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By Pirvics AI, Whitworth NR, Tuppurainen JMI

Process control applications to the unit operations in both the Lead and Copper Smelters are reviewed. The basic aim of this control is to smooth plant inputs to produce an output of consistent quality in terms of chemical composition, temperature and physical properties. Most effort has been put into the process bottlenecks, namely in the process baghouse of the Lead Smelter and in the Copper Smelter reverberatory furnaces. The method of approach is discussed, firstly extensive plant measurement and data logging plus identification of factors which most affect the unit operation and secondly control of these factors to smooth out variations. This has been possible due to the development in-house of on-line instruments to measure the critical variables and the external use of computers for plant control. Some of these instrument developments are also briefly discussed.

Jan 1, 1984

By Mishra S. N, Mishra R, Sen P. K

Control of silicon in produced through the submerged-arc furnace can result in reduced power and coke consumption in addition to improving the quality of the hot metal. A thermo-chemical analysis of the production of ferro-chromium was carried out to devise strategies to control the recovery of silicon during the manufacture of ferro-chromium. The presence of three thermochemical zones in the furnace with respect to the reduction of silica was recognised from this analysis. Any strategy for the control of silicon recovery has to take cognizance of these thermochemical zones. The effect of various strategies on the silicon level in the hot metal have been evaluated. Possible strategies, such as the reduction of coke level in the charge; the replacement of quartz; pre-reduction of the ore and the control of the temperature profile are discussed in this paper.

Jan 1, 1999

By Baynes F. J, Bermingham A. G

The 6000m long King Headrace Tunnel will be driven through hard Owen Conglomerate in the Eastern third and feldspar porphyry in the Western two thirds, with the anticipated hardness up to 350MPa unconfined compressive strength. Since the Commission had not driven a long, large diameter tunnel for some twenty years, major research was undertaken to assess the current tunnelling trends. Tunnel boring machines were compared with drill and fire equipment. Rail equipment was compared with rubber tyred equipment. Tenders were called with tenderers invited to submit alternatives if desired. Commissioning and production excavation using the equipment is discussed with the final conclusion being that the individual items of equipment purchased combined to make an efficient hard rock drill and blast system capable of progressing through all rock conditions likely to be encountered on the King and Anthony Schemes.

Jan 1, 1987

A large scale distributed process con-trol system has been successfully applied to the automatic control of aluminium reduction cells at Boyne Smelters. A three stage hierarchy of minicomputers and microcomputers is used to continuously monitor and control conditions in each cell and to manage the data generated during the process.The automation hardware was purchased on the basis of low cost, high reliability, prior use in the aluminium industry and a high level of backup under failure conditions. The hardware has met performance criteria to date.The process control strategies have continually been updated to minimise the energy and raw material consumptions in each cell. A major change to systems software has recently been made to decrease the development time for-future changes. Various low energy potline retrofit alterations are currently being investigated requiring significant changes to the process control strategies.

Jan 1, 1985

By B Cope, N Hastings, D Webb

A Feasibility Study was completed in late 2002 to ascertain the risk and reward profile from the proposed deepening of operations at Perseverance Nickel Mine in Western Australia. The system and approach adopted to this brownfields extension work is outlined and the main components of the study are overviewed. In particular, emphasis is given to the integration of mine design and scheduling tools through to financial evaluation. Detailed comment is given on the ability of the system used to provide a robust project schedule complete with 3D animation. The level of importance in eliminating scheduling errors is demonstrated in relation to the reported bottom line viability of the project. It is suggested that this is an area where brownfields Feasibility Studies have lacked clarity and authenticity, leading to the creation of an unrealistic benchmark for project implementation.

Jan 1, 2003

By L E. Setiawan

The mining and milling groups at Batu Hijau are tasked with increasing SAG mill throughput by approximately ten per cent. Avenues used for this process are blasting and crushing optimisation, ore blending and predicting SAG mill throughput in relation to the geological model. This is in line with traditional æMine to MillÆ studies. At Batu Hijau, mill and mine sequencing cannot readily be configured to perform the surveys traditionally required by a æMine to MillÆ study while meeting the daily production target of 140 000 tonnes per day and processing from varying ore types in one pit. A program called BOCCOST (blasting optimisation crushing conveying optimising SAG throughput) has been implemented to capture approximately 200 variables from blasting, mining and milling operations and assign them to a common point in space in the geological model in real time. Interpretive analysis of data from BOCCOST is used to model relationships between the 200 variables to determine which and how these factors affect SAG throughput. Once these relationships are determined, the blasting, ore blending and crushing process can be optimised to generate a product that maximises mill throughput. The relationships modelled from BOCCOST are also used to generate a SAG mill throughput estimator, which can be coded into the production block model. The block model can be reconciled with the geological block model for correlation by geological domain. Once this relationship is established, SAG mill throughput domains can then be established for predicting SAG mill throughput. This SAG mill throughput estimator is then used in conjunction with revenue calculations to determine an ore cut-off, which combines these two elements to maximise metal production.

Jan 1, 2002

The key elements required to maintain final wall integrity and hence slope reliability are discussed. Failure modes and mechanisms in highly structured rock slopes are then reviewed. The impact of blast disturbance on rock masses in general is discussed and the relationships between the slope failure mode and blast disturbance is then explored. The question of how designers can incorporate such impacts into the slope design process is then addressed. This necessarily involves rock mass strength consideration and two case studies are used to demonstrate a recent dilemma in this regard. Some progress regarding this dilemma has also been reported for the second case study. The major conclusions are that: Slope reliability can be severely compromised if the slopes are damaged by blasting and this impact is not often incorporated into the slope design process. The location and extent of the blast damage will impact some slope failure geometries and failure mechanisms more than others. The concept of failure mechanism specific vulnerability needs to be further developed. The evidence indicates that this aspect is even more extreme for weak ground conditions. The quantification of the reduction in rock mass strength due to blast damage is not well understood and limitations exist with some recent guidelines. The use of the Hoek-Brown criterion for slopes in blocky rock masses requires considerable judgement. Further applied developments in this regard would be very beneficial to the industry. Some promising methods to incorporate blast damage estimates into the slope design process are emerging. It is good business to minimise final wall blast damage otherwise a whole range of issues relating to reduced slope reliability emerge.

Jan 1, 1999

By M Wortley, A Cantarutti, T Ozkocak

The estimation of the grinding mill charge weight is vital to ensure its efficient performance. Mill underloading or overloading can cause losses through decreased production or unplanned down time. Metso Minerals Process Technology Asia Pacific and South America (MMPT) has developed two systems for measuring mill load. The first is an acoustic system (SmartEarÖ) and the second is an online model-based charge estimation system. The aim of both systems is to facilitate better operation of grinding mills. SmartEarÖ performs analysis on an audio signal from the mill and allows each different frequency component to be viewed, analysed and used in process control for load estimation. By isolating different frequencies, SmartEarÖ can give an estimate of mill load. The online dynamic mill model uses measurable mill parameters (such as power) to predict the current total load. Kalman filtering can also be utilised to further increase the accuracy of the model. Both of MetsoÆs systems have been installed at BHP BillitonÆs Cannington mine to measure the load within their autogenous (AG) mill. In this paper, the methods of mill load estimation are reviewed and compared to the bearing pressure reading, which is the current method used by Cannington to control mill load. The redundant estimates of mill load provide increased confidence and consequently more robust grinding operation under a wide range of conditions.

Jan 1, 2008

By Teague JWS, Jung RF, Kadletz O, Jones DR, Jones CJ

A study of the passive treatment system for Hilton minewater revealed that it consists of four main process steps. The water, which contains soluble and particulate iron and zinc and is supersaturated with CO , is pumped to the surface and then passes throuqh a degassinq unit into settling ponds where larger particles of iron hydroxide, containing some adsorbed zinc, can settle out. The still turbid supernatant is pumped to the top of a hill, from where it is allowed to trickle in a broad sheet, releasing CO , towards an earthen channel in the valley below. Consequently the pArises from around 6 to 7.5. This in turn promotes further decrease in the concentration of soluble zinc by increased adsorption of zinc on to iron hydroxide particles. The channel then transports the water to the third process in the system - a 53 ML pond acting primarily as a flocculation-sedimentation basin. The clarified water overflows into a second channel, downstream of the pond, which constitutes the fourth process in the system. Here, copious quantities of filamentous algae further reduce zinc concentrations to acceptable levels before the water is collected for recycle into mine operations. The work reported here represents a detailed study of this system and describes the optimisation of the operation of each of the individual steps involved.

Jan 1, 1988

By S Youds

The backfilling operation at Olympic Dam mine supports a 9.8 Mtpa underground Long Hole Open Stoping (LHOS) operation. It involves a combination of Cemented Aggregate Fill (CAF), surface rockfill and underground rockfill. The fill material is introduced from the surface via boreholes into the top of the stopes. Due to the deleterious effects of the dust and the thickness of the atmosphere in the stope it is not possible to view the filling process either at optical or infrared (IR) wavelengths. The need for a means to measure the filling process is driven by the placement of both rock and CAF fill in the stopes. The large volumes and high relative cost of CAF makes the minimisation of CAF fill a business priority. Incorrect filling can lead to the sterilisation of ore reserve. The use of millimeter wave radar to view through the haze to give real-time data on the relative positions of the different fill masses is being developed as an in-stope fill monitoring device. This paper reviews the salient points of the technology and its potential use in the backfilling operation at Olympic Dam. The broader potential of this technology for use in the mining industry by æseeingÆ through water and dust laden environments such as that found in stopes and ore passes is also discussed.

Jan 1, 2002

The first thing to be aware of is that the warming effect of carbon dioxide is strongly logarithmic. Of the 3¦ that carbon dioxide contributes to the greenhouse effect, the first 20 ppm has a greater effect than the following 400 ppm. By the time we get to the current level of 384 ppm, each 100 ppm increment will produce only about 0.1¦ of warming. With atmospheric carbon dioxide rising at about 2 ppm per annum, temperature will rise at 0.1¦ every 50 years for the next couple of hundred years before the effect becomes minuscule. The warming of the 20th century, as the Earth came out of the Little Ice Age, was a consequence of short, high-amplitude solar cycles. A number of solar physicists have predicted that the next solar cycle, Solar Cycle 24, will be quite weak. Based on the correlation between solar activity and the EarthÆs climate, a temperature decline of 2¦C is predicted for the mid-latitude regions over the coming decade, equating to the experience of the Dalton Minimum. Anthropogenic warming due to carbon dioxide will not ameliorate this temperature decline. Increased atmospheric carbon dioxide is wholly beneficial due to itÆs fertilisation effect. Efforts to inhibit Australian carbon dioxide emissions are exactly wrong in science.

Jan 1, 2009

By Sturgul J. R

A major electricity generating authority have a proposal to construct a Power Station. An understanding of the operation of the bunker system is of importance to the designers and a computer simulation model of the operation was constructed. The computer language used was GPSS/PC which is a recent form of the language designed for the per- sonal computer. The model simulated trains arriving at the power sta- tion and unloading onto conveyors which carry coal to the power station bunker. Coal was drawn from the bunker at a specified feed rate to the power station. Numerous restrictions were placed on the model, if the bunker level got too high dozers would pull coal out of the bunker onto the stockpile, and if the level got too low the dozers would push coal back into the bunker. The conveyors and dozers were unavailable due to breakdown'at various times and trains would arrive randomly about a mean interarrival time. The system was simulated for 30 years of oper- ation and the model used a basic time unit of 30 minutes so that the system was updated 525,600 times during the simulation. The results of the simu- lation gave the designers a greater understanding of the critical factors in the operation, which may now be engineered to minimise adverse Effects.

Jan 1, 1988

The Rotary Kiln at TeKumi was commissioned in February 2002. The process involves burning limestone at 1000 - 11 000¦C to produce a burnt lime (CaO) product. This paper describes the design and installation of a trifoil system to improve the energy efficiency of the kiln. An energy balance showed that 32 per cent of the energy was being lost through the flue gases, compared to 5.8 per cent in shell losses and 2.5 per cent lost as heat in the product. The trifoil proved to be the best way to tap the energy from the flue gases. Drying tests showed that a trifoil improved the drying time of limestone by 37.5 per cent, compared to only 25 per cent for a lifter system. The trifoil system increases the surface area for heat transfer in a Rotary Kiln by 180 per cent. The overal energy efficiency of the Rotary Kiln was improved by 15 per cent, resulting in a 15 per cent increase in production and an 80¦C reduction in flue gas temperature. This has reduced dust build up in the ducting while reducing maintenance costs through a reduced fan speed. The trifoil hub was designed with tooths at the centre to prevent shifting. Each trifoil leg has an anchor block on the down side to prevent downward movement of the trefoil legs.

Jan 1, 2003

The proportion of coal production from underground operations in Queensland, is likely to increase in the future. A portion of this increase will come from mines working under farming areas. The degree of compatibility between underground coal mining operations and farming is examined. Two case histories are considered in detail. These relate to farming areas in the Moura and Emerald districts. Mining the Moura, area has been undertaken for the last two and half decades, while in the Emerald area, large scale underground coal mining is currently being planned. Interference to watercourses and water harvesting programmes, damage to crops, and ponding in cultivated areas have been experienced in mining areas. With expansion of underground mining in farming areas, the principle areas of likely conflict are the effects of surface subsidence on irrigation and erosion control structures. Other potential problems that may arise in particular circumstances include reduction in availability of water for harvesting, pollution, surface cracking and damage to surface structures. Finely textured soils and erratic and violent rainfall patterns make farming in central Queensland particularly vulnerable to severe soil erosion unless strict precautions are taken. Soil erosion control is an essential part of farming. Contour banks are used to ensure that runoff velocities are suitably low. Where steep slopes are encountered, grassing is the most effective way to prevent erosion.

Jan 1, 1987

THE power requirements of the Mount Lyell Mining and Railway Company at Queenstown, Tasmania, have, since the inception of smelting operations in June, 1,,896, been derived continuously from the extensive forests in the watershed of the Queen River, adjacent to -the works, the firewood being of good quality, mainly composed of myrtle or beech (Fagus Ounninghami), eucalypts, and manuka (Leptospermum ericoides).The country is very rugged and mountainous, indented by numerous ravines and gullies, and intersected by many creeks, which are subject to periodical floods, under the influence of a heavy and persistent rainfall. The areas so far exploited aggregate a total of about 42 sq. 'miles, and this denuded country gives promise of ultimately becoming very valuable pastoral ground for cattle-raising. The tonnage of wood yielded per acre varies from 40 to 100 tons on stack measurement of 80 cub. ft. per ton, 60 tons per acre being considered a good average yield. The gross amount of firewood handled during the past 13 years approximates 1,200,000 tons, the greater portion of which has been obtained by ordinary tramming methods. The company's main line of railway, 3-ft. 6-in. gauge, has served as a trunk line for all supplies derived from the Queen River valley, south of the reduction works, while the northern and western areas have been exploited by means of...

Jan 1, 1911

By Nilmani M, Fountain CR

Injection of gases into slag-melt mixtures produces various zones as a result of bubble formation and disintegration within the melt. The extent of these zones depends on the type of reactor used. When compared with ferrous processes, non ferrous processes are character- ised by large bubbles formed adjacent to the tuyeres, low flowrates and shallow tuyere sub- mergence. These features can result in a greater proportion of reaction occurring above the bath, more refractory wear and tuyere blockage with more splashing. The large bubble zone adjacent to the tuyeres has been investigated using the tech- niques of physical modelling, mathematical modelling and plant trials. Large bubble form- ation in physical models was recorded using a high speed camera and a rapid response pressure transducer coupled to an oscilloscope and data recorder. It was found that the bubble volume (Vb) could be correlated at low flowrates using the single bubble model Vb = 1.378 Q6/5 g-3/5 Deviations from this correlation occurred with increasing gas jet momentum. Plant trials were carried out on a copper converter at Mount Isa Mines during five different charges. Pressure measurements were made through the tuyeres during the slag blow and commencement of the copper blow. The power spectrum density showed that the dominant pulse amplitude occurred at a frequency of approximately 3 pulses/sec. Plant data from this and other converters were correlated using the same relationship as for physical modelling. De- viations occurred due to the state of the re- fractory, bath composition or bath circulation effects.

Jan 1, 1984

Before proceeding I wish to say that the excellent diagrams by which my paper is illustrated are the work of Mr. C. H. Barnes, Constructing Engineer of the Kalgurli Gold Mines Limited, and I am also much indebted to Mr. F. A. Moss, manager of the mine and for the privilege piIling information not previously made public.The limited time at my disposal has coolled to, curtail the scope of my paper to a few practices in ore treatment which are being worked on the Kalgurli Mine, but which I believe are of more than ordinary interest to thp~e Goncerned in modern treatment of gold ores. As an introduction to my subject it is, necessary that I should give a brief outline of the process by whiGh the gold is won from the complex sulpho-telluride ore of the Kalguili mine.My business is not to enter into any discussion as to the relative merits of the two rival sulpho-telluride ore treatment processes at work on the Kalgoorlie field, viz, the treatment of the unroasted ore after shining by solutions of bromocyanide, as against the treatment of the ore-after roasting by solutions of potassium or sodium cyanide either in filter presses or percolating sand vats. Even if reliable costs and percentages of extractions were obtainable in each case, it would not constitute an infallible basis of comparison, as the larger plants would necessarily have an advantage in cost per ton as against the small plants, and the other conditions obtaining are in many Cases dissimilar.

Jan 1, 1903

The use of operational research in mining is illustrated by simple examples of the techniques of simulation, linear programming, theory of sampling, and experimental design.Statistical simulation of the delays in answering telephones was used to compare the efficiency of alarm systems in collieries, and to determine stock control policy for a bin in mucking, filling, and tramming operations. Linear programming was used to help minimize transportation costs between collieries and washeries. The theory of sampling was applied to separate and balance the components of error introduced at the' various stages in the collection and reduction of routine samples of coal, and to the assessment of errors of estimates of grade in orebodies from drill samples. 'l'he principles of experimentaldesign were used to compare wear of different conveyor beltings and costs of battery and diesel locomotives in underground transport.INTRODUCTIONIn operational research some of the procedural techniques and professional attitudes of mind found among scientists and, in particular, mathematicians and statisticians, are applied to operational problems in industry ranging from policy making in the broadest sense to the humblest sampling procedures. These apply in mining equally with other industries.Anyone who reviews a procedure critically and in a systematic way may legitimately claim to be doing operational research. On the other hand, what is found in books on operational research is usually a collection of mathematical and statistical techniques which, though forming only a corner of operational research activity, illustrate the novel approaches to problems which characterize the discipline and which would probably not occur to the un...

Jan 1, 1962

By Zamel GI

The utilisation of fossil fuels, including coal (of which Australia is a large producer and exporter) is a significant contributor to the emission of greenhouse gases. Methane gas, formed during the coalification process, is present in coal seams to varying levels depending on the rank and depth of the deposit. This gas usually escapes to the atmosphere during mining operations without prior conversion to C02 or utilisation as fuel. The quantity of methane released can represent from less than one percent to more than five percent of the carbon content of the coal mined. Per unit of carbon, methane has a greenhouse impact many times that of C02. The emission of uncombusted methane to the atmosphere can therefore represent a greenhouse impact of similar porportions to that of the CO2 formed by combusting the mined coal. However, greenhouse emissions from coal can be minimised by collecting the coal seam methane and converting it to water vapour and the less damaging form, CO2. If such conversion is carried out while performing useful work, the methane can further reduce greenhouse emissions by displacing other fossil fuels. Technology has been developed to allow coal seam methane gas to be economically collected in a pure form, uncontaminated with air. This pure methane can be used to supplement natural gas supplies, to generate power or for the production of chemicals or substitute transport fuels. By collecting and utilising coal seam methane, the greenhouse impact from the mining and use of coal can be minimised, with significant reductions possible in the case of gassy deposits.

Jan 1, 1989

By P Andersson, P Marklund

Evaluation of different techniques for bottom fill stabilisation showed that frozen fill was the most economical method. In order to test the method a full-scale field test was performed in the Rehnstr÷m mine. The test was instrumented with temperature gauges and extensometers. Before the field test, frozen fill was tested at the laboratory. The mechanical properties of the frozen fill were determined by uniaxial compression and creep tests. A deformation model for the frozen fill was set up. Calculation procedure for design of spacing between the freezing tubes, time for freezing and calculation of the necessary capacity of the refrigeration plant was developed. These procedures were calibrated against the field test. The results of these investigations allow the following conclusions: From a mechanical point of view, frozen fill has excellent properties as a structural member and it also has excellent properties to support itself and the fill above. Methods for the thermal and mechanical design of freeze stabilisation have been developed and found adequate. The need to place the freezing tubes several years in advance of the future sill pillar mining, requires careful long-term planning and accurate documentation.

Jan 1, 1998