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By A Black, A de Jo, J Cavanagh, J Harding

Acidic and metal-rich waters have been discharging from Sullivan Mine, West Coast, New Zealand since the closure of the mine during the early- 1990s. This has resulted in a decrease in pH from a background of 4.5 to 2.8 and an increase in metallic elements in nearby Rapid Stream. In addition to the chemical effects on Rapid Stream, a study of freshwater macro-invertebrates revealed the absence of most biota downstream from the discharge. An attempt is being made to use the Sullivan Mine as a case study of problem and remediation analysis.

Jan 1, 2003

By Jason J. Ballentine

This paper presents a case study of how an asset strategy and zero based budget was developed for an existing crushing plant that had been purchased from the contract service provider by an Australian Iron Ore miner. The goal was to directly align the strategies and budget to the business goals. This however was not a simple task due to poor historical records and a general lack of information. These challenges were overcome and the benefits of a documented maintenance strategy, a justifiable zero based budget and employee engagement were realized.

May 1, 2007

The introduction of a new mining method to Australia is not without its risks and challenges. This paper discusses the processes of planning a new operation, with particular emphasis on block caving and its Northparkes adaptation. As well as applying advanced technologies, here also is the opportunity to develop the art and science of block caving for its application to a wider range of geotechnical conditions than previously Envisaged.

Jan 1, 1995

By B. K. Gorain

"Mining of low grade deposits along with the necessity to design and operate process plants requiring high throughputs presents unique metallurgical environmental and sustainability challenges that need to be addressed to reduce project risks, improve project economics and to sustain the profitability of operations over the life-of-mine.Some of the key challenges include poor recovery of valuables and concentrate quality issues due to complex mineralogy and high ore variability, water scarcity and quality issues, high energy costs, complex environmental issues including tailings management, high capital and operating costs, worldwide constraints on resource availability, complicated regulations in emerging economies, changing demographics of mining operations with ever-changing cultural or community issues and the urgent need for a better assessment of project viability to reflect the dynamics of present mining scenario. Developing breakthrough solutions to these problems is the key to success of any new project and maintaining profitability of a mining operation. An integrated multi-disciplinary approach to problem solving is crucial along with the need for a more lateral thinking, strategic partnerships and collaboration involving the right players. This paper presents some of the key findings based on experiences from a large number of challenging projects and operations focused on solving complex metallurgical problems.IntroductionThere is a plethora of challenges in developing new ore bodies. The metallurgical complexity of these deposits has increased significantly due to the need for mining lower grade ores along with the presence of deleterious elements that have environmental and processing implications. In addition, many of the mining projects are capital intensive due to high throughput requirements to be economical along with the need for building infrastructure due to remote locations, while operating costs steadily increase due to high reagent, energy and labour costs, increased state royalties and community obligations, to name a few of the key factors. There is also scarcity of water in many regions requiring the use of sea water or brackish water, which has both environmental and metallurgical implications. The shortage of qualified technical manpower adds significantly to the woes of many mining companies. Considering these multiplicity of challenges, it has become imperative for many mining companies to be innovative in addressing these issues."

Jan 1, 2015

By Jesse L. Duke

Outline ?Understanding the context ?The Business, political, social and legal environment ?Recipes for Success (three Ps) ?Develop effective Partnerships/relationships ?Plan carefully ?Actively Manage the ?Process? Business Environment ?Nunavut?Impressive mineral potential ?Emerging diamond industry ?Dominated by Juniors ?NWT ?Maturing Diamond industry ?Emerging oil and gas industry ?Yukon ?Alaska Highway Pipeline ?Junior-dominated exploration and development ?Growing acknowledgement in Canada of the importance of northern resources ?Shift of thinking: north-south infrastructure (vs. East-west)

May 1, 2006

By Darren Medd

Kumtor Gold Company (KGC) currently operates the 500,000 tonnes per day Kumtor open pit gold mine located in the Issyk-Kul region of the Kyrgyz Republic at an elevation of more than 4,000 m. To supplement the open-pit mill feed with high grade underground ore from outside the current pit limits, KGC started pre-production design and development of the underground mine for the SB ore zone in late 2006. The initial phase of pre-production development consists of exploration and haulage declines which, upon completion, will provide ventilation and access to the underground mine. Design and construction of these declines presented many challenges to the project team considering the mines unique location at high altitude, the limited experience with Western underground mining techniques in the Kyrgyz Republic, and the impact of the nearby Davydov glacier and resultant ground conditions. Completion of the exploration and haulage declines was undertaken jointly by KGC and mine contractor, J.S. Redpath Limited (Redpath). The initial phase of development including several ground falls provided detailed information on geotechnical ground types and conditions that were useful in determining the overall mine design and methodology for production. This paper covers the various aspects of the design and construction process of developing the declines under the glacier, minimizing the likelihood of further ground falls, and the journey of both KGC and Redpath which led to the successful breakthrough between the declines on 01 July 2012.

Aug 1, 2013

By K Higuchi, K Saito, O Ishiyama

Iron ore in Australia is predicted to increase in its phosphorus content in the near future, which is detrimental to properties of steel product. Steelmakers are concerned by the content of phosphorus in iron ore will exceed limits for steelmaking and increase the converter slag ratio to molten steel, which will finally lead to a decline in competitiveness in high-grade steel production. In this paper, fundamental development of a dephosphorisation technique by reduction gasification is considered. Basic reduction examination was carried out using Australian and a synthetic model iron ore sample with phosphorus compound reagent, varying reaction time and composition of substances to find out suitable process condition for dephosphorisation. With successful lowering of phosphorus concentrations by gasification reduction of the iron ores, dephosphorisation was assumed and further elucidation works were carried out. More than 10 mass per cent of dephosphorisation ratio is obtained from Australian iron ore through batch-type 25 g furnace experiment using hydrogen as a part of reducible mixed gas. Lowering of phosphorus content occurred preferentially either in wustite or in another reducing zones, suggesting a relationship between reducing conditions to efficient dephosphorisation of iron ores. Another result of the fundamental experiment using a model sample with reagent is different dephosphorisation occurred with different reagents contributing to with unified reduction model for phosphorus, providing positive possibility for comparative evaluation, even if new morphologies of phosphorus in iron ore are clarified in future. According to these approaches, it is important to reduce iron ore efficiently and to avoid gasified phosphorus retaining and reattaching to adjacent iron ore particle at the same time. A kiln-type furnace is suggested to overcome previous technical issue, and additional experiments using larger rotating furnace were carried out for verification.

Sep 18, 2023

By Giuliana A. Zelada-Tumialan

Reduced workability and flowability of the concrete through the tremie tubes and drilled shaft reinforcement have been identified as the main causes of tremie-concrete drilled shaft concrete defects. This paper discusses two recent case studies of defective tremie-concrete drilled shafts. The defects (soft inclusions, aggregate segregation, and low concrete strength) were primarily caused by the combined effects of the tremie placing sequence, rapid concrete slump loss, and poor passing and blocking characteristics of the approved concrete mix design. The level of detail contained in the drilled shaft specifications varied between projects. However, even when the specifications incorporated several of the more recent recommendations for tremie-concrete placement, the case studies showed that typical provisions for concrete mix proportioning and placement can be further improved to minimize construction defects such as those described in this paper. Based on the findings of the case studies presented, recommendations for the development of more effective specifications are provided. The recommendations include requirements for mock-up testing of proposed concrete mix designs and evaluation of the tremie-concrete placement sequence. Performance of such testing and evaluation would greatly reduce the potential for drilled shaft defects and consequent time and financial burdens associated with them.

Jan 1, 2009

By L Mikhael Gurieff, D Baas

The Phu Kham Copper-Gold Operation (Phu Kham Operation) is located in the Lao People's Democratic Republic and is owned and operated by the Lao-registered company, Phu Bia Mining Limited (PBM). Australian-headquartered copper and gold producer, PanAust Limited holds a 90 per cent interest in PBM; the Government of Laos owns the remaining 10 per cent. The Phu Kham Operation was commissioned in 2008 with an initial concentrator nameplate throughput of 12 million tonnes per annum (Mt/a). Subsequent improvement projects, including the Phu Kham Upgrade Project (PKU), completed in 2012, and the Phu Kham Increased Recovery Project (IRP), completed in 2013, increased the design throughput to 18 Mt/yr. In 2016, the actual mill throughput exceeded 19 Mt/a, this throughput is budgeted to be maintained until the end of 2020.The concentrator flotation circuit upgrade, completed during the IRP, called for a non-selective bulk sulphide concentrate to be generated from the rougher circuit. This in turn caused the mechanical flotation cells in the cleaner circuit, particularly those in the second cleaner bank, to become volumetrically overload. The overload reduced the cleaner circuit performance to approximately 92 per cent copper recovery at a 23 per cent copper concentrate grade, below the expected 95 per cent recovery. This bottleneck restricted copper units entering the plant to approximately 14.5 tonnes per hour (t/h) due to uncontrolled recirculating load build-up in the mechanical cleaning circuit.Maintaining the operating methodologies would have led to a copper production shortfall beyond 2016, to address this shortfall the Phu Kham Operation looked to optimise the Jameson Cell and mechanical cleaner circuit performance. The work included fundamental application of flotation practice and modelling, mineralogical analysis, bubble size analysis, plant surveys and test work. The results were used to develop and implement an innovative automated control system strategy incorporating flotation theory and operating strategies. The automation has the ability to quickly adapt to disturbances in the circuit and maintain optimised performance with little or no intervention by flotation operators.Upon completion, cleaner recovery increased to 95 per cent at a final concentrate grade of 23 per cent copper, and copper units entering the plant increased to 17.5 t/h.CITATION:Baas, D and Mikhael Gurieff, L, 2018. Developing flotation circuit control and automation for the Phu Kham Copper-Gold Operation concentrator, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 37–58 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

By M. Galetakis

The difficulties that rise during the evaluation of multiple-layer lignite deposits come from the deposit structure (alternating lignite layers with intercalated material of varying thickness), as well as from the limitations of the applied selective mining. Thin layers of lignite and interbedded waste layers are grouped under specified assumptions regarding thickness and ash content, to form the exploitable blocks. However, in practice the decision for excavating a block is made under subjective constraints of different importance or by using uncertain data. Advances in Fuzzy Inference Systems (FIS) have provided a new approach to the evaluation of multiple-layer lignite deposits. FIS have the ability to handle imprecise or incomplete or linguistically ambiguous information and to incorporate them into decision-making processes. In the developed FIS (Mamdani type) new linguistic variables, concerning with working conditions, operators? experience and production were involved. The FIS was used for the estimation of quality characteristics and reserves of the exploitable lignite produced from Southern Field mine, Ptolemais (Greece).

Jan 1, 2005

By Richard W. Graeme, James J. Komadina

Gold Fields acquired an option to purchase the Cerro Corona project, located in Hualgayoc, Cajamarca Department, Peru, in December 2003. In January 2006, the option was taken up and the transaction closed. During the intervening months, project development occurred against the backdrop of a presidential election, increasing national social activism and environmental regulation, rapidly escalating operating and capital costs, as well as an unprecedented demand for engineering and technical skills. Project “Lessons Learned” are discussed in the context of an evolving strategy. The Cerro Corona project forms part of a porphyry copper-gold deposit situated within the Hualgayoc Mining District in northern Peru. It is located in the highest part of the Western Cordillera of the Andes, close to the headwaters of the Atlantic Continental Basin. It lies approximately 90 km (56 miles) by road north of the Department of Cajamarca’s capital city and near the village of Hualgayoc. Access to the Cerro Corona project from Cajamarca is by two roads, one from Cajamarca to the Yanacocha Mine 45 km (28 miles), and then from Yanacocha to the village of Hualgayoc and the town of Bambamarca 45 km (28 miles).

Jan 1, 2007

By Marcel Vallée

Frequently, costs overruns and defaults in mining project performance result in serious problems and headaches for all project participants and impact on corporate objectives, profits and image and, occasionally, lead to project failure. As mining professional s, we should be very concerned that, in a recent World Bank paper (Weber-Fahr, 2001), geological and technical risks were considered the most important ones facing mining projects. Whenever we manage to reduce or minimize these risks, we are in better position to overcome the environment-, market-, finance- and community-related ones. The causes of this situation seem rather systemic, as a fairly long list of industry problems with new pro jects has been described in industry papers in pas t and recent years. A brief review of industry problems with mining projects will be given first, followed by a review of the basics of the current Quality Management and Continuous Improvement perspectives that have evolved from earlier quality control and quality assurance systems and policies. Particular particular attention will be given to the work of W. E. Deming. As the system approach is an essential part of such policies, it will be described succinctly. Given that poor communications and interactions among geologists, mineral processors and mining engineers/operators ca n seriously affect project efficiency and profitability, these interrelated processes with in the mining systems will be analyzed and modelled and the impacts of such situations will be described through a number of anonymous case histories and examples. A synthesis of Dr Deming's management system, includ ing his Four teen P oints and System of Profound Knowledge, will be prese nted .

May 1, 2002

By M. Seeger

The demographics and the growing numbers of people provide a strong signal that the demand for electrical power in Southern Africa will grow considerably over the foreseeable future. Without a steady and increasing supply of electricity development of the continent is likely to be constrained. The inventory of solar, wind, hydrothermal, geothermal and biomass resources will probably provide sources of energy for the future The parallels between extraction of natural resources in the minerals industry and the green energy industry is striking, and the well-established project development process in the minerals industry provides an ideal and useful template for comparing the establishment and development of green energy projects. The potential levels of power generation and carbon savings are described.

Jan 1, 2010

By E. K. Albert

In 1977, Congress enacted Title IV of the Surface Mining Control and Reclamation Act (SMCRA), providing for an "abandoned ml.ne reclamation fund". This fund, taken from a fee collected from operating coal mines, provides capital for the reclamation process. However, given the number and extent of abandoned mine sites in some states, the question of project selection is important. This paper describes a project in progress to create a Management Information System application for project ranking under multiple objectives. The benefit of this project for the need of new environmental control technologies will be discussed.

Jan 1, 1990

By Terry McNulty

There are many potential pitfalls in the commercialization of innovative technology. The failures often are remembered longer than the successes, thereby serving as deterrents to subsequent attempts. The mineral industry's future depends on effective innovation. So it is essential that the causes of failure are understood. Innovation can be examined equally well in the context of geophysics, geology or mining. However the author's experience has been in mineral processing and chemical engineering. So the following discussion is limited to processes and/or plants for producing mineral concentrates, metals or inorganic chemicals. More of what follows has to do with underachievement or failure than success. But this article demonstrates that there is a strong element of predictability in the former. Furthermore, it is a credit to the minerals industry and to the engineering profession that a very high percentage of projects succeed in achieving design capacity and forecast operating costs. Innovation means the introduction of something new. In this article, the words "innovative technology" are used broadly. They include new processes and novel combinations of established unit operations, as well as novel types of processing equipment or largest-ever equipment models. The discussion of project outcomes is based on personal experience or on published information. Citations are given for technical publications that provide either project information or insights into the methodology used to analyze project performance. However, specific projects have not been identified due to the rather negative connotations of some of the conclusions drawn about the less favorable outcomes.

Jan 1, 1998

By Jason J. Ballentine

This case study presents the results of a maintenance review of a soot blower system at a coal fired power generation station. The power generation station was following a ?repair when it breaks? maintenance strategy for its soot blowers. The efficiency losses incurred as a result of failures in the soot blower system and the resulting interruption and out of service time was found to have a significant effect on the plant output. The maintenance strategy for the soot blowers was reviewed using Reliability Cantered Maintenance and lifecycle simulation. This methodology provided visibility to the monetary implications of failures and allowed alternative types of maintenance to be assessed and where justified were added to a maintenance schedule in the Maximo work order management system. By reducing unplanned breakdowns the predicted reduction in efficiency losses was 45%.

May 1, 2007

By J. R. L. Read, A. N. Ogden

This paper describes mining industry funded research that is being undertaken to address the critical gaps and uncertainties in our knowledge so that we can develop new approaches and create more effective ways for predicting the reliability of rock slopes in large open pit mines. It is envisaged that this research will not only lead to more effective pit slope design but further reduce the potential for unforseen geotechnical risks by enabling the geotechnician to communicate the risks more effectively with management and to optimise site specific control measures. To achieve this, several research tasks are in hand. The first is to accurately represent the structured rock mass with a 3D computer model (Siromodel) that creates polyhedral blocks from structural distribution data characterised by position, orientation and persistence. Siromodel is being coupled with particle flow and other numerical codes to evaluate how the structured rock mass deforms in the stress environment of an open pit and how a candidate failure surface may propagate through the dilating rock mass along the path of the least shear and/or tension resistance. A beta version of the Siromodel software has been distributed to 20 Sponsor mine sites for technical evaluation. The end state is to develop methods of analysis that characterise the reliability of a described candidate surface, and the probability of the candidate surface propagating to failure, recognising that the rock mass strength may well be defined in a different way than before.

Jan 1, 2006

By Ian Bruce

Tailings and water management facilities are essential and integral components of mine and mill operations. They must be managed for the long term in order to ensure that safe and environmentally responsible stewardship is achieved. Toward this end, in 1998, The Mining Association of Canada (MAC) published A Guide to the Management of Tailings Facilities, which recommended the implementation of a tailings management framework (Figure 1) to integrate environmental and safety considerations into each stage of the life cycle of a tailings facility, from initial site selection and design, through construction and operation, to eventual decommissioning and closure. By February 2000 it was becoming apparent that while mining companies were making significant progress toward implementing and documenting tailings management systems, and integrating them with overall environmental management systems, further effort was warranted in their application at the operational level. In particular, a need was identified for further guidance in preparing manuals that outline procedures for the safe operation, maintenance and surveillance (OMS) of tailings and water management facilities.

May 1, 2002

By D Baas, D Bennett

This paper describes how Brisbane-based PanAust Limited develops process control strategies that are implemented at all operations and are used in functional descriptions for plant upgrades and new projects.The process control strategies are determined by operating management philosophies designed to maximise returns from the company’s assets.The approach is endorsed in the project planning and design phases to ensure facilities and equipment that form the major production assets are fit for purpose and capable of enabling the production managers and operators of the projects to maximise shareholder returns.PanAust’s process control approach has been to develop sets of process control standards which focus on two key areas. The first area covers hardware requirements and architecture, software objectives, control models and individual loop tuning methods. The second area defines control room layout, graphic standards and the alarm philosophy. The application of these standards in a new plant or upgrade decreases the time required to achieve design capacity and optimal performance.The PanAust process control strategy changes the operator’s role from one that controls a number of individual loops to one that sets the control objectives of the processing plant. To achieve optimal performance, all the process areas of the plant are analysed to identify opportunities to improve throughput, recovery and stability. Once a key opportunity is identified, a process control strategy is developed which defines the objective of the control, its functionality and how an operator will interact with it. After development of the control model the operators assist engineers to test and debug it. Once the model is robust, it can then be duplicated throughout the group and developed as a group process control standard.CITATION:Baas, D, Bennett, D and Walker, P, 2014. Developing process control standards for optimal plant performance at PanAust Limited, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 325–334 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

By Sevket Acar, Tim Acton

"Zarafshan/Newmont is a 50/25/25 joint venture between Newmont Gold and the State Committee for Geology and Mineral Resources, and Navoi Mining and Metallurgical Combinat, two entities of the Republic of Uzbekistan. The Zarafshan/Newmont joint venture consists of a heap leaching operation which will process 220 million metric tonnes of existing low-grade oxide ore stockpiles (averaging 0.036 oz Au/t) from the Muruntau mine. Net recovery over the 17-year life of the project is expected to be 4.8 million ounces of gold.The plant construction started in October 1993 and operations commenced on May 25, 1995. The crushing plant consists of four stages of crushing and screening to produce a 95% passing 3.35 mm product, followed by heap leaching and gold recovery by the Merrill-Crowe process. The dore metal is refined at the Muruntau refinery. All gold produced by the joint venture is sold on the world market. IntroductionThe Muruntau mine and nearby town of Zarafshan are located in the center of the Kyzylkum desert, 250 miles west of Tashkent, capital of Uzbekistan. Following a mining conference in Moscow in 1990, a Newmont geologist was among the first team of westerners to visit the Muruntau Mine, the second largest gold producer in the former Soviet Union. At Muruntau, they found 220 million tonnes of low grade gold ore that had been stockpiled during the previous 25 years. In February, 1992, six months after Uzbekistan's independence, Newmont signed a 50/50 joint venture agreement with the Uzbek government to use heap leach technology to process the ore. The feasibility study was completed in November of 1992. Plant construction started in October, 1993 and operations commenced on May 25, 1995.Newmont Metallurgical Services performed metallurgical studies to obtain heap leach process design criteria parameters. The initial metallurgical study on 20 grab samples is the subject of this paper."

Jan 1, 1997