rock dumps. The lack of dumping schedule could cause delay in development construction, ie tailing storage facility and run-of-mine pad. Other downstream effect due to the over-simplification is inaccurate estimation of required truck hours, which could have huge financial impact on the operation.In this paper, mixed integer programming (MIP) models of different objective functions, ie maximise truck productivity by minimising the overall haulage distance, minimise required truck deviation between adjacent years, and a hybrid between the two objectives, are utilised to generate the long-term optimum rock placement schedules under the criteria of satisfying site specific conditions. All three MIP models are implemented in a large scale open pit mine. The numerical solutions from the models forms three different rock placement schedules, based on which, the yearly truck requirements are easily calculated and compared. The graphical results show the three corresponding waste dump progression patterns over the life-of-mine, providing the optimised long-term forecast of the operation.CITATION:Li, Y, Topal, E and Ramazan, S, 2014. Optimising the long-term mine waste dump progression and truck hour schedule in a large-scale open pit mine using mixed integer programming, in Proceedings Orebody Modelling and Strategic Mine Planning Symposium 2014 , pp 335–344 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 24, 2014

By K. Barbetti

"The carbon-in-pulp (CIP) process has been the dominant gold recovery process since the early 1980s. CIP has proven to be very adaptable for a wide range of ores and circuit configurations. The key performance indicator for CIP circuits is the minimisation of soluble gold losses to tailings, however, it is also important to operate the circuit efficiently (maximising gold loadings on carbon and minimising carbon inventory). Over the last 30 years the Curtin Gold Technology Group has studied CIP circuits as part of an on-going collaborative industry funded project (the AMIRA Gold Processing Technology Project). In the early years the project undertook basic research into understanding activated carbon, and its management in the circuit. More recently the development of process models and instrumentation has provided additional tools to assist operators. The results show that while most CIP circuits operate well, there are still significant opportunities for further cost savings, or additional revenue. This paper reviews the observations arising from this work, including key requirements for good carbon management, the results of benchmarking and industry surveys of carbon circuit over 20 years, the value of process modelling of CIP circuits to establish operating parameters, and the use of automated instrumentation to better optimise carbon control in the circuit.INTRODUCTION The introduction of activated carbon to recover gold from cyanide leach solutions in the last quarter of the 20th century was the most significant development in gold ore processing since the advent of cyanidation seventy years before. Replacing the Merrill–Crowe zinc cementation step with carbon-in-pulp (CIP) or carbon-in-leach (CIL) circuits provided a process that allowed the treatment of lower grade and problematic ores (e.g. high-clay ores), at lower capital and operating costs, and higher metal recoveries. The CIP circuit was first developed in the 1950s at the Carlton Mill, Cripple Creek, Colorado. All the components of the modern CIP process came to fruition at the Homestake Mine in South Dakota in 1973 (Fast, 1988). From the late 1970s onward a variation of CIP, carbon-in-leach (CIL) which combined the leach and adsorption stages, became the preferred circuit design in most parts of the word."

Jan 1, 2017

By D Pateman, F de Fredrick

The Bentley underground mine, which is located 60km north of Leonora, Western Australia, is owned and operated by Round Oak Minerals Pty Limited. A high-grade Zn-Cu Volcanogenic Massive Sulphide (VMS) orebody, Bentley was discovered in 2008 with production commencing in 2012. Long-hole open stoping is employed to mine the steeply dipping ore body, and in recent years the Avoca method has been adopted. This requires all development in a particular area of the mine to be completed prior to stoping commencing in a bottom up sequence. Voids are commonly backfilled with loose Run-of-Mine (ROM) waste loose rockfill (LRF); or alternatively cemented rockfill (CRF) can be used. Stopes in the 3860 AOS and 3900 AOS panels were located below previously extracted Avoca zones, with LRF situated immediately above them. These high-grade stopes were originally designed with rib and sill pillars to maintain control of the existing backfill during extraction. Due to changing factors over time, including mining economics, alternative options to achieve full extraction of the stopes were reviewed, including: • Mining small successive full height stopes which would involve drawing a blanket of LRF down with the extracted ore (stoping under waste); • Stabilisation of the existing LRF above the stopes and implementing a primary/secondary stoping sequence, with the primary stopes backfilled using a cement fill. An assessment of these options was undertaken which determined that the second full extraction method was the most beneficial to the operation, and could be achieved using a cement grout (Minova’s FB200 grout) to stabilise the LRF in conjunction with implementing a sequence where the primary stopes would be backfilled with cemented aggregate fill (CAF). Footwall drives were developed adjacent to the rockfilled stopes, allowing for the installation of horizontal grouting conduits, as well as providing access to the top of the planned 3860 and 3900 level stopes for the placement of CAF. An interval at the base of the previously rockfilled stopes was grouted at multiple horizons to achieve the required thickness, with a comprehensive quality assurance/quality control (QA/QC) process undertaken. Primary stopes were CAF backfilled via an arrangement of downhole winzes, linking the top of primary stopes to cross-cuts developed off the associated footwall drives. CAF was delivered underground through an open reticulation network that was extended to the specific levels. Overall the successful implementation of the revised mining method effectively increased ore recovery while maintaining control of overbreak and dilution, providing significant financial upside. This was achieved while maintaining effective controls in light of the changes to the risk profile. Stabilisation of the existing rockfill has allowed the extraction of stopes to full height, including the originally designed sill pillars, representing an average 23% increase in ore tonnes on the initial design, with dilution from the stope crowns averaging less than 1%. The use of CAF in association with primary/secondary stoping, eliminating the need for rib pillars, has yielded an average 47% increase in ore tonnes compared to the base case mine design.

Mar 15, 2021

By Gloria Lara

El presente texto señala la aplicación de la metodología de daño proporcionales a tres casos de correas transportadoras críticas que funcionan sobrecargadas en una minera al norte de Chile y así determinar el nivel de carga necesario para mantener un nivel de confiabilidad.

Mar 1, 2015

By Joseph Javes Aramburú

El presente texto describe la optimización del circuito de molienda y clasificación de la planta de hierro, el cual comprende un molino de barras y de bolas. El proceso se inicia con la exploración geológica, se determinan las reservas probadas y probables, y se establece la forma de explotarloLa eficiencia de la molienda está en función del volumen útil del molino a diferentes volúmenes de llenado que permite determinar los parámetros óptimos de la operación.

Apr 1, 2013

By Miguel Calderón Rojas

"Quiruvilca, es una mina con sistema de mineralización de vetas angostas , donde el buzamiento de veta es variable entre 35° a 85°, y la calidad de roca es baja. En ese sentido, el presente trabajo describe el proceso de optimización del sostenimiento de las labores de minado (corona) a través del uso de pernos splits set y malla de acero electro soldada, en reemplazo de la madera. De forma que se genera mayor tiempo para elproceso de perforación y se determina labores que realizen voladuras masivas, mejorando la productividad y minimizando los ciclos de perforación y voladura."

Sep 14, 2009

By Jimmy Gabriel, Hugo Aráoz

El agua es un componente ambiental que prácticamente afecta todos los procesos de las operaciones minero – metalúrgicas en la UNIDAD MINERA Orcopampa, en este sentido la gestión de recursos hídricos busca justificar todos los posibles usos del agua en las operaciones, el que también incluye las medidas de control o mitigación que permitan reducir los riesgos de manera preventiva y proactiva. En este sentido las actividades implícitas a la gestión de recursos hídricos van desde la evaluación de las fuentes de agua disponibles a fin de cumplir con la demanda de agua para las operaciones mineras a corto y largo plazo.

Sep 1, 2017

By Christian Huihua, Armando Moyonero, Jorge Escalante, Alberto Valera

A raíz de una mayor demanda de horas hombre para cumplir con el mantenimiento de la flota de camiones de acarreo de Antamina, se puso en marcha la optimización de la gestión del mantenimiento preventivo (PM), cuyas estrategias principales eran la reducción del tiempo de parada de los camiones por PM y la extensión del intervalo de frecuencia de los PM. Así, se logró extender la frecuencia del PM de cada 250 horas a cada 500 horas y se logró reducir el tiempo de parada mensual por PM de 21.0 a 10.5 h por camión, sin afectar la confiabilidad.

Sep 20, 2019

By Henry Brañes

El presente trabajo describe el proceso de optimización metalúrgica de la planta concentradora “La Inmaculada” de la U.P. “El Cofre en Puno, dado que la mina no contaba con reserva suficiente para abastecer a la planta concentradora. Para ello, se ha dejado de realizar el blending de los minerales oxidados, mixtos y sulfurados y ahora se efectúan los tratamientos metalúrgicos en forma independiente para cada tipo de mineral (sulfurado, mixto y oxidado). Así también, se mejoró la calidad del producto final de molienda del orden y se ha modificado el reporte del balance metalúrgico diario de la planta concentradora, efectuando los balances por cada turno de operación, con indicación de controles de molienda, suma de recuperaciones y recuperación económica; representando este último es un índice indispensable y primordial que nos indica la eficiencia final económica con el que estamos operando.

Sep 14, 2009

By Enrique Echegaray Muñiz

Luego de realizarse un estudio integral sobre la recuperación de minerales en la unidad productiva de Cerro de Pasco y relacionarlo con la problemática experimentada durante años sobre la metalurgia defectuosa producida, se ha planteado desarrollar una correspondencia entre la mineralogía y el tratamiento para reducir el producto defectuoso en la concentradora Paragasha. Es asi, que a partir de 1965 la concentradora inicia su tratamiento de zinc, bismuto, magnesio y zinc, obteniendo 635 TMS / d por flotación selectiva. Posteriormente, en 1895 se presentan recuperaciones de plomo y magnesio en 72% y 41%, respectivamente, al tiempo que se dan pérdidas del 20% y 39% en el contenido metálico alimentado a planta y grado del zinc concentrado (49%) por los relaves de Quiulacocha. En este sentido, el presente texto señala una alternativa de tratamiento aplicado durante el período de 1960 a 1990 a la mina Paragasha, donde se recupera la plata 61.8% y el plomo a 85%, respectivamente. Asimismo, se estabiliza la flotación por eliminación de sales solubles interferentes, consumiendo menos reactivos.

Apr 1, 1991

By Sergio Quiñones Manga

En los circuitos de molienda de la Concentradora Toquepala fue implementado el Sistema Experto con el objetivo de optimizar la capacidad de molienda. En este sentido, el presente texto describe la operación de este sistema en dicha concentradora, así como sus beneficios en la minería. El Sistema Experto se basa en una plataforma proporcionada por un software, al cual ha sido integrada en forma de modelos matemáticos y lógicas de control, la experiencia operativa de profesionales y técnicos de la Concentradora Toquepala. De forma que las acciones del Sistema Experto están orientadas a maximizar el tonelaje procesado, manteniendo en la pulpa producida para la flotación, así como las condiciones de calidad adecuadas para optimizar las recuperaciones de los elementos valiosos.

Sep 14, 2009