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Cannington Mine is an underground, hard rock, metalliferous mine located in North-Western Queensland, Australia. Weld mesh is installed to prevent the failure of rock from between the installed reinforcement elements. Corrosion reduces the capacity and life expectancy of mesh and presents a real hazard to underground personnel and equipment as it reduces the effectiveness of the support system. Corrosion influences the economics of the mining operation through the need to conduct rehabilitation of the ground support which involves re-installing new mesh or shotcreting over the affected mesh to protect it from further corrosion. The requirement for rehabilitation is determined by the geotechnical engineer based on an individual visual assessment with little or no engineering input. It was identified that a more quantitative method was required that considered the safety and economic risks involved. A project was undertaken to develop a simple method to evaluate corroded mesh and to provide selection criteria for rehabilitation. A weld mesh corrosion classification has been developed that relates the average wire diameter of corroded mesh to the remaining capacity of the mesh. Accompanying selection criteria provides recommendations as to when rehabilitation may be required based on the estimated residual mesh capacity, the remaining development life, and the level of personnel exposure.

Nov 25, 2010

By D Connelly

Magnetite ores can be used to produce very high-grade concentrates that are suitable feed for the direct reduction process route but the high sulfur content of some concentrates can cause substantial environmental issues. Processing of high sulfur magnetite ore is therefore increasingly problematic for the industry. Generally, the industry demands a concentrate with <0.05 per cent sulfur and <2 per cent silica. This paper reports the outcomes of a study to produce a concentrate with the requisite low sulfur content from a sulfur-rich magnetite ore. The main findings may be summarised as follows: if the sulfur is present in magnetite as nonmagnetic pyrrhotite or pyrite, it can be beneficiated using magnetic separation and hence, monoclinic pyrrhotite is magnetic and is magnetically recovered with magnetite leading to a concentrate that is too high in sulfur. X-ray diffraction and QEMSCAN analyses revealed that the magnetite concentrate was liberated at P80 30 microns and was associated with maghemite, pyrrhotite (magnetic), carbonates and hematite with very low amounts of chalcopyrite, sphalerite and arsenopyrite. Sulfur removal using flotation was the first stage of investigation and this required flash flotation in the grinding stage followed by column flotation of the initial concentrate to generate the final concentrate. At the same time, it was observed that oxidation of the pyrrhotite had a negative effect on its flotation requiring copper sulfate to activate it. Bioleaching and concentrate leaching were also considered and achieved over 90 per cent sulfur removal but were deemed unsuitable owing to the production of highly reactive wastes and high CAPEX. Reference is made to a number of operating magnetite producers and how they manage the sulfur in feed.

Sep 18, 2023

By M Rankin, F Medina, R Verburg

We conducted a preliminary assessment of an extensive deposit of historic tailings discharged over a period of 40 years to the shoreline along a Southern Peruvian coastline. The tailings formed an extensive beach approximately 2.4 km long and 300 m wide. The tailings consist principally of pyrite (37 to 59 per cent), hematite (nine to 20 per cent), magnetite (three to 13 per cent) and quartz (11 to 36 per cent). The present operating company was required to evaluate the feasibility of capping the ocean side tailings deposit, however, given the size of the undertaking and the potential to reclaim residual minerals from the tailings, it was prudent to first evaluate whether capping would in fact reduce the impacts to the marine environment. Therefore this preliminary assessment examined: 1. metals contamination in tailings, shoreline porewater and marine sediments; 2. reactivity of tailings and acid generation potential; and 3. the potential for biological effects from metal contamination in the uplands tailings (solid phase) and beach porewater. Based on mineralogy, column leach studies and chemical results, the upland tailings have a high geochemical potential to acidify and release metals, especially copper, nickel and zinc, should they be subject to oxygenated and aqueous conditions. But, the extreme arid climate results in very low potential for precipitation and virtually precludes the transport of acid drainage reaction products from the upland tailings towards ocean. Wind erosion caused by offshore winds is likely a small source of tailing transport to the ocean. Since some potential exists to reprocess the tailings in the future, capping does not seem justified at present.

Jan 1, 2003

By D W. Evans

Research into the dynamic properties of ground support elements continues to grow at a global level, given the increasing importance of this field of application within underground hard rock mining. Measuring the mechanical response of such elements under the rapid onset of simulated rock burst loads forms the basis for this experimental work, typically utilising gravitational drop testing methods. This field of research is fundamentally driven by an increasing need for dynamic performance data, given the constant evolution of rock bolting product designs, materials selection, combination testing and specific application needs based on ground types and loading scenarios. A smaller number of globally recognised dynamic test facilities have predominantly lead research within this arena, typically in association with academic institutes, larger industry groups and government research institutes. However, due to the increasing requirement for dynamic performance data, additional facilities have now emerged in order to satisfy the overall demand for test work. These newer facilities are more typically associated with suppliers to the underground hard rock industry, with experimental designs looking to replicate, at least in part, the work of the primary facilities. For standardisation, repeatability and calibration purposes, the cross validation of test data between primary and secondary facilities becomes an obvious and important consideration across this field of research. This paper outlines the development of a new dynamic drop test facility for testing rock bolts, including the structural design and associated high speed data capture system. Based on the utilisation of identical bolt types, material grades, anchoring systems and decoupled ‘free-lengths’, comparative data has been generated to provide cross validation of the new test facility against data generated by a globally recognised primary facility. The cross validation of data provides increasing confidence in the repeatability and accuracy of the new facility as activity continues towards the provision of further experimental test work.

Nov 29, 2022

By T A. J Hopper, S Mukkisa, K-O Ott, D Palmer

RIG Technologies has developed new technology that can successfully acquire high quality natural gamma ray (GR) and hole deviations, downhole while drilling, on reverse circulation drills. This technology survives the hostile downhole environment with shocks of between 400–2500 g for 7– 10 days at a time. The Logging While Drilling (LWD) service eliminates the need to run in-rod surveys, either by the driller or by wireline trucks and crews. This time saving is in the middle of the drilling process, thus enabling drills to keep drilling and increase their productivity. Additional to the natural GR and directional survey, the downhole tool is equipped with sensors to measure the downhole dynamic response of the drilling system providing insights into rock hardness, density and potentially clay types. These parameters have never been acquired behind the hammer before and coupled with surface measurements from the drills themselves, form a rich data set for trainable machine learning algorithms shortening the time to receive advanced geophysical answer products from sometimes months, to live feeds directly from drills (Hopper, 2019). Alive, high speed, two-way data link between surface data acquisition systems and downhole geophysics tools has been established and incorporates calibrated surface measurements of dynamic forces directly on the drill string to match up with those measured downhole. Receiving live streams of natural GR and hole deviation surveys as the drill is drilling allows true remote decisionmaking with live data available anywhere in the world. The combined data from surface and downhole dynamics builds a data set that could begin to enable true optimisation of autonomous drilling processes.

Nov 8, 2021

By C P. C David, J P. T Domingo

Addressing nutrient deficiency, among other factors, is vital to the growth and establishment of plants in mine spoils and tailings ponds. Although several organic amendments are available for this purpose, it is important to determine the appropriate ameliorant for the selected plant species. This research examined the effect of different amendments on the growth and ground cover of Centrosema molle, Calopogonium mucunoides and Sorghum spp. in copper/gold tailings. Plant growth and ground cover drastically increased with the application of organic ameliorants, especially manure. Among the three plants, Calopogonium exhibited the best growth and has shown its capability to establish a dense ground cover even in unamended tailings. Results suggest that the plant species and the ameliorants used in this study could be effective in a low-input approach to mine rehabilitation.CITATION:Domingo, J P T and David, C P C, 2014. Legume and grass revegetation of mine tailings, in Proceedings Life-of-Mine 2014 , pp 525–534 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 16, 2014

By L Cain, C Every, S Mirlatifi, J Ashley

This paper presents a geographic information system (GIS) based method for the prediction of ground movement and the associated impact on existing buildings and structures due to tunnelling in the North West Rail Link (NWRL) project. The NWRL is a priority rail infrastructure project for the New South Wales (NSW) Government and includes 15 km of twin tunnels between Bella Vista and Epping, which will be Australia’s longest rail tunnels. The NWRL tunnels will be constructed in an urban environment where the prediction of ground movements induced by tunnelling and the associated impacts to existing structures must be assessed in the early design stages of the project. An assessment process was developed using GIS able to respond to design changes.An iterative GIS analysis methodology was developed to generate ground settlement contours and identify impacted buildings and structures in response to multiple changes in tunnel alignment during design development stages. The GIS analysis undertook to rapidly provide detailed and accurate parameter information including tunnel depth from surface, tunnel separation, diameter and sample point proximity to the tunnel and assess ground movement contours along the project alignment. Determination of the ground surface settlements were based on empirical methods proposed by Peck (1969) and Mair (1993). The control parameters and the relationship between damage categories and risk classifications for impact assessment were based on Burland, Broms and de Mello (1977), Rankin (1988) and Boscardin and Cording (1989) methods.The GIS-based ground movement impact assessment approach adopted for the NWRL project demonstrates an efficient, iterative and robust approach and could provide an initial framework for other similar tunnelling projects where rapid design changes and early understanding of tunnelling impacts are required to bring greatest benefit to all stakeholders.CITATION:Mirlatifi, S, Cain, L, Ashley, J and Every, C, 2014. An iterative geographic information system based approach for the assessment of tunnelling impact to existing buildings and structures, in Proceedings 15th Australasian Tunnelling Conference 2014 , pp 647–652 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 17, 2014

By C Mann, S Swapp

"The mining industry is often challenged with the task of evaluating narrow vein open pit deposits. A realistic mineable solution from optimisation needs to accurately represent mining dilution and the practical limitations of mining equipment. Open pit dilution is driven according to mining method and fleet selection as this dictates the ‘selective mining unit’ (SMU) that can be practicably mined.Common evaluation methods represent dilution by:a mathematical dilution assumption addition of a dilution skin reblocking of the model to an appropriate SMU.This paper will explore an alternative method of applying dilution by adapting an underground stope modelling tool. By considering an SMU as a stope, automatic stope shape creators such as Datamine’s Mineable Shape Optimiser (MSO) can be used to create wireframes for each mining unit over the entire deposit. Using these wireframes, the model can be subblocked and assigned as either ore (inside the wireframe) or waste (outside the wireframe) prior to optimisation.The MSO process considers SMU geometry and a depth specific value-based cut-off. The result is an optimised solution for the deposit based on practical and achievable mining constraints rather than one based on generalised modifying factors.To evaluate the economic impact of the methods above, results have been costed and scheduled and a comparison of operating cash flows made.Citation:Swapp, S and Mann, C, 2016. Optimisation Improvements for Narrow Vein Open Pit Deposits Using Mineable Shape Optimiser, in Proceedings Ninth AusIMM Open Pit Operators' Conference 2016, pp 50–59 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Nov 15, 2016

As students progress further into a degree, the decision of vocation selection, and even more importantly û securing employment in a particular industry sector, can become quite daunting. However, with a little initiative, students can overcome these issues by not only researching what employment opportunities exist, but by applying for summer vacation employment. Undergraduate vacation employment, especially with a world-leading hydrometallurgy research organisation such as the Parker Centre, can dramatically alter a studentÆs perspective of particular industries and possibly even alter their selection of vocation pursuits upon graduating. Students can also use vacation employment to enhance their networking capabilities, technical skills and knowledge by dealing with challenging new topics such as sulfur dioxide leaching, which is also discussed in this article.

Jan 1, 2005

By M Steinberg, M Amarant

Upstream Classifier are well-known in the iron ore industry for at least 15 years. At present, more than 60 units are in operation in Western Australia. The advantage of this technology is their capability to produce three products with one equipment – iron ore concentrate, iron ore middlings for further processing and slimes (tailings). The principal of this beneficiation process – upstream classification and upstream separation – will always remain. However, the optimisation of the classification and separation efficiency of the equipment itself is a continuous process driven by enhanced automation and instrumentation, design changes and the use of upstream and downstream information and requirements. Besides efficiency, the safety, maintenance and replacement conditions are very important subjects for the operation of an iron ore mine. The aim of this paper is to present a new allflux® upstream classifier design, which has been developed together with several iron ore producer from Western Australia. The new design benefits from its sustainability approach by dividing the entire equipment into small reusable parts. As a result, maintenance is minor, replacement much faster, lifetime much longer and costs much lower. Furthermore, it demonstrates new features to prevent hazardous working conditions such as confined space as well as new fixing devices to speed up the replacement of certain items and parts.

Sep 18, 2023

By T Sprague, D Pateman

"The Gosowong Gold Project is owned and operated by PT Nusa Halmahera Minerals (PT NHM), an Indonesian company 75 per cent owned by Newcrest. It is located on Halmahera Island, in the North Maluku Province of the Republic of Indonesia, approximately 2450 km north-east of the national capital, Jakarta (Newcrest, 2017).Kencana is one of two underground gold and silver mines at the Gosowong Operation where ground conditions vary from competent to very poor. Development headings occurring in poor rock mass conditions require high capacity ground support including long tendon cable bolts. Manual installation of cable bolts in these development headings has been a time consuming process due to borehole collapse, blockages requiring subsequent re-drilling and a minimum eight hour grout curing time interval. The installation of cable bolts including the setting, plating and tensioning can impact the critical path for development heading advance resulting in development cycle delays.A review was conducted by PT NHM on current industry practices for alternatives to manual cable bolting. PT NHM subsequently approached Minova to assist with the development and trialling of self drilling anchors (SDAs) installed using jumbos with a rapid setting pumpable resin, CARBOTHIXTM. A series of system development trials were conducted and a reliable bolting system was developed utilising the existing jumbo drilling fleet with minimal required modifications.The system developed was a ‘one pass’ bolting process to install and grout SDAs using a two component resin with a remote, mechanised system. Improvements achieved from the system include: eliminating hole closure issues and more immediate support in poor rock mass effectively reducing personnel exposure to poor ground conditions by removing the requirement to access the drive backs reducing grout set time with full installation times for 6 m SDAs averaging 25 min.The resin grouting system has now been successfully implemented to effectively manage areas of poor ground conditions and to accelerate advance rates in high priority headings.CITATION:Pateman, D and Sprague, T, 2017. Development and implementation of a long tendon bolting system utilising resin grouting technology, in Proceedings 13th AusIMM Underground Operators’ Conference 2017, pp 79–84 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 16, 2017

Coal production from Coal & Allied&apos;s Hunter Valley No 1 open cut is presently hauled 10 km by road to washing and train loading facilities at Liddell. This road haul, using bottom dump trucks on a bitumen sealed road, presents some unique earthmover tyre problems. Sound tyre management has controlled one potentially serious problem, that of heat damage, implicit with such a long haul. Tread abrasion or wear is therefore the limiting tyre performance factor. Study of abrasion mechanisms and interpretation of abrasion patterns has facilitated an understanding of the wear processes involved. This understand- ing has highlighted the importance of front tyre wheel alignment. The development of irregular wear is shown to be related to the mildness of the abrasion and methods of remving irregular wear are presented. In conclusion haulage by large off highway trucks on long sealed haul roads has been eooncoically and technically successful at Hunter Valley No 1. INTRODUCTION Hunter Valley No 1 (HVl) is a major open cut coal mine, owned and operated by Coal & Allied Operations Ltd, and located in the Hunter Valley of New South Wales. Present

Jan 1, 1982

By R McIlwraith, B Breul

"This paper discusses the successful use of bituminous geomembranes (BGMs) in mining applications since their development in 1974. It explains and illustrates the structure of a BGM composite, which is a geomembrane manufactured by impregnating a polyester geotextile with a compound of bitumen, elastomer and filler. Examples of applications of BGMs in the mining industry are also presented in the following contexts.Storage of solid waste: storage of mining waste at mines in Canada heap leach pads in France, Peru, Chile and Turkey at the base of a mining waste landfill in Brazil capping of solid mining waste in Chile and Canada temporary capping of mining stockpiles in Australia (with possible reuse of the BGM for other works).Examples of the application of BGMs for the storage of liquid waste in mining containment reservoirs in Canada, Guatemala and Peru will also be given.For each example given, reasons are supplied that supported the choice of BGMs by the clients and consultants, drawn from the following advantages of the BGM:BGMs have excellent puncture strength, due to the internal polyester reinforcement, as well as excellent ultraviolet resistance. This often eliminates the need for a cushion geotextile or cover soil over the BGM.BGMs have a very long life expectancy, in excess of 300 years, in subsoil conditions (Breul et al, 2004).BGMs can be installed in very harsh climatic conditions. They are suitable for high wind environments as their heavy mass per square metre makes them resistant to wind uplift. The low coefficient of thermal expansion means that BGMs are suitable for installation in mines where very low or very high temperatures are expected. This reduces construction delays and allows for a quicker use of the mining facility.The fact that the BGM can be installed by the mine’s own workforce, after appropriate training from the BGM manufacturer, allows for a more flexible construction sequence on the mine.Ability of the BGM to connect to other materials such as concrete, steel, rock and other geomembranes that may be on the mine site.The technical advantages of a BGM enabled the engineering consultants to prepare solutions for their mining clients that had a lower environmental risk, had a faster completion schedule and were overall a cheaper option than with a polymeric geomembrane.CITATION:Breul, B and McIlwraith, R, 2015. Bituminous geomembranes in mine construction, in Proceedings Tailings and Mine Waste Management for the 21st Century, pp 289–296 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Jul 27, 2015

Many mining companies aim to integrate sustainability principles into their new projects. There is an intention for improvement, but frequently this results in little more than &apos;business as usual&apos; projects that retrospectively categorise controls for environmental and social risks as sustainability initiatives as part of a public relations exercise. The successful implementation of sustainability requires a change of mind-set and behaviours at an organisational and personal level. In addition, sustainability incorporates a very wide range of interests and technical disciplines. One of the key challenges is in understanding how and when to pull these diverse threads together within a project or organisational process. This paper will explore a number of themes: What does it mean to implement a project in accordance with sustainability principles? How far beyond &apos;business as usual&apos; is it reasonable to go, and what is the business case for this? Why do the intentions for sustainability sometimes fail and how can we prevent this happening in future? People are instrumental in delivering sustainability; how do we embed sustainability thinking into their behaviours and decision-making? The approaches that have been taken to integrating sustainability in design; what has and has not worked and some of the barriers to integrating sustainability into design? The authors will discuss these themes drawing on case studies from URS&apos; experience in integrating sustainability into large projects. The authors will discuss the need for: a strategic approach which provides a simple framework for tactical decision-making and the consequences of taking tactical decisions in the absence of this framework, alignment of the project team and promotion of a culture of innovation, a shift from a risk/compliance mentality to an opportunity identification mindset, and a systematic approach to integrating sustainability into project design processes.

Jun 1, 2010

By R Carstens, L Munsamy, L Prinsloo, C Huang, C Zhang, R Liang, I Canbulat

With recent advances in machine learning, data-based automated decision-making has been proven successful with promising outcomes in many industries. Its application in the mining sector can be ground-breaking; particularly the data-driven analytics that can support decision-making in the mine and consequently enhance mine safety, efficiency and sustainability. However, the current data science applications in the mining industry are mostly noncomprehensive, especially inadequate in evaluations, thus often requiring further study to be potentially beneficial to operations. Furthermore, it was found that existing literature paid limited attention to understanding the role of such techniques. Hence, in this paper we aim to build an end-to-end machine learning powered data-driven framework for intelligent geo-hazard analytics to support decision-making for underground mining data management, where multiple types of data are managed in an integrated database to support the unified machine-learning model. Here we present the framework as data-driven workflow processes, including data gathering, data preparation, data processing and data presentation. In addition, we present an application scenario of the proposed framework, where falls of ground (FoG) is managed with the historical FoG investigation reports, related panel hazard ratings, compliance data and rock mass characteristics. A demonstration can be dynamic forecasting of high-risk areas for FoG based on both spatial and temporal factors, including a 3D data visualisation. Such a scenario shows the potential of the proposed framework to establish connections among various data fields across a diverse category of data. Furthermore, the results offer important insights for ground instability management and can potentially optimise the underground operation flow.

Nov 29, 2022

By Plyley WF

Kidston Gold Mine is a 3.5 million tonnes per year operation located 280 kilometres west of Townsville, Queensland. Kidston&apos;s ore body consists of 44.3 million tonnes graded at 1.79 grams per tonne gold and 2.22 grams per tonne silver. Full production commenced in March, 1985. During the remainder of 1985, Kidston milled 3.77 million tonnes of ore and produced 213,614 ounces of gold.The ore is comprised of granodiorite, polymictic and volcanic breccias. The degree of oxidation of the rock influences the milling capacity and therefore determines the cut-off grade; ore is categorised as oxide, transition and fresh. The milling rates are 15,400, 12,000 and 9,600 tonnes per day for oxide, transition and fresh ore respectively.The ore is treated in a conventional cyanidation/ carbon-in-pulp plant (CIP). The plant consists of a primary crusher, semi-autogenous grinding (SAG) and ball mills, leach circuit and carbon-in-pulp circuit. Carbon stripping and dore smelting are done on site. The major difference between the Kidston plant and other Australian CIP plants is that a cyclone separation and washing circuit rejects half of the dry tonnage as a sand tail prior to CIP treatment. This difference allows the CIP circuit at Ki.dston to be smaller and makes the CIP less sensitive to the grind circuit product size.

Jan 1, 1986

By B Chapman, B Gaida, L Drowley

The 372 MW Ulu Jelai Hydroelectric Project is a peaking power scheme located in the Cameron Highlands, Malaysia. The main features of the project include an 84 m high roller compacted concrete dam; two weirs which divert flows from adjacent catchments via transfer tunnels into the main reservoir; an underground power waterway; and an underground power station complex comprising three large caverns with connecting tunnels approximately 240 m below surface level. The project includes approximately 25 km of tunnels excavated in fresh granite rock mass with some distinct shear zones of weaker material. The majority of the tunnels are being excavated using drill and blast, with the two transfer tunnels being excavated with a tunnel boring machine (TBM).This paper focuses on the design and construction of the Telanok underground power station complex and also some aspects of the design for the headrace tunnel. Topics covered include geological site investigations including in situ measurements of rock stresses; development of a geological model and parameters for rock support design; three-dimensional modelling to assess interactions between the caverns to optimise rock support; design of a rock anchored crane beam; construction of the caverns and design of the unlined headrace tunnel taking into account hydraulic jacking and operational pressure fluctuations.CITATION:Drowley, L, Gaida, B and Chapman, B, 2014. Design and construction of large caverns in granite – Ulu Jelai Hydroelectric Project, Malaysia, in Proceedings 15th Australasian Tunnelling Conference 2014 , pp 361–368 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 17, 2014

By McAuley T. J

Computer software is an integral part of mining operations today with many sites using six or more software packages on a daily basis. However, the use of these different programs generates the need for substantial staff training. The current trend toward large integrated packages to solve this problem is counter-productive because the relatively small companies producing specialised mining software do not have the resources to develop quality software with all the required features. Software standards are being proposed by various parties but recent history indicates these will be unsuccessful. An alternative approach is suggested using the various standards which have been developed for the Windows operating system.

Jan 1, 1995

By Takasaki Y, Ohzeki S, Hotta H

TO measure high temperature properties of blast furnace burdens ( the change of gas permeability accompanied by contraction, soft- ening and melting ) which govern the gas flow and its distribution, a series of experiments were carried out under simulated blast furnace conditions, using sinter, acid pellets and self -fluxing pellets. 1) The high temperature properties are affected by the ore&apos;s reducibility ( up to 1000 -1200¦C ), and the composition, and volume of gangue before reduction. Generally, the burde- ns with high basicity ( Ca0/Si02 ), high reduc- ibility and low volume of gangue have good high temperature properties. Good high temperature properties are : a high temperature at which the gas permeability rapidly decreases, a high melting point and a low maximum pressure drop. 2) Using acid pellets, slow-down of red- uction rate occurs around 1000¦C because the pellet forms a dense metallic shell, while its slag core, resulting from a FeO, Si02 and A1203 reaction, has a lower melting point. 3) The addition of MgO sources improves high temperature properties both of sinter and Pellets.

Jan 1, 1980

By A Horeth, E Duggan, B Versiani, A Gooch

Iron ore screening plant productivity is strongly affected by the performance of the shuttle operation, with the control system robustness and associated strategies having a direct impact on utilisation and throughput rates. A number of aspects intrinsic to the methods and technologies traditionally applied on the motion control of shuttles are often observed to decrease the efficiency of the ore distribution process across multiple screening modules, which ultimately impacts the plant’s production. Those include the number of operational scenarios that are unmanaged by conventional discrete control logics which may intermittently lead to undesired events, such as ‘high level alarms’ and ‘low level interlocks’ in the screening bins. This outcome usually demands excessive manual intervention by Control Room Operators. A Reinforcement Learning (RL) Artificial Intelligence (AI) solution was deployed to control the motion operation of the scalping and products screening shuttles in an iron ore handling plant. The RL algorithm was trained in advance to handle multiple operational scenarios and generate optimised outputs. In nominal operation, the shuttles are moved in a modulating and highly predictive fashion over the whole range of safely reachable bins. When the need occurs, the AI control agent deviates from that modulation behaviour, limiting its travel range or moving to other groups or clusters of available bins by employing ‘bin jumping’ or ‘ore break’ strategies. The RL platform capabilities include the ability to learn in real time to account for and auto-adapt to new operational patterns and process changes whilst applying improved strategies for shuttle dwelling times, target setting and speed control. The deployed Reinforcement Learning AI solution has better managed the existing challenges associated with the shuttle operation and control, and resulted in a more efficient ore delivery process, superior operations stability and increased production rates.

Nov 8, 2021