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By M A. Rhamdhani, R Z. Mukhlis

Removing the ledge formation in the Hall-Heroult cell during the electrolysis process may significantly reduce the energy requirement of the aluminium production process. In the absence of the ledge, however, the sidewall-material types become heavily restricted since the cryolite is very corrosive at the electrolysis temperatures. This paper study the corrosion behaviour of sintered nickel ferrite, nickel aluminate, and magnesium aluminate refractories (as possible candidates for sidewall material) in molten aluminium and cryolite melts with various alumina content at 980°C. Immersion tests of refractories with various porosity were conducted to assess the suitability of the refractories in the corrosive environment of the electrolysis cells. Microstructural change of the refractory after immersion were analysed using secondary scanning electron microscopy (SEM). Sampling of the melts were taken at 0, 10 min, 30 min, and each hour up to 6 hrs, and subsequently analysed by Inductively Coupled Plasma (ICP) spectroscopy. Based on the projected concentration of the refractories constituents in the melts, it was predicted that the corrosion rate of NiFe2O4, NiAl2O4 and MgAl2O4 in cryolite with 11 wt per cent Al2O3 were 461 × 103, 1.03 × 103, and 798 × 103 cm/a, respectively. Much lower corrosion rate of 2.3 cm/a for NiFe2O4, 2.6 cm/a for NiAl2O4 and 0.3 cm/a for MgAl2O4 were predicted if the refractories in contact with aluminium melts. Erosion played an important role in the corrosion as the concentration of the refractory constituents in the melts were beyond its solubility limit. It is therefore crucial to increase the densities of the refractory and improve its wetting characteristics.

Aug 21, 2024

By J Jones

A common problem in the mining industry is that company exploration groups operate in relative isolation to the rest of the company; resulting in poor knowledge transfer (Qureshi and Briggs, 2006) and often priority conflicts with mine geology, operations and project departments. In recognition of this problem, Newcrest created a Minerals Division responsible for stewardship and governance of mineral assets across the value chain from reconnaissance to rehabilitation. It was recognised at an early stage that effective collaboration both internally and externally would be required to improve decision making, deliver faster cycle times and improve governance.Collaboration in companies is generally associated with the introduction of new IT functions. However, modern IT-based collaboration systems and practices are relatively simplistic compared to the long-standing practices associated with collaboration and knowledge management in science and engineering disciplines such as geology and mining.The authors of this paper have started a trial of a 12-point plan for effective collaboration, which recognises that significant efficiencies can be gained and barriers to future success removed if more effective collaboration can be achieved between science and engineering divisions in a company along with external professionals and with the collective intelligence (Tapscott and Williams, 2006) of the outside world. To meet growth aspirations some companies, like Newcrest Mining Ltd, are adopting this comprehensive, step change approach by moving from a closed model the isolates mine geologists to an open and collaborative model that uses IT visualisation systems strategically. The paper describes how an open model provides people with the right work environment and the right information at the right time, which will help individuals and workgroups to work more collaboratively day-to-day. The aim is to achieve speed, focus and mitigate risk through an environment where everyone and anyone can contribute effectively (Cisco, 2008).

Aug 22, 2011

By P Holt, M Allen

On the first of July, 2012, the Australian GovernmentÆs Clean Energy Act commenced. From this point, a price of $23/t of CO2-e will apply to facilities that trip the liability threshold. This first part of this paper concentrates on the mechanics of the Clean Energy Future legislation and how it will be applied to the mining and mineral processing industry.The second part of this paper contains analysis of the data presented for typical mine operations. Methodologies for constructing a carbon strategy are also presented. This will entail determining what the objectives of the carbon strategy are, and defining what the strategic priorities for a business should be. An action plan to address the risks identified from the Clean Energy Act is also developed as part of the strategy.Details such as the advantages and disadvantages of opting into the carbon price scheme for liquid fuels are shown. Other considerations such as the ability to acquire permits through the carbon farming initiative or through overseas clean development mechanism projects are explained.CITATION:Allen, M and Holt, P, 2012. Implications of the carbon price and developing a carbon strategy, in Proceedings International Mine Management 2012, pp 105-114 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 20, 2012

By D A. Sims

This paper outlines the contributing factors to a series of erroneous Mineral Resource estimates which led to considerable loss, including significant reduction of mine life and consequently a large write-down of asset value. The error prompted divestment of the mineral asset in the short-term by the owners, a major mining company. There were multiple and complex contributions to the result: • The mine was undergoing a transition in the deposit geology with increasing depth that was not accommodated in the models. Early indications of the geological transition in initial drilling were generally unrecognised in resource modelling. The shortcomings of the models became apparent with increasing infill drilling and subsequent production reconciliation. • There was a lack of recognition of, and confidence in, site-based input and skills by corporate technical management. The site had a reputation internally for over-delivery to plan early in its life and that supported the anticipation of ongoing metal delivery into the mine plan by management. • A corporate lack of confidence in site being able to adequately domain the mineralisation led to the use of a CIK domaining process, rather than one which was geologically based. This domaining process led to gross over-statement of mineralisation trends reflected in the subsequent OK estimate. • Timelines on the outsourced estimation process were so short that validation was not possible. Obvious errors in the estimate versus data were not able to be used to correct the issues and the site’s Competent Person sign-off occurred without adequate checks. This case study is presented to reinforce the concept that Mineral Resource estimates are not solely based on the ability of the Competent Person to satisfactorily guide the process. There are usually multiple complex issues in the estimation process which need to be recognised and considered in judging reconciliations of model to actual.

May 24, 2023

By G M. Evans, C M. Phan

This paper presents an analysis on the dynamic adsorption of frothers and collectors onto air bubbles in flotation. The analysis was carried out using the theory on the surfactant transfer by diffusion and adsorption. The bubble size was considered when solving the diffusion equation for the dynamic surface excess. The adsorption kinetics was modelled employing the Langmuir adsorption isotherm and its extension with the inclusion of the lateral interaction of the adsorbed molecules (the Frumkin adsorption isotherm). The numerical computation was applied to solve the governing equations. The dynamic adsorption of the surfactants was measured in terms of the dynamic surface tension for sodium dodecylbenzene sulfonate (SDBS) and Dowfroth 250, using pendant bubble tensiometry. The results show that for air bubbles with diameter of the order of 1 mm, the bubble size effect on the dynamic surface tension is small and the solution of the diffusion equation for a planar gas-liquid surface can be used to describe the dynamic adsorption onto the air bubbles. The experimental data obtained with SDBS were well described by the Frumkin adsorption isotherm and the molecular diffusion. The model description for the experimental data obtained with Dowfroth 250 required the kinetic equations. The paper is relevant for further analysis of the role of the adsorbed surfactants in the particle collection.

Jan 1, 2005

By D Hope, D Mitchell, B Metcalfe

In recent years there has been a major change among mining companies in their mining methods. This has been driven by the need to increase shareholder value and optimising the value from an operation. With this understanding there has been a need for all producers to become more efficient in their mining processes. An analysis of the coal losses at Mount Thorley Operations indicated that the major losses were in the dragline section of the mine due to coal damage from throw blasting. This damage was evident after the removal of the overburden by the dragline.Coal and Allied Mount Thorley Mine in partnership with Orica Explosives developed a process to reduce the coal loss associated with the throw blasting of Mt Thorley. Orica provided its specialised knowledge and experience in the drilling and blasting area and combined this with the local mining knowledge and expertise of Mount Thorley Operations personnel to conduct the project. This partnership reduced coal loss in excess of 50 per cent whilst maintaining targeted dragline productivity.

Jan 1, 2001

By B R. Castley

Consumable materials used in mines are often transported to the working areas down shallow angle decline shafts, typically at anywhere between 10¦ and 30¦ to the horizontal. The winding equipment is usually a relatively small single-drum winder and the material is transported in one or more cars, running on rails in the decline. The winding rope is attached directly to the cars, which are mechanically coupled together. For small rock hoisting declines, the cars are replaced with hoppers or skips. The winder is normally of basic design, fitted with only the minimum required safety devices and very elementary brake control. Since these winders are not ælicensedÆ and are usually located in remote areas, the standard of maintenance on the installations is often poor, leading to frequent accidents, resulting in runaways, derailments and broken ropes. These problems can be overcome easily with the application of the rope haulage principle. When large volumes of ore have to be transported to surface, belt conveyors are used on shallow angle inclines, or high-capacity friction winders are used in vertical shafts. Conveyors are limited to inclines no steeper than 14¦ and vertical shafts with large friction or drum type winders are extremely capital-intensive. Rope haulage systems can be used on decline shafts where the inclination is too steep for belt conveyors and too shallow for conventional drum winders. Rope haulage systems also offer a variety of safety, technical and cost advantages over other winding and transport systems. This paper describes the adaptation of the rope haulage principle to modern requirements and, combined with 21st century electronic technology, explains how the principle can be used as an efficient, safe and practical solution to some problems associated with the transport of materials, personnel and ore in mines. The authors describe the designs, methods of operation, safety aspects, automated control, loading and unloading facilities of modern rope haulage systems used for transporting personnel, material and ore. This paper considers a variety of systems already designed for different applications, from small material-only installations to multi-purpose and large rock-hoisting systems with payloads as much as 180 t. It also describes in more detail, a material transporting system recently commissioned in South Africa.

Jan 1, 2005

By G B. Douglas

Lime-based neutralisation has long been the remediation treatment of choice for acidic mine pit waters. While suited to the attenuation of acidity, lime-based neutralisation may be difficult to implement efficiently due to variation in quality and the partial loss of neutralisation efficiency due to armouring. Large volumes of gypsum-bearing sludge may also require mechanical dewatering and transfer to final voids prior to resumption of in-pit mining or closure. Thus, operational costs may be substantially higher than primary neutralisation alone. Lime production also results in large greenhouse gas (CO2) emissions.Hydrotalcites (HT) are a class of Mg-Al layered double hydroxide minerals with the composition Mg6Al2(CO3 )(OH)16.4H2O. A range of other divalent and trivalent cations may also readily substitute for Mg (eg Cu, Ni, Pb, Zn), Al (eg Fe, La, Ce) and metalloids/oxyanions (SeO42-, AsO43 -/CrO42 -, MnO4-) for CO3 into the hydrotalcite structure. A common feature of acid mine pit waters, often overlooked in assessment of potential remediation options, is the frequent predominance of divalent and trivalent cations as a consequence of partial decomposition of both ore and gangue minerals during in-pit wall rock leaching. Thus, given the presence of substantial divalent and trivalent cations in acidic mine pit waters, an opportunity exists to exploit and in effect work harmoniously with the prevailing pit water composition to form a polymetallic hydrotalcite.The utility of hydrotalcites in the remediation of acidic mine pit waters lies in their ability to incorporate a wide range of contaminants; instantaneous formation, often in a single step; simple post-treatment solute composition; rapid settling; low sludge volume; and the potential to form ore-grade precipitates potentially amendable to reprocessing to (partially) recover remediation costs. Examples of hydrotalcite formation as a method to remediate contaminated acidic mine pit waters at laboratory-scale to full-scale will be presented.CITATION:Douglas, G B, 2015. Whither lime? In situ hydrotalcite precipitation as a method of remediation for acidic mine lakes, in Proceedings Tailings and Mine Waste Management for the 21st Century , pp 97–104 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 27, 2015

By R McIlwraith, B Breul

Two case studies are presented in this paper. The first one discusses a roller compacted concrete water supply dam that was constructed in El Mauro in Chile to provide water for agriculture activities downstream of a copper mine during the dry season. The 23 m high dam used a bituminous geomembrane (BGM) as the low permeability upstream facing element on the dam to control seepage through the dam. This is the first time that a BGM has been used in this application. A deep cut-off trench was used to control seepage beneath the dam and through the abutments. This paper briefly presents the design of the dam, including selection of the concrete mix and maximum aggregate size that the use of the Coletanche BGM allowed, and provides details of the construction, quality control and assurance of the installation of the BGM. An ultrasonic apparatus was used as part of the quality control on the BGM seams.The second case study discusses a tailings dam in Cerro Lindo, Peru (near Chincha), where a watertight BGM was installed on the upstream face. Results are presented of the survey done by a consultant on the behaviour of the dam and in particular of the BGM following an earthquake of magnitude 8.1 in Chincha close to the site. These findings on-site were checked by trials in a laboratory in California. Test results are given and explained.CITATION:Breul, B and McIlwraith, R, 2015. Case histories – roller compacted concrete dam waterproofing with a bituminous geomembrane in Chile and a tailings dam in Peru subject to an earthquake of 8.1 magnitude, in Proceedings Tailings and Mine Waste Management for the 21st Century , pp 367–372 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 27, 2015

By S Coward, C Xu, P A. Dowd

"This paper provides an assessment of the current challenges in strategic mine planning and design and suggested approaches for addressing them. The specific challenges covered are: realistic quantification of downstream processes applied to orebody models to provide an integrated approach to mine design and optimisation modelling, estimation and simulation of geometallurgical variables and their integration into resource and reserve estimation and mine planning modelling, estimation and simulation of new variables for new forms of mining – deep mining, particularly block caving, and solution mining flexibility in planning and design to manage risk and minimise its impact information technology (IT) infrastructure and platforms for rapid online data collection, storage, access and processing.Most of these challenges require new types of data, variables, modelling and estimation methods. Foremost among the new types of variables and data are geometallurgical and dynamic rock mass characterisation variables. New types of data and data collection include rapid generation of very large amounts of online sensor data and the consequent need for rapid processing and modelling of these data.This paper outlines the challenges and strategies in each of these areas and uses examples of models and outputs to illustrate approaches and potential solutions.CITATION:Dowd, P A, Xu, C and Coward, S, 2014. Strategies for mine planning and design, in Proceedings Orebody Modelling and Strategic Mine Planning Symposium 2014, pp 41–50 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Nov 24, 2014

By M Parcell

"Ventilation risks in an underground mine have essentially remained the same for centuries, yet theevidence suggests that there are many coal mines that have failed to adequately control these risks.The conduit for the knowledge learned by previous generations exists in the mining legislation. In an ideal world, mines would not need legislation to tell them what to do; they would resolve the risks to an acceptable level so as to protect the safety of persons in the mines based on the acquired knowledge. There will be some who have been personally aff ected by a mining disaster but for the majority they will be remembered as a vague recollection of an event from long ago. The mining legislation is the repository for the knowledge and outcomes from inquiries of past disasters. The challenge for the current generation, and the generations to come is to appreciate the legislation that exists, so as to not ælearn the hard wayÆ. In reviewing most disasters there is comment or discussion on the adequacy of the legislation, which ultimately results in some amendment to the law. For each person, there is an increasing responsibility to ensure that the same mistakes are not repeated. Understanding the legislation, its history and its purpose is the fi rst step in ensuring thatventilation risks are eff ectively managed. Failing to do this will be disastrous. This paper discussesthe relevance, importance and potential pitfalls of coal mine ventilation regulation."

Jun 1, 2012

By A Turns

In a survey conducted by symplexi with underground miners in Australia; 78 per cent of participants believed that ‘safety’ is all about people. If ‘safety’ is about people, then is the mining industry focusing on the wrong thing? It would be fair to say that the mining industry is heavily systems focused. Companies develop a safety management system and use this to show regulators that they comply with legislation – however, that is only half of the picture.

May 5, 2022

By N Kojola, A Vickerfält, J Huss

The possibility of using an acidic autogenous hydrogen direct reduced iron (H-DRI) slag as a basis for vanadium extraction is investigated. For a raw material to be suitable for producing high-quality FeV, the vanadium oxide content should be sufficiently high and the phosphorus oxide content in a tolerable range. Therefore, the feasibility for vanadium extraction relies on fulfilling two demands: the predominate partitioning of phosphorus to the metal and vanadium to the slag. Correspondingly, the behaviours of phosphorus and vanadium in the Al2O3-SiO2-FeOx-VyOz-P2O5-Fe system were studied experimentally. Slag, 10 g, was put in contact with liquid iron, 30 g, for different durations (2–24 hrs) in closed alumina crucibles at 1873 K. The slag composition was varied between 33.1– 49.3 wt per cent Al2O3, 27.1–46.7 wt per cent SiO2, 16.6–30.1 wt per cent FeOx, and 2.5– 8.8 wt per cent V2O3. The equilibrium phosphorus distribution was 0.42, while the vanadium distribution ranged from 7.6 to 43.4, increasing with the Al2O3- and the FeOx-content.

Jun 19, 2024

By J Palise

As cities become more populated and the need for tunnelling increases, we continue to dig deeper urban tunnels in more challenging ground conditions. At the same time our expectations for durability and long-term performance are increasing.It has become increasingly apparent in recent years that repairing water leaks in tunnels can be very costly and unplanned infiltration can cause undesirable outcomes for long-term maintenance costs, structural durability and environmental impacts. For this reason, tunnel constructors are investing more time and effort upfront into drainage and waterproofing systems.Tunnel membrane systems are becoming accepted as a necessary part of tunnel construction, however the knowledge surrounding selection of appropriate systems, design detailing and installation methods has not increased at the same rate. Currently Australia relies heavily on International Standards from Europe and the United States with no immediate program in place to establish our own locally relevant industry standards.This paper gives an overview of where the industry in Australasia is heading in terms of adopting relevant standards. Current basic waterproof detailing options for drained and undrained tunnels with success and failure of various methods are also addressed. Finally we look at the Brisbane Airport Link as a case study for how tunnel waterproofing contract methods, design and installation issues are being addressed in context with recent projects including the Epping to Chatswood Rail Link in Sydney, Auckland Northern Gateway Tunnel, Eastlink Tunnel in Melbourne and Sydney City West Cable Tunnel.This paper’s primary objective is to propose guidelines for how tunnel waterproofing could be implemented on large infrastructure projects in the future and to map a path for preparing and introducing a ready to use document for selecting appropriate tunnel membrane and drainage systems whilst implementing detailing methods which are appropriate for local conditions.

Mar 8, 2011

Opening AddressThank you for inviting me here today to open what promises to be a significant conference on the technological aspects of extractive metallurgy. I would especially like. to welcome delegates who have travelled great distances in order to contribute to, and be participants in, this examination of the technical innovations which have always been a crucial part of our industry.

Jan 1, 1992

By A Huebner, A Noack

Companies all over the world are very sensitive concerning their IT and network security. In most network connected technical installations and machines however, network security is not taken into account to a significant extent: insecure protocols are run, unencrypted information is exchanged freely and even broadcasted wirelessly and networked machines are accessible via insecure file transfer protocol (FTP).What happens in case of malfunctions of such technical installations? Who is responsible? Who can be held liable in case of accidents? The first computer worm for automation systems (æSTUXNETÆ) (Symantec, 2010) was discovered during 2010.The paper is intended to create sensitivity among decision makers for potential security and resulting safety leaks and points out the current status quo in technical network security. It outlines best practices for secure networking and procedures for remote access and remote software updates on stationary equipment and mobile mining machinery. It describes how to ensure authentic and genuine configurations and software targets and how to ensure secure communication for autonomous and remote controlled equipment. For such equipment in particular, the following statement should apply: æThere is no safety without network securityÆ.

Sep 26, 2011

By M I. Pownceby, S P. Suthers, V Nunna, G J. Sparrow

Global demand for iron and steel has increased substantially over the past 20 years and there has been a greater focus on developing suitable processing options to treat low-grade hematite-goethite ores containing higher levels of silica and alumina impurities. The processing applicable to reduce the impurity levels in these lower-grade iron ores depends on their mineralogy and a thorough understanding of the process dynamics associated with the separation technology. Different separation technologies used to remove silica and alumina from low-grade iron ores were reviewed. The major concentration methods that may be applied to upgrade lower-grade lump iron ores include magnetic separation, wet and dry heavy media separation, and air-pulsed jigging. The technologies applicable to beneficiating iron ore fines include wet and dry gravity and magnetic separation, flotation, and roasting followed by magnetic separation. It is necessary to investigate the application of separation technologies on a case-by-case basis to select economically viable beneficiation strategies suitable for the particular low-grade iron ore. A commercial flow sheet is expected to involve the implementation of several separation technologies.

Nov 8, 2021

The Kaltails Project is situated close to the city of Kalgoorlie-Boulder in Western Australia. Located on the south-eastern fringe of the Golden Mile, Kaltails has been in operation since June 1989. The tailings forming the reserve for Kaltails have been derived from 100 years of underground mining on the Golden Mile, but, some of the re.;erve has been retreated in the past. A map of the tailings reserves and treatment plant site is presented as Figure 1. The gold project is a joint venture between Poseidon 90 per cent and Gold Corporation (ten per cent) and is managed by Poseidon Gold Kaltails.

Jan 1, 1992

By F Wu, H Wang, W Chen

A pressurisation method with multiparallel fans has been adopted at HongLiuLin Coalmine to control the significant external air leakage through the goaf area of coalface 15207. Potential damaging effects of large external air leakage on a coalmine’s ventilation system are analysed according to the current air leakage status caused by the exploitation of shallow-covered coal seams. The use of pressure balanced ventilation to prevent external air leakage through goaf areas is introduced. The calculation of ventilation network of HongLiuLin Coalmine shows that the air resistance of an external air leakage branch through a goaf area and the air pressure drops from the intake slope to the working face can be adopted to determine the values of pressure to be increased by regulating fans and airflow controlling parameters of regulators. By investigating airflow requirements of the pressure-balanced area as well as the performances of the auxiliary fans currently used in the coalmine, the number of pressurisation fans needed is fixed. The expected result is achieved after the pressurisation method has been carried out, which can be helpful for other coalmines to handle similar problems.CITATION:Wu, F, Chen, W and Wang, H, 2015. Multiparallel fan method to prevent significant external air leakages through a goaf area of a shallow covered coalmine, in Proceedings The Australian Mine Ventilation Conference, pp 267–270 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 31, 2015

By M Player, R Klug, N Schwarz

There are several technologies available for thickening and dewatering of mining process slurries. The most commonly used are thickeners and filters, but technological developments have made solid bowl decanter centrifuges a viable option and their use, as a modern and alternative technology, is being considered more and more. In terms of tailings, the main goal for all mine operations is to minimize operating costs and the environmental impact of the disposed material. The high potential risk of wet tailings storage in tailings dams is causing this technology to become unpopular, and there is a strong drive in many parts of the world, by governments, communities and environmental agencies to limit any further construction and use of such facilities. For the alternative disposal method of dry disposal of tailings, two aspects of the process have to be evaluated, namely the maximum dryness of the separated solids and the maximum liquid recovery. For most mining operations dry disposal is a new concept. Presenting these companies with examples of operations where this processing option has been successfully applied and proven, will help them to adapt to the changing requirements in the future. Focus has been placed on adapting decanter centrifuges to the mining environment. Modern decanters stand out in terms of their small footprint, low water demand, high availability and their high degree of automation, combined with the excellent cost / performance ratio. Decanter centrifuges have started to play a key role in applications such as tailing dewatering, drilling and tunnelling muds processing, hydrometallurgical processes of gold, nickel or zinc and separating crud in solvent extraction plants. This paper will present advantages of decanter centrifuges compared to the traditional technology and corroborate these advantages by case studies.

Jul 1, 2021