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By B Haase, R Saha

Conditional simulation (CS) has been extensively used in metal industry to assess uncertainty of geo metallurgical variables to build robust distributions around grade tonnages across different time horizons. Coal’s entry to nonlinear stochastic modelling is relatively new and this paper summarises the work done at BHP to enable its practical usage from production time frames to Life of Asset planning. CS in coal using Sequential Gaussian Simulation (SGS) is used to understand resource confidence around specific variables within pre-defined boundaries of spatially continuous domains for each coal seam. The variation between simulations for a given parameter reflects uncertainty. This paper demonstrates the use of CS to profile resource based upon agreed seam/parameter uncertainty thresholds which affect planning, forecasting, extraction and inform identification of key production risks and defining mitigation strategies. The end goal is to de-risk long-term plans by optimising infill data collection and improve stability in short-term planning through increased understanding of confidences locally rather than at global resource definition stages. The paper also briefly discusses the use of automated workflows and systems to minimise the time spent on the process to enable use in decision-making.

Mar 22, 2022

By J Siliézar

The Ernest Henry Mine (EHM) is situated 38 km north-east of Cloncurry in the Mount Isa – Cloncurry mineral district of northwest Queensland. The EHM orebody is an iron oxide copper gold deposit with an average grade of one per cent copper, 0.5 g/t gold and 23 per cent magnetite, with current reserves of approximately 88 Mt.The copper concentrator is a single line plant with a nominal throughput rate of 1300 tonnes per hour. An average of 350 000 tonnes of concentrate is produced each year containing around 100 000 tonnes of copper metal and 120 000 troy ounces of gold.In December 2009, Xstrata Copper announced approval of a $589 M investment to extend the life of EHM to at least 2024, through the transformation of open pit mining operations to a major underground mine together with the construction of an associated magnetite extraction plant.The EHM magnetite plant extracts the magnetite from the copper concentrator’s tailings stream. It will produce approximately 1.2 Mt of magnetite concentrate per annum at full capacity for export to Asia, making EHM Queensland’s first iron ore concentrate exporter. Construction of the magnetite extraction plant commenced in July 2010 and was completed in January 2011.This paper gives an overview of the development of the EHM magnetite extraction plant flow sheet from the early mineralogy and laboratory test work through to the plant commissioning and early operation of the base plant. It has a major focus on the commissioning learnings from the plant start-up and includes a review of the operational performance of the plant versus original design and expectations.

Jul 11, 2011

By S Gulati, N Sarkar, T Vink, S Battersby, L Okada

This paper examines a successful project implemented by BHP Mitsubishi Alliance (BMA) and the Polymathian team at Deswik, aimed at enhancing short-term scheduling processes to reduce vessel turn times in the BMA Central Queensland coal value chain. The project’s objective was to digitalise the planning process to enable planners to make data-driven insights to improve the profitability of the value chain. The strategy involved developing a digital mining system that incorporates data storage, cloud computing, and the ability to meet the integration needs of both internal and external business systems. This was complemented by a sophisticated, optimisation-based, decision-support tool to enhance the planning teams’ ability to make timely and effective decisions.

Sep 1, 2024

By P Vaikkattil, K Li, J Bullock

Unlocking maximum value is essential when designing a stope and the associated drill and blast packets. This is becoming increasingly important at Olympic Dam as the operation continues to expand south into the new mining areas away from existing infrastructure, increasing operating costs and required capital investment; into areas with less competent ground conditions, requiring smaller stopes and increased interactions. The introduction of Orica’s WebGenTM system is one way in which Olympic Dam can continue to unlock value into the future by decoupling traditional drill and blast limitations. The Lime 390 stope was the first stope at Olympic Dam to trial the new technology on the last blast packet. This paper reviews the drill and blast design of the Lime 390 stope, including the technical and operational challenges associated with the stope and the trial of the Orica’s WebGenTM system for the firing of the last blast packet.

Mar 15, 2021

By A Grace, C Sennersten, T Taylor, A Davie, R Lyu, D Pentecost, C A. Lindley, J Craig, L De Macedo Camargo

Many underground mine void spaces are not suitable for human entry due to unprotected roofs, instability or having an unknown safety state (eg if they are many decades old). Investigations of these voids may nevertheless be important for general mine safety, for example to detect propagating collapses or water accumulation, prevent accidental intrusion by new developments or drilling to reassess old spaces for re-mining. Robots are an ideal technology for investigating these spaces, especially flying, rotary-wing robots that can access and map vertical structures and spaces while avoiding rocks, water and mud that have accumulated on void floors. To operate in underground mines, we are developing customised unmanned aerial vehicles (UAVs) as well as interactive 3D virtual models of the vehicles and their underground environments for controlling vehicle operation and visualising incrementally gathered survey data. Using a game/simulation engine to provide an interactive interface for UAV operation makes it possible to orchestrate external spatial information and video feeds with in-game cameras for optimal visualisation that is not limited to the position, orientation or field of view of cameras mounted on the UAV. First and third-person points of view with respect to the UAV are provided, together with 2D and 3D gaze tracking to provide effective interfaces for geology and mine engineering experts without the need for specialist UAV piloting skills. Ongoing work is addressing the provision of greater levels of autonomy for these vehicles to support mapping well beyond the line of sight of operators and geological characterisation of rock surfaces using sensors mounted on them, including miniature X-ray fluorescence and Raman spectrometers. Gathered data is fed into more general 3D models of the mine, block models and orebody so that the UAVs function as elements of a mobile perceptual system for intelligent mining.CITATION:Sennersten, C, Lindley, C A, Davie, A, Lyu, R, Grace, A, Evans, B, Pentecost, D, Taylor, T, De Macedo Camargo, L, Craig, J, Salomao, G N, Hellicar, A, Biggins, D, Timms, G, Coombe, M, Shahriar, M S, Smith, G and Rahman, A, 2015. Unmanned aerial robots for remotely operated and autonomous surveying in inaccessible underground mine voids, in Proceedings Third International Future Mining Conference, pp 101–108 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 4, 2015

By J Zhang, B Wei, T Zhao, K Wang

Understanding mining-induced surface movement and fissures is critical for environmental protection and geological prevention. In this study, image recognition algorithms, satellite remote sensing and unmanned aerial vehicle photogrammetry (UAVP) were combined to identify surface movement and fissures caused by mining, and a case study was conducted in a coalmine in western China, and the following conclusions were obtained.

Sep 1, 2024

By P J. Cullen, B P. Banerjee, S Raval

Continuous monitoring of mining impacts on the surrounding environment is a necessary sustainability criterion. Traditional monitoring approaches such as in situ sampling and airborne and satellite-based remote sensing have several limitations. Over the past few decades, unmanned aerial vehicles (UAVs) have evolved into popular platforms for remote sensing. UAV-based remote sensing has been successfully applied in different sectors, including agriculture, forestry, urban environments and disaster management. However, the potential of UAVs for mine environmental monitoring has not yet been fully established. This paper envisages the use of UAVs and sensor systems to monitor the environment of future mines.CITATION:Banerjee, B P, Raval, S and Cullen, P J, 2015. Unmanned aerial vehicles for mine environment monitoring, in Proceedings Third International Future Mining Conference, pp 137–144 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 4, 2015

By Kerkhoff G, Wood J

The maximum gas emission into underground workings can be predicted by the use of established methods which have world wide recognition. Changes in gas emission and the influence of the gas and geological environments during longwall mining at Pacific Colliery, were found.to be a typical. The relationship between longwall mining and gassy conditions is found to vary from the European experience because of the different mining and geological conditions encountered, and the higher productivity achieved, by single longwall panels in Australia.

Jan 1, 1988

By J Lainé, M Badawi, A C. de Araujo, Y Foucaud, C Veloso

Flotation is the one of the most used techniques for the mineral separation of non-ferrous ores worldwide. However, the increase of the complexness along with the decrease of ores liberation sizes ought to become important challenges for mineral processing, including flotation. It now appears necessary to better understand the fundamentals of the flotation process, particularly the adsorption of flotation reagents at the liquid/mineral interfaces, to propose further improvements. Flotation relies on different phenomena: surfactants adsorption, on one hand, and collision, adhesion, and transport of particles with bubbles, on the other hand. For acknowledging the reagents adsorption mechanisms, molecular modelling tools borrowed from chemical and material sciences, are increasingly used. Atomistic simulations were successfully applied to study the flotation reagents interaction with various mineral surfaces, eg of two common minerals from iron ores, kaolinite, and magnetite surfaces, or with fluorite surface, a tungsten ores common gangue mineral.

Aug 24, 2022

By A Manfrino

The Iron Bridge magnetite mine and infrastructure project is currently in development as a joint venture between Fortescue Metals Group, Formosa and Baosteel. It is supported by an extensive database of reverse circulation drill hole samples analysed by X-ray fluorescence (XRF), with a large subset tested for concentrate mass recovery, concentrate and tail grades by Davis tube recovery (DTR) testing. A limited number of rock physical testing results, including unconfined/uniaxial compressive strength and crushing work index, completes the database.By combining all available information – assays, DTR results, geology, stratigraphy, mineralogy and rock physical results – and using multivariate statistical analysis techniques, the impact of the critical factors that control concentrate quality, mass recovery and grindability characteristics have been outlined. A set of geochemical groups was created by using a cluster analysis technique from the combined XRF-DTR data. These groups allow optimal separation of material with consistently high concentrate Fe grades and mass recovery. This approach is superior to domaining based on stratigraphic logging or mass recovery as it is commonly used in standard magnetite estimation models. Using the results of a normative mineralogy study, the main geochemical groups were given a mineralogical profile fitting their geochemical characteristics. These findings further refined the understanding of the link between the process characteristics of the samples and their geochemical signature and mineralogy.The geochemical grouping defined on head grades and DTR concentrate mass recovery was generalised into a ‘geomet’ code based solely on the routinely assayed head grades, thus bypassing the need for systematic DTR testing. The geomet code identifies spatial domains with homogeneous geochemistry, mineralogy and process characteristics in both oxide and fresh material that form the basis of the current Iron Bridge resource model. The allocation of geometallurgical characteristics in terms of concentration amenability and concentrate characteristics on a block-by-block basis over the whole project allows for an optimum mine schedule and plant feed. This ensures that the desired concentrate characteristics and mass recovery can be better predicted over the life-of-mine, thereby improving the mine’s economics and stability by derisking the mine schedule and optimising the performance of the concentrators. A key benefit of the geomet code devised for the Iron Bridge mine is that it can be attributed in an automated manner to all samples analysed for a routine XRF analytical suite, from exploration to blasthole drilling. This allows each sample to be allocated to a geometallurgical material type with predictable process response in terms of concentrate mass recovery and concentrate quality without the need to complete systematic DTR testing.A standard multivariate analysis coupled with a cluster analysis has allowed the linking of interdisciplinary results between geology, mineralogy, geochemistry, process and metallurgy to better understand, predict and ultimately mine and process the Iron Bridge deposits. This allows plant operations and product quality to be optimised through each stage thanks to the predictable ore characteristics embedded in the mining model.CITATION:Manfrino, A, 2015. Unravelling the factors impacting on concentrate quality by geometallurgical data analysis at Fortescue Metals Group’s Iron Bridge magnetite mine, in Proceedings Iron Ore 2015, pp 567–578 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

By D Lawie

Prior to resource modelling, sample scale data is normally grouped into spatial domains that reflect zones of homogenous properties. These domains are usually based on a combination of grade and other variables that reflect, for example, geology and alteration, or variables known to correlate with properties of the samples that affect downstream processing. Domaining and wire-framing sample scale data is a time intensive task and it is difficult to track more than a few variables simultaneously while establishing domain boundaries. This is especially the case in operations with complex data, for example, a combination of multi-element assaying of total element concentrations, and/or phase specific assaying such as sulfide sulfur, carbonate carbon, cyanide available gold, and/or downhole geophysical measurements. To minimise unintentionally grouping samples of contrasting properties within the same domain, unsupervised statistical methods are available that can automatically identify samples atypical of the domain, both as univariate tests, and as tests that take correlation within the domain into account. Unsupervised methods in this context means methods of identifying atypical samples that require just the selection of the domain and input variables. Thresholds are derived robustly from the data itself, and the results are therefore repeatable and operator independent. Atypical samples may be thought of as outliers, ie, samples that are separated from the ‘majority’ of the data. If these atypical samples are themselves spatially associated, they may be allocated to an alternative existing domain or allocated to a new domain. Care should always be taken to ensure that identified outliers are due to meaningful causes and not due to data coding and storage errors, although the identification of the latter is still valuable. *This is an abstract only. No paper was prepared for this abstract.*

Sep 5, 2011

By N Armitage, C Young

In the dynamic realm of mining health and safety, addressing psychosocial hazards is crucial. Legislative requirements now demand employers navigate this complex terrain, but uncertainty often clouds effective management. The resource industry’s skills in managing physical hazards are showcased in their adaptability in this case study. Integrating the Critical Risk Management framework with organisational psychology, a mining company achieved a transformative breakthrough. They identified and assessed psychosocial hazards and established a sustained and risk based approach to managing these hazards within the workplace. This innovative approach encompasses strategic steps. Key learning from the case study was: - Beyond Bow-tie Analysis: Discover why a linear risk analysis tool, like Bow-tie Analysis, falls short in capturing the dynamic and interdependent nature of psychosocial hazards. - Psychological Safety Power: Learn why psychological safety is vital for gathering accurate data and ensuring control effectiveness. - Dive into how it creates a data-driven foundation for success. - Broadening the Brush: Explore the impact of preloading Broad Brush Risk Assessments, an educational and dynamic hazard-identification tool. Control Mastery: Gain insights into how the Critical Risk Management framework ensures ongoing control monitoring and effectiveness for psychosocial hazards. While this implementation’s outcomes are still in their early phases, promising key indicators such as absenteeism, turnover and cultural engagement have emerged. These metrics are set to experience positive shifts as controls prove adequate. As the conference nears, we anticipate having data to showcase these transformative results. Join us in this illuminating presentation as we journey toward a safer, more psychologically resilient workplace.

Apr 16, 2024

By Adams F. C, Ridley K. L

Economic conditions after WorId War II made the recovery of Australian sources of sulphur one of considerable national importance. From 1947 to 1949 an investigation was made of recirculation techniques to produce acid plant grade gas from the Dwight-Lloyd down-draught sintering plant.During 1949 it appeared feasible to produce a gas of suitable 802 concentration and a decision was made to construct a gas purification train and a 150 tons/day contact acid plant. However, a number of difficulties remained in the production of the gases for sulphuric acid manufacture and as a result of research conducted to overcome these troubles the continuous up-draught sintering process was developed.The principal difficulties were:(a:) The down-draught sintering practice, as developed, produced an unusually high metallic lead precipitation in the windboxes. The disposal of this lead interrupted sintering operations and the delivery of gas to the acid plant.(b) The production capacity of the existing sintering plant was fully extended and the adoption of recirculation of gases, in an endeavour to satisfy acid plant requirements, would probably reduce the plant production capacity.(c) The prevailing high temperature of water available for purification train cooling required a higher than...

Jan 1, 1956

By R Belissont, C Veloso, L Senez, F Vasconcelos, E Kleiderer, J Mesquita, Y Basselin

Mont-Wright mining complex is an important asset of ArcelorMittal located in the province of Quebec, Canada. It is composed by Mont-Wright and Fire Lake mines, operating 365 days per annum, and producing 25 Mtpa of iron ore concentrate with 66 per cent Fe. Mont-Wright concentration plant is composed by seven lines with a flow sheet encompassing AG/SAG milling, primary and secondary classification stages, spiral concentrators (rougher, cleaner and recleaner stages) and dewatering unit operations. In this context, an equation called ‘Wrec’ was developed in 1971 with the objective of estimating the mass recovery of the different blocks in the beneficiation plant and support the mining planning works of Mont-Wright complex. This equation was based on the correlation between the results of heavy liquid tests performed with drill core samples and spiral concentrators pilot scale tests, returning an estimative of concentrator yield. However, since its first development, no updates have been done in the equation, which lead to some deviations from expected recoveries in the last years. This is probably due to the changes in the process and in the ore fed into the concentrator during the period. In this way, the study presented here corresponds to the execution of heavy liquid/spirals pilot scale tests with 26 composite samples collected at Mont-Wright deposit aiming at revising and updating ‘Wrec’ equation. Based on test work results, an updated formula was established to estimate the plant recovery and a comparison performed using industrial data showed that the old formula overestimated the real yield by 5.40 per cent, on average. At the end of the study the new equation was incorporated into the mining planning process.

Sep 18, 2023

Among countries afflicted with insLantaneous outbursts of coal and gas, Australia is noteworthy because of lesser disturbances of the seams and of the occurrence of CO2 in the seam gas from place to place. Research sLarted with the 1954 occurrences at Collinsville and Metropolitan Collieries leading to early publications reviewing the problem, describing occurrences and assessing variations in proneness factors in the two affected coal basins.The basic requirements for proneness include coals of high gas sorptive capacity, high ground stress, use of a mining method which provides higher stress concentrations and limits emission of seam gas, including high rates of advance. With CO2 in the seam gas proneness is greater.The mechanism is complex and not fully understood, but involves the coal, the roof, the floor, the gas, the mine opening, the ventilation, the kind of work and the rate of work. Geological disturbances such as faults and dykes increase proneness and tend to localise occurrences. On-occurrence of outbursts in some mines is difficult to explain.Outbursts are seen as a continuing threat to modem deep Australian mining of high rank coal.The simplest contributory factor to reduce is gassiness - despite the low permeability of outbursting coals - and present practices are showing promise. The greatest challenges for the future are partial degasification to below a known threshold figure and confirmation that this reduction is achieved and identification of anomalous geological structures ahead, the most likely locations for instantaneous outbursts to occur. The advances made to date give promise of a future with reducing experiences of uncontrolled instantaneous outbursts. For the Bulli seam particularly, working to achieve prediction and prevention is most urgent.

Jan 1, 1993

By K L. Brown

Sampling and analyses of deep waters from Wairakei and Rotokawa geothermal systems indicate a wide range of precious metal concentrations (<0.1 to 23 ppb Au; 6 to 2400 ppb Ag), suggesting that eastern ôandesiticö TVZ geothermal systems (eg Rotokawa) have higher aqueous gold and silver than western ôbasalticö geothermal systems (eg Wairakei); this interpretation is consistent with known occurrences of high grade precipitates in wells from eastern systems. The fact that the deep waters are undersaturated in gold further suggests that the aqueous gold concentrations of deep waters are limited by metal availability. The flux of gold for the two systems ranges from ~1 to 50 kg Au/yr, and the flux of silver ranges from 65 to 6900 kg Ag/yr. At Rotokawa, it only takes ~600 years to flux one million oz of Au and >100 million oz of Ag. The supply of hydrothermal gold and silver is obviously important during genesis of an epithermal deposit, but ore formation also depends on the existence of a suitable ôtrapö that efficiently extracts metal from solution in a small volume of rock. Such traps seem to have been poorly developed until geothermal drilling in the TVZ.

Jan 1, 2006

By C Bailey, T Kojovic, M M. Hilden, M S. Powell

The Julius Kruttschnitt semi-autogenous grinding (SAG) mill model was developed by Leung in the 1980s and extensively updated to the variable rates model by Morrell and Morrison in 1996. Since then only minor upgrades have been incorporated in the version distributed in the JKSimMet simulator. A number of improvements, developed over the course of the AMIRA P9 project and in recent independent work, have now been incorporated. These improvements are based on a power-based model that directly relates the degree of breakage with energy consumption. The new size-dependent breakage function has been incorporated. The upgrades include more accurate predictions for a wide range of mill fillings (ten - 40 per cent), slurry hold-up in the mill, pebble discharge rate and the influence of changes in feed size and ball load.The paper presents the status of progress in the model development. The upgraded model will greatly enhance its application to challenging design and optimisation studies required to optimise the performance of SAG milling circuits.CITATION:Kojovic, T, Hilden, M M, Powell, M S and Bailey, C, 2012. Updated Julius Kruttschnitt semi-autogenous grinding mill model, in Proceedings 11th AusIMM Mill OperatorsÆ Conference, pp 71-80 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Oct 29, 2012

By Zhang S

A probabilistic approach is proposed for updating open pit slope sta- bility based on successful performance. The suggested approach is developed within the framework of Bayesian probability theory. In seeking solutions to geomechanics problems consideration must be given to inher- ent variability of shear strength parameters and to the errors in the esti- mation of these parameters. The latter can be significant and may lead to consistent overestimation or underestimation of the values derived from site investigation and testing. Conventional deterministic methods of slope stability analysis do not allow systematic modelling of uncertainties in applied loads or in shear strength parameters. Within a probabilistic framework indicators of stability may be calculated, e.g., the reliability index and the probability of failure. Based on observation of slope per- formance at any given stage of a project, the mean or the standard devi- ation (or both) of a shear strength parameter may be updated. Consequently the indicators of stability can also be updated. The appli- cation of such an approach is demonstrated by an illustrative example.

Jan 1, 1989

By Green A. D M

The establishment of the Imperial Smelting Furnace at Sulphide Coporation Pty. Limited for the smelting of zinc and lead made it necessary to design and install sintering capacity to produce approximately 500 t.p.d. of zinc-lead sinter. The updraught sintering process installed is a recent development and the plant was designed with adequate flexibility and equipment to enable operating staff to investigate the process and achieve maximum production under optimum operating conditions.Sulphur dioxide gases from the sinter machine are passed to a contact acid plant for the manufacture of sulphuric acid.

Jan 1, 1964

By C G. Ferguson, S L. Makin

The Cawse nickel project is a new generation pressure acid leach (PAL), solvent extraction and electrowinning process used to produce LME grade nickel metal and cobalt sulphide concentrate containing 40 per cent cobalt by treating nickel and cobalt oxide ores from a lateritic ultramafic profile. The project is located 50 kilometres NW of Kalgoorlie in Western Australia. The commercial success of the Cawse nickel operation is dependent in part upon the ability of the principal ore type to be beneficiated. A simple process of rejecting lower grade material on the basis of particle size achieves this. The process is called upgrading and allows subgrade material to become commercial ore grade and also allows higher ore grades to be processed in the early parts of the operation. The success of the upgrade process is dependent upon the physical and chemical properties of the ore being processed and the nickel grade of the ore. The upgrade ore type represents >80 per cent of the Cawse nickel resource and is hosted mostly within a limonite unit, represented by goethitic clays in the upper saprolite zone. In the upgrade processing circuit the ore is crushed and slurried. It is then passed over a series of screens that remove all material over 0.5 mm. This ensures that coarse material is removed from the main ore stream. Upgrade is reliant on selectively rejecting lower grade or barren material, which can include silica, magnesite and relict saprock. To predict leach feedgrade, the grade control estimates the head grade and upgrade percentage for all ore delivered to the run of mine ore pad. To do this reverse circulation (RC) drill holes are logged for ore type, assayed for a range of elements and undergo simulated upgrade testwork. The percentage and grade of material rejected through the upgrade circuit has the most influence on upgrade per cent. This reject is determined by the physical properties of the rock mass and drum scrubber parameters. The correlation between nickel upgrade and reject can be established to predict upgrade from the known mass reject. Parcels of upgrade ore milled to date closely follow projected correlation trends. Upgrade circuit results have been excellent, with average nickel grades upgrading by 34 per cent, cobalt by 23 per cent, with 55 per cent mass passing.

Jan 1, 2000