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By Muldoon T

Water sprays on mining machines are generally put there to reduce dust; however, research by the Bureau of Mines and others has shown that considerable airflows may also be generated by these sprays. This recognition of water spray-gen- erated air movement led to the "Spray-Fan" - a continuous miner auxiliary ventilation system which was shown to reduce methane peaks by a factor of 15. Recent successes and failures of the Spray Fan are reviewed. More recently, the same principles were used in the design of the "Shearer- Clearer" for reducing dust at longwall shearer operators. The original design was successful; however, a new design is now available which is more practical to install and does a much better job of holding the dust against the face downwind of the shearer. The latest research objective is to eliminate the negative impact of spray- generated air turbulence on continuous miner dust control. Most coal faces in the USA are ventilated in the exhaust mode using "line curtain", and the forward airflow on the side of the heading opposite the curtain is inevitably weak. Air turbulence generated by sprays which are incorrectly located and/or operated at excessive pressures can cause roll back - in which the dust cloud at the face is forced unwind against the ventilation and spreads over the miner cnerator. The general approach to reducing "roll back." is reviewed and art anti-roll back water spray system is presented.

Jan 1, 1983

By B Lance, D O’Brien

The Hidden Secret ore body is located within the Mt Charlotte underground mining system in Kalgoorlie, Western Australia. Mineralisation of the Hidden Secret ore body is lode style and therefore differs from the typical economical mineralisation mined at Mt Charlotte and consequently demanded a novel approach to the mining methodology. The ore body is lens like in shape, extending 200m along strike, 210m vertically, and dipping at 55 degrees. The lode width varies from 1.5m at the extremities to over 22m in the central zone of the ore body. Average grade is 3.4 Au grams per tonne. The initial mining methodology was Modified Avoca utilising Longhole Open Stoping with pillars, in a bottom up stoping sequence. However, as Hidden Secret became better defined and wider than initially modelled, it was identified that a high portion of gold would remain in the pillars and other mining concerns emerged such as remote backfilling large open voids and potentially unsafe vertical standoff distances between levels and wide open stopes. A re-evaluation of this method was undertaken and a new approach adapting a variation of Avoca methodology was identified to remove the rib pillars and replace them with a sill pillar separating the 4 levels into 2 distinct blocks. This new approach provided an immediate advantage by removing the bogger backfilling activity from the same level of the active stope front, enabling stope drilling and prepping to occur during the backfilling cycle. Bogging productivity has also improved as the fired ore is funnelled to the draw point by the backfill rill, significantly reducing the requirement for remote bogging thus improving bogging productivity. This mining method is currently in progress in the first of the two mining blocks and is on track to realise the targeted recovery of 7,700 ounces from the rib pillars.

Mar 15, 2021

By P Crittenden

Thiess Pty LtdÆs Australian Mining business unit used 7.6 PJ of energy in the 2007/2008 financial year. This represented more than 85 per cent of Thiess Pty LtdÆs total energy use and therefore meant that the Australian Mining business unit is required to conduct energy efficiency assessments and report publicly on the outcomes by December 2008 under the Federal GovernmentÆs Energy Efficiency Opportunities (EEO) Act. Thiess Pty Ltd has a policy commitment to sustainable development throughout its operations. This includes minimisation of its carbon footprint and the Australian Mining business unit has a strong focus on efficiency in all of its operations. It approached the energy efficiency assessment as an opportunity to further improve and build on its energy efficiency and greenhouse gas reduction focus in the business. As a mine contractor, Thiess faced a number of challenges in designing an assessment process that would be both effective and efficient to deliver. For example, unlike most other companies involved in the Energy Efficiency Opportunities program, the energy use associated with the Australian Mining business unit is not fixed to any single geographic location in Australia. Mining vehicles are moved from site to site according to the specific requirements of mine owners and the timing associated with the commencement and completion of contracts. Thiess departed from a traditional æsite by siteÆ based assessment and designed a ærepresentative assessmentÆ approach that involved detailed investigation of data across all sites and a focused assessment on a single site.Data and analysis was an essential part of the assessment and indicators at company, mine and site level were essential in identifying opportunities and tracking progress. Forty-six potential energy saving opportunities were identified and four of these are currently being implemented. The projects being implemented are: payload management, automating mobile lighting equipment, plant idle time management, and turbo idle downtime. The potential savings from the four major projects that have been identified are approximately 150 800 GJ/annum, equivalent to 10 600 tonnes of CO2-e/annum with a simple payback period of less than two years. Beyond the fuel savings however, there are a number of other benefits from the assessment, including operational efficiency, reduced maintenance costs and even a potential reduction in the number of vehicles required to complete the work. The EEO assessment has significantly increased the importance and urgency of energy efficiency and facilitated the sharing of good practice across all Thiess operations. Not only have four projects been adopted for immediate implementation but a further pipeline of projects is available for future possible implementation. This case study describes: how Thiess conducted its assessment including the use of energy data and indicators, the opportunities identified that are currently being implemented, and the lessons learnt and how other organisations can use these to improve their approach to energy efficiency assessments. This case study is a more comprehensive version of a case study developed for the Commonwealth Department of Resources, Energy and Tourism. The assessment results reported in this case study are drawn from the Thiess Energy Efficiency Opportunities Report 2008.

Jan 1, 2009

By K Edwards, A J. J Mouton

Hematite represents the vast majority of iron ore exported from Australia as the development and processing cost of magnetite is generally seen as a barrier to the development of vast magnetite resources. However, a number of magnetite projects have attracted a significant amount of interest and investment from large Chinese steelmakers.This paper compares the relative merits of the development of Australian magnetite and hematite ore from the point of view of the steelmaker, taking into account the factors that influence the capital costs of the development of the ore types and the relative costs of operating the process plants to treat these ores. By modelling the relative operating cost for the production of hot rolled coil in China for the two ore categories, the paper demonstrates the economic drivers behind the Chinese steelmakers’ large investments in the magnetite resources of Western Australia. It does this by estimating the potential value of magnetite concentrate to the steelmaker in the event that the maximum potential is realised by operating the blast furnace with a 100 per cent pellet burden.Under the conditions described, it was found that direct reduction (DR)-grade magnetite concentrate could command a price premium over 62 per cent Fe fines of up to 46 per cent (December 2014 on a cost and freight (CFR) basis). The corresponding premium for blast furnace (BF)-grade magnetite concentrate is 17 per cent, which demonstrates the dependency on grade.The capital expenses for a 14 Mt/a concentrate plant is estimated at US$3.1 B for BF-grade magnetite and US$3.35 B for DR-grade, with operating expenses at US$45 and US$50 respectively. The corresponding free on board price for a break-even net present value is calculated at US$82/t for BF-grade magnetite and US$90/t for DR-grade. The minimum long-term iron ore price (62 per cent Fe) that would be required to underpin such a project is estimated at US$78/t CFR for BF-grade magnetite and US$68/t CFR for DR-grade concentrate.Apart from the financial benefits, it is demonstrated that the use of magnetite concentrate in ironmaking has the potential to reduce CO2 emissions by approximately 400 kg per tonne of hot rolled coil.CITATION:Mouton, A J J and Edwards, K, 2015. Magnetite – a higher-grade blast furnace feed and its potential benefits for the ironmaker, in Proceedings Iron Ore 2015, pp 613–620 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

By H W. Wu

Occupational exposure limits for diesel particular matter (DPM) are progressively being adopted in a number of countries. Many of these follow the lead of the US Mine Safety and Health Administration initiated in 2008. In line with adoption of best practice it is accepted that all exposures should be reduced to as low as reasonably achievable. The management of diesel emissions and occupational exposures to those emissions requires an integrated strategy incorporating efforts from all key departments on a mine, including management, production, maintenance, supply and occupational health and safety.Australian coalmine longwall moves rely on the use of high-powered diesel equipment such as chariots and other machines that produce exhaust pollutants of gases and DPM. To reduce mine personnel’s exposure levels to DPM a hierarchy of controls can be followed. Minimising the use of diesel equipment, better operator positioning in relation to exposure source, using efficient engineering methods and adopting better ventilation to reduce concentrations through dilution are some of the controls that can eliminate exposures. Approaches generally adopted in Australian longwall mines currently rely on a combination of strategies such as optimisation of ventilation, use of diesel particulate filters and use of diesel tag boards that minimise the number of vehicles through recording entry and exit into working panels.A study has been undertaken into the mine ventilation systems currently in use during longwall moves within Australian modern longwall extraction mines. This paper reviews current longwall section ventilation systems and discusses evolving changes being adopted to address the more complex problems in dealing with section DPM during phases of the operational moves. The effects of DPM on crew members as well as the diesel equipment operators within a longwall section are examined. Issues that should be considered in designing the longwall section ventilation during the moves are discussed.CITATION:Wu, H W and Gillies, A D S, 2015. Review of ventilation optimisation strategies during longwall moves, in Proceedings The Australian Mine Ventilation Conference, pp 133–140 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 31, 2015

By D P. Murphy, R F. Dewhirst

Traditionally closure has been seen by the Resource sector solely as a green or an environmental issue, focused primarily on the requirement to rehabilitate the site following cessation of production activities. In addition to operational, maintenance and production aspects of processing plant design, future design teams will need to take a more holistic view and consider an increasing number of sustainability issues including safety in design and cleaner production as well as closure itself. Sustainability principles being adopted by industry such as the Minerals Council of AustraliaÆs Enduring Value Framework are now broadening our understanding of closure. While issues around the closure of tailings dams and associated infrastructure have been widely studied, few investigations have looked closely at the implications of closure on the design of minerals processing plants. It is likely that design teams may be able to make a significant contribution to meeting industry objectives by adopting innovative designs which, in addition to meeting production objectives, deliver sustainable and cost effective plant closure outcomes. This presentation explores the opportunity for innovative design of mineral processing plants through the assessment of alternative closure objectives. This assessment specifically looks at current industry standards and statutory requirements, as well as potential risks and opportunities associated with each objective. Alternative design strategies to meet these objectives are discussed.

Jan 1, 2006

By P Christen

The Ernest Henry Copper gold mine situated in North West Queensland, Australia, is owned and operated by Xstrata Copper. Currently the open pit produces 11 Mtpa of ore. With open pit mining ceasing in mid 2011 development has begun on an underground sublevel cave mine to extend the life of the operation by another 12 years. When completed the open pit will be 530 m deep and 1.5 km in diameter. The orebody dips at approximately 45° and has been outlined a further 450 m below the base of the pit. This provides some challenges for the Ernest Henry underground mine which is designed to initially truck development and production ore from the end of the pit until a hoisting shaft is commissioned in 2013. Production will then increase to 5.0 Mtpa on its way to an ultimate rate of 6.0 Mtpa in 2016.This paper will focus on the capital development and infrastructure requirements for the underground mine. Areas covered include mine accesses, ore handling system, accommodations for the dip of the orebody, primary ventilation design, dewatering systems and selection of an underground workshop over surface only maintenance.Discussions include the complications arising due to the mine being located directly below a large open pit and the combination of first principle cost analysis and risk assessment which has been used to safely optimise the feasibility study designs.

Mar 21, 2011

By M Graham, R Brunning, C Andringa-Bate, S Westergren

In 2010, Rio Tinto Iron Ore’s operations commenced the planning and design of a sampling and analysis system for the new 50 Mt/a Cape Lambert Port B (CLB) facility. Current sampling systems at the ports consist of automated robotic, mass-based sampling protocols employed at Dampier, and semi-automated, time-based sampling systems operating at Cape Lambert Port A.The new sampling system at CLB has brought together a fully automated sampling and analysis system utilising time-based sampling, with the capacity to sample ore products of medium quality variation as defined in ISO 3082 (ISO, 2009). The CLB system is required to sample at shiploading rates from 6000 t/h to 13 440 t/h and provide full load-port analysis. The sampling approach is to proportionally extend primary increments (of varying mass relative to shiploading rate) to a standard length using variable speed aero-belt conveyor systems. This enables a fixed number of secondary cuts to be achieved for all primary increment masses and to be delivered to the automated cell. The cell is required to be capable of concurrently processing four individual shipments, each containing multiple cargoes.Achieving the target sampling precision for all export cargo sizes has culminated in the planning, design and construction of the largest automated iron ore port laboratory in the world. The CLB sampling and analysis cell was commissioned in Q3 and Q4 2013. This paper discusses the sampling philosophy and commissioning outcomes.CITATION:Brunning, R, Andringa-Bate, C, Graham, M and Westergren, S, 2014. Cape Lambert Port B shiploading, sampling and analysis, in Proceedings Sampling 2014 , pp 79–90 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 29, 2014

By M McGrory, A Rodolfo, J Paredes, L E. Manguba, K A Villaspir, G Webb, R Setiagani, H Cardenas

"OceanaGold’s Didipio operation has been in operation for three years. Integral to the flow sheet design is a flash flotation circuit treating a portion of cyclone underflow, consisting of an Outotec SK-500 flash rougher and an Outotec TC10 flash cleaner and a SB-2500 falcon treating flash rougher concentrate to recover fine free gold.Flash copper recovery has been holding steady at 60 per cent, while flash gold recovery at 50 per cent. Gold recovery from the gravity circuit is 22 per cent, bringing the overall flash plus gravity gold recovery to 72 per cent.Operation of the flash rougher is mainly by pulp level control. Control of copper grade in the flash cleaner is mainly controlled by air inflow and flash cleaner pulp level control drives copper recovery. Gold recovery around the circuit is mainly driven by gold head grade.SB-2500 concentrate is scalped with a 250 micron screen with the coarse fraction reporting to a SB-250 falcon, concentrate of which combines with the screen fine fraction to a Gemini table.Citation:Cardenas, H, McGrory, M, Webb, G, Paredes, J, Setiagani, R, Villaspir, K A, Manguba, L E and Rodolfo, A, 2016. Didipio Flash Flotation and Gravity Recovery Circuit, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 123–126 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By A Castleden, G Cavanough, M Kochanek, J Cunningham

ROES« is a proposed new mining system for underground hard rock mines. Ore is accessed from within a shaft, which is located close to or within the stope, and pitched either vertical or within approximately 20 degrees of vertical. The shaft is designed to exclude personnel entry so production drilling and explosive placement is done using remotely controlled or automated machines. Routine remotely controlled survey of the shaft, stope back and broken rock within the stope is typically done following each blast. The survey may include excavation geometry, rock fragmentation and geotechnical characteristics. Blastholes are surveyed before placement of explosives. This provides mine operators and engineers with real-time data, allowing them to monitor production performance and risk factors so that they can make rapid changes as required. ROES« is designed to apply to open stoping or sublevel caving situations either in disseminated, geologically defined, thick tabular or narrow vein orebodies. The technologies developed for ROES« will also have potential applications to block caving operations to reduce the risk of frozen ore and poor fragmentation. In a typical sublevel open stope application, ROES« will reduce the amount of stope-associated development by about half and therefore will allow ore to be brought on-stream sooner and at significantly reduced cost. Other savings are expected to flow from the centralisation of mining activities and operational data, reduction in mining fleet, reduction in ventilation requirements, improved occupational safety and reduced mine complexity. CSIRO and Orica Mining Services are developing the required technology and AMIRA is seeking sponsorship for a project to trial the mining method. This paper details the ROES« method, expected benefits and applications and includes typical stope and mining block designs and design requirements.

Jan 1, 2008

By R O’Sullivan, D Taylor, J G. McLellan, B Miller

The Mount Isa copper deposit is located adjacent to the city of Mount Isa, Queensland, and lies within a series of Palaeoproterozoic to Mesoproterozoic Superbasins. The deposit is hosted almost entirely within the Urquhart Shale (US), a unit of the Mount Isa Group sediments and part of the Isa Superbasin. The copper mineralisation is separated into two distinct orebodies: the X41 mine (1100 and 1900 orebodies) and the Enterprise mine (3000 and 3500 orebodies). The orebodies are situated in the hanging wall of the major controlling structures, the Paroo Fault, which has juxtaposed older basement Eastern Creek Volcanics against the younger Mount Isa Group sediments cf 1655 ± 4 Ma. Conjecture remains over the exact timing of this thrust event. However, it is clear that inflections on the Paroo Fault have a close association with the orebodies and are an important structural feature in the mineralisation of the Mount Isa copper deposit.The life-of-mine is reducing steadily and new geomechanical modelling techniques were employed to target structurally controlled mineralised zones in three dimensions. Following a structural review of the mine using underground mapping, structural data and core shed observations, a conceptual 3D mine model was constructed utilising existing data modelled in MineSight®. This conceptual model included all the main lithological units and structures. The conceptual model aimed to test the effects of deformation on the main lithological and structural components of the system and attempted to highlight areas of anomalous stress and strain that may indicate a higher likelihood of fluid focusing and mineralisation potential. This project was focused on testing the latter stages of a D3 event (NE–SW compression) and D4 event (SE–NW compression), which are considered to be responsible for the current location of the mineralisation.The fully coupled 3D finite element analysis models resulted in highlighting anomalous patterns of stress and strain and subsequent fluid flow as a result of the two deformation events. The NE–SW D3 simulation provided the best correlation with the known distribution of mineralisation. This event also indicated several areas on the Paroo Fault and within the US that have potential to host further areas of mineralisation. The SE–NW D4 simulation provided less of a correlation with known mineralised zones. However, this event may have been responsible for post mineralisation re-mobilisation of copper on a relatively small scale. Areas of maximum shear strain, shear stress, volumetric strain and fluid flow correlated well with areas of minimum principal stress and provided the best overall match with known mineralised zones. Furthermore, several additional highlighted areas provide a high potential for further discovery of copper mineralisation. Recent exploration drilling north of the Enterprise mine 3000 orebody, utilising geomechanical modelling as part of the targeting criteria, intersected copper mineralisation, providing further validation of the modelling results.CITATION:McLellan, J G, O’Sullivan, R, Miller, B and Taylor, D, 2014. Geomechanical modelling of the Mount Isa copper deposit – predicting mineralisation, in Proceedings Ninth International Mining Geology Conference 2014 , pp 197–206 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 18, 2014

By D J. Brake

Most mine ventilation engineers are involved in ventilation planning and design in some capacity. Ventilation modelling software used by a competent experienced ventilation engineer is extremely useful in developing good ventilation designs by allowing assessment of a wide range of potential options. Unfortunately, ventilation modelling undertaken by persons who do not have sufficient experience or knowledge usually results in a façade that covers up a fundamentally unsatisfactory design. Ventilation models are produced for a wide variety of purposes including: fault-finding of a problem area in a mine and options analysis for resolution of such problems; a complete review or optimisation exercise of an entire mine’s ventilation system; or a much longer life-of-mine type of study. Models can be intended as the basis for studies with diverse purposes such as primary shaft or airway sizing, primary fan specification, examining re-entry times after blasting, resolving leakage or recirculation, or investigating the impact of fires or underground climate or cooling requirements. The concepts of ‘materiality’ and ‘fitness for purpose’ are essential to developing or using a ventilation model and serious mistakes have been made in wrongly using a ventilation model for purposes for which it was never intended, often because it is simply the most recent model on the mine site. Mistakes at this level often translate into faulty ventilation strategies and inefficient or ineffective use of scarce capital for ventilation projects. Validating a ventilation model is a time-consuming and expensive process and not every model must (or even should) be fully validated to meet the objectives at that time. This paper discusses the application of quality assurance in ventilation planning with particular respect to the ‘basis of design’ (BOD) as well as the standards for validating a ventilation model. It also provides a recommended way of dealing with non-conformances in measured versus modelled values of critical parameters in the model.CITATION:Brake, D J, 2015. Quality assurance standards for mine ventilation models and ventilation planning, in Proceedings The Australian Mine Ventilation Conference, pp 221–228 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 31, 2015

By S N SHEARD

The use of geophysics in mineral exploration in Australia, and overseas, has increased dramatically over this century. This paper shows that using simple equipment with clever interpretation that the foundations of modem geophysics were laid, using all the same principles. The plethora and diversity of mineral exploration geophysical techniques does not allow a full description of their evolution to be given in such a paper. To convey this evolution, however, the progress of two different geophysical methods, magnetics - a potential field (passive) method, and electromagnetics - an electrical (active) method, are described. Examples of magnetic survey data from the 1920s and more recent vehicle home and airborne surveys are given to show the increase in data quality through technological improvement. A set of four airborne electromagnetic data sets spanning three decades is used to indicate the improvement in electromagnetic techniques. It is argued, that considerable progress is still required in the electromagnetic field to increase its interpretability.

Jan 1, 1992

By P Collier

From 1972 until 1989 when operations were suspended Bougainville Copper Limited (BCL, owned 53.58 per cent by Rio Tinto Limited) operated a large open pit mine and processing facility at Panguna on Bougainville Island, Papua New Guinea producing copper concentrate containing significant quantities of gold and silver.BCL has a stated vision of recommencing operations at Panguna. In 2008, Rio Tinto, on behalf of BCL, conducted a multi-disciplinary study to assess the technical and financial viability of redeveloping the Panguna operation. One of the key outputs of the study was a Joint Ore Reserves Committee (JORC) Code compliant mineral resource statement based on the existing block model and fundamental data, archived since mine closure. Historical data (including the resource block model and drill hole data) was recovered from computer archives by a former Panguna mine employee familiar with the various obsolete data formats, thus maintaining an unbroken chain of custody of the data by Rio Tinto since operations were suspended. No additional data were collected as part of this study.The extensive data and documentation archive facilitated a sufficiently detailed evaluation of the fundamental data and model to support an updated resource statement. Table 1 of the JORC Code was used to guide the model validation process.Reconciliation of blasthole and metallurgical plant data with the reserve model, indicated that the copper and gold drill hole composite database was significantly biased towards underestimation in several key domains due to a combination of the following: mineralisation loss during core loss, core loss (minor), vertical drill holes failing to intersect sufficient subvertical mineralised fractures and veins, drill hole spacing too wide, and variable diamond drill hole core size. The resource model evaluation was based on three material types (all previously mined at Panguna), that were defined based on cut-off grade and rock type parameters: direct feed ore – material for delivery directly to the plant, preconcentration and screening ore – subeconomic material beneficiated to produce fines of economic grade, and waste. Three pit shells and designs were generated based on three separate sets of economic parameters. These economic parameters were also used to assign material types to the block model. The three resulting models were then evaluated against the corresponding pit shells.Classification of the resource was approached conservatively due to the inherent bias in the drill hole data. Consequently only Indicated and Inferred resources were tabulated.The study highlighted the importance of maintaining detailed documentation pertaining to resource estimates and operational history, particularly reconciliation, and the value that can be added by a simple, low-cost data compilation exercise.

Aug 22, 2011

By A G. L Pratt

Operational readiness is a commonly used term in mining and many other industry settings. However, translating this term into a coherent scope of work that is practical and meaningful is a challenge faced by many mining projects. This inhibits the allocation of resources to the work and its completion. The problem is with understanding how the terminology applies to establishing a mining operation. Resolving this problem requires clarity around what operational readiness means for a mining project’s transition to operations and who owns the tasks of completing operational readiness. The motivation for resolution of this problem is in appreciating the consequences arising from any lack of clarity in definition of this task, the timing of the work, and ownership for its completion. In broad terms, these consequences amount to an erosion of value at a critical time for both the new mine and the company and shareholders. This situation often arises where operational readiness is not adequately addressed in project’s study phases. As a result, neither time, resources nor money are adequately provided to complete the work required. In other cases, operational readiness is sometimes assimilated with the delivery of the project’s physical assets by the project’s construction team, rather than aligned with the establishment of the operating team to deliver the desired operational outputs. This paper argues that operational readiness starts in a project’s study phases and flows through into the start of operations. The definition of operational readiness is discussed as a task, and a model for its planning and completion is presented. This discussion includes assigning ownership for operational readiness planning and delivery to the General Manager of a new operation and the operations leadership team, who are central to the success of this work. After all, the reputations of this leadership team depend on the performance of the operation in its first few years. The author’s work over the last 20 years, leading operational readiness programs and the preparation of feasibility studies for mining projects, has provided the insights and evolution of ideas that are central to this paper. Operational readiness is fundamentally directed at ensuring a new mining operation gets away to a successful start and builds a solid foundation for the future of the mine/operation/province. It requires clarity of purpose, ownership and coordination by people in the operating team, and their preparation of the requisite process definition and establishment of the significant relationships required for operations. Without its successful completion, it is unlikely the new operation will meet and sustain its start-up targets. This paper discusses a practical approach to operational readiness for mining projects.

Mar 29, 2023

By M S. Cassola

It’s expected that the world economy will face a stable and continuous growth in the demand of iron ore, reaching more than two billion tonnes per year within the next year. After decades exploiting resources with high content of iron ore, now the industry faces the challenge to exploit and beneficiate more complex ores.According to the industrial practice, the flotation technology is one of the most important and effective beneficiation processes to deal with low-grade iron ores around the world. However, even with this, it is still necessary to search for new processing routes or promote the optimisation of the existing circuits.The broad application of this technology is an outcome that deeply relies on the proper selection of flotation chemicals specifi cally designed for each system. New collectors are in continuous development as flotation performance significantly relies upon their optimisation.The reverse iron ore flotation in Brazil, mainly constituted by haematite and quartz, uses ether amines as collector for silica minerals and caustic corn starch as depressor for haematite. The process selectivity is highly impacted by the features of the etheramine, such as:• mono or di-etheramine,• neutralisation degree,• chain length,• branched or linear chain,• the flotation pH, and• the size distribution of the flotation feed.This paper describes the experience obtained from laboratory and industrial trials on different ores, conducted to improve the selectivity and recovery in the reverse iron ore flotation by selecting the required collector for low-grade ores.

Jul 11, 2011

By J Caron, M Athayde, F Lavoie, R Joyce

Decarbonisation has become a major challenge for the global steelmaking industry, turning towards new technologies aimed at carbon footprint reduction, which on its own accounts for approximately 9 per cent global emissions. The iron and steel industry represents a ‘hard to abate’ sector, where much of efforts are currently being deployed into initiatives aiming to decarbonise the ironmaking through the use of green hydrogen, carbon capture utilisation and storage and state-of-the-art operation of current technologies, while little efforts being deployed to find carbon-efficient solution to iron ore burden preparation, where high-grade iron concentrate will increase in importance to ironmaking regardless of the chosen reduction route. Quebec Iron Ore (QIO), a subsidiary of Champion Iron Limited (Champion), produces high-grade hematite concentrate with one of the lowest carbon global footprints. Still, QIO is partnering with its clients to the development of burden solutions to minimise CO2 emission, in the seek for a decarbonised steel. In a strong technological partnership, Binding Solutions Limited (BSL) has developed a novel, coldbinding technology to provide a cleaner, more cost-effective alternative to induration. The technology allows miners and steel producers to reduce Capex significantly and reduce energy consumption and CO2 emissions by 90 per cent. QIO and BSL have partnered to adapt the disruptive cold binding technology developed by BSL to QIO’s concentrate to produce a high-quality low emissions iron ore agglomerate. This paper describes the efforts taken to further develop BSL’s cold binding technology and its application to QIO’s high-grade iron ore concentrate to produce a hematite cold bonded briquette (hCBB) showing comparable performances with high quality seaborne fired pellets.

Nov 8, 2021

By D Veneziano, J Van Dyck, R Snow, W Pytel, O Zanoli

Best practice standards generally recommend assessment of the environmental and societal risks posed by tailings storage facilities, but they rarely specify how the analysis should be made. As a case study, this paper describes a safety assessment of the Zelazny Most tailings pond operated by the Hydrotechnical Unit of KGHM Polska Miedz SA in Poland. The complete assessment includes a failure mode effect criticality analysis (FMECA) that considers all conceivable failure modes, but this paper focuses on one key mode, the loss of stability during the planned raising of the crest above its current level. Reliability against static dam failure considers uncertainty on the safety factor in a limit equilibrium approach. The threat of dynamic (earthquake induced) instability is assessed by developing a model of future seismicity as a function of the mining plan and considering uncertainty on the induced permanent displacements along critical sliding surfaces. We quantify the additional level of protection against outflow provided by the beach using an event tree with expert-assigned probabilities. Continuous monitoring of the dam for premonitory signs of instability and a set of loss-prevention plans in the case of a spill provide additional layers of protection; their effectiveness is quantified by estimating the fraction of the population that could be evacuated as a function of warning time. The probabilistic analysis indicates that the safety targets are met and produces practical recommendations on how to maintain and improve the safety level while the dam crest is raised above its current level.CITATION:Van Dyck, J, Pytel, W, Veneziano, D, Snow, R and Zanoli, O, 2015. Safety of a tailings storage facility against dam instability, in Proceedings Tailings and Mine Waste Management for the 21st Century , pp 253–262 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 27, 2015

By R Young

Independent Project Analysis (IPA) is in the business of benchmarking the performance of capital projects on behalf of owner companies in the processing and extractive industries. IPA assesses between 500 and 800 projects each year. The projects are conducted globally and range in size from about $1 million to over $30 billion. Using the data, we are able to benchmark the performance of Australian projects against the rest of the world. This presentation focuses on the performance of large (greater than $100 million) projects that involve chemical or thermal processing.We regularly hear calls for more processing to be conducted in Australia but on the other hand industry leaders are concerned about the poor success rate of solids processing projects in Australia. Data gathered by IPA indicates that there is good reason for the concern. Out of a sample of 31 large processing projects conducted in Australia, 23, or 74 percent, were classed as failures. This performance is significantly worse than for similar projects in other parts of the world. The presentation analyses why the performance is worse and demonstrates that many of the reasons behind the failures were manageable by the project team. Furthermore, members of the project teams on at least half the failed projects knew that the projects were on a path to failure before the project was authorised but could not be heard.The presentation discusses how large projects that involve process design and, in many cases, new technology, need to be set up for success. *This is an abstract only. No paper was prepared for this abstract.*

Aug 8, 2011

By B K. Da, S A. Balaji, G P. Roy, T K. Dutta

The raw material handling complex at the Durgapur steel plant provides iron ore, crushed coke and flux to two sinter plants. Either some facilities were not envisaged or not properly designed before the project stage which caused problems during operation of the plant. The absence of an in situ roll turning facility, used to increase maintenance activities for disassembly, transportation of rolls to central machine shop and assembly of rolls, led to decreased crusher availability and increased activities for the maintenance crew. The provision of a smaller vibro feeder/screen in place of a suitable sized screen caused jamming of the screen deck, adversely affecting screening efficiency and the crushing index of crushed coke. Some design modifications and developmental work was undertaken, such as the development and installation of an in situ roll turning facility in the existing limited space, achieving low feed (0.1 - 0.2 mm/rev), lower cutting speed of 30 - 40 m/minute for 350 BHN hard roll, which was also a difficult engineering challenge to bring within the tolerable limit of vibration. This was successfully achieved. Modifications to the screen deck, introduction of differential speed crushing and modification to the vibro screen and vibro feeder for uniform distribution of feed have been incorporated. These innovative design modifications to the in situ roll turning have led to a drastic decrease in maintenance activities and an improvement in the crushing index. Modifications to the screen have resulted in the elimination of jamming and improved screening. Modifications to the vibro screen before the primary crushers and to the vibro feeder before the secondary crushers have prevented excessive wear in the central portion of rolls, ultimately leading to increased roll life. Incorporation of differential speed crushing has resulted in an increased crushing index and decreased generation of micro fines. All the above modifications have led to distinct improvements in equipment availability, increased roll life and a decrease in maintenance activities and improvement in crushed coke granulametry, ultimately resulting in improved productivity and quality of iron ore agglomeration at the sinter plant. The innovative design modifications mentioned above are discussed in detail in this paper.

Jan 1, 2005