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By K White, R Hardie, J Merritt, B Kirsch, R Lucas

Constructed stream diversions are a common element of mine sites across Australia. A review of constructed stream diversion performance in the Bowen Basin funded by the Australian Coal Association Research Program (ACARP) in 1999 found over 80 per cent of constructed stream diversions failed to meet regulator and operator expectations. Since that time, improvements have been made in the assessment, design, monitoring and management of constructed stream diversions. Fundamental to these improvements has been the development of a better understanding of the regional stream systems and efforts to replicate the natural stream processes in the function and operation of constructed stream diversions.This paper discusses the history of constructed stream diversions through the Bowen Basin in central Queensland recorded in the outcomes of a series of ACARP funded research projects. Further, the paper reports on the outcomes of a current ACARP funded project that has reviewed the success or otherwise of constructed stream diversions in the region. The assessment has compared the performance of diversions that have been designed to replicate and provide for ongoing stream geomorphic processes with those diversions that were designed and built prior to the development of these design improvements. Based on these investigations we have identified design and construction successes and issues requiring further research and management attention.CITATION:White, K, Lucas, R, Hardie, R, Merritt, J and Kirsch, B, 2013. Challenges and opportunities for constructed stream diversions in the Bowen Basin, Central Queensland, in Proceedings Water in Mining 2013 , pp 73-82 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 26, 2013

By S Jeon, K Haga, A Shibayama, L Godirilwe, C B. Tabelin, I Park, A Buronov

Open pit/underground mining and mineral processing can generate large amounts of waste that contains sulfide-type minerals such as pyrite (FeS2), and it can produce acid mine drainage (AMD) when exposed to oxygen and water. This highly acidic wastewater contains heavy metals and this is one of the most serious environmental issues after mining operations taking several decades to completely remediate with high costs. For green mining, the present study focused on the development of a recovery technique for gold from an eco-friendly solvent, thiosulfate, by utilising mine wastes, tailings. First, gold recovery experiments in ammonium thiosulfate system were carried out using model samples representatively present in tailings (ie SiO2, Al2O3, FeS2, Fe2O3, and Fe3O4). The results showed that gold recoveries were negligible when using Al2O3, SiO2, Fe2O3, and Fe3O4 while pyrite shows a recovery efficiency three-fold as high as the maximum recovery efficiency when using others. Subsequently, the study also addressed the identification of the recovery mechanisms and post-recover process. The results indicate that tailings can be sufficiently utilised for gold recovery in the hydrometallurgy process and a further sustainable process can be established.

Sep 1, 2024

By T Angerer, N H. Maund, S Hagemann, D R. Cowan

Cliffs Natural Resources Pty Ltd - Asia Pacific Iron Ore's (formerly Portman Iron Ore Limited) K deposit (Dowd's Hill), at its Koolyanobbing operation in Western Australia, hosts enriched magnetite mineralisation below the presently mined haematite-goethite ore zone. Two distinct northwest-southeast elongated, highly magnetic anomalous bodies that dip to the north-east appear to be sourced by this deeper mineralisation. Magnetic modelling indicates significant remanent magnetisation with Qratios around 1.5, directed shallow down. The north-west anomaly is overlain by a ridge of uneconomic banded iron formation (BIF) and the present waste dump, whereas the south-east body was partly exposed during ongoing mining of overlying haematite-goethite ore. Sections of the magnetite mineralisation in this south-east anomaly were intersected previously by diamond drill holes. Review of the historic cores identified potential magnetite enrichment, with grades and mineralogy that might be amenable to beneficiation. A first-phase reverse circulation drilling program was designed to further delineate the trend and extent of the two anomalies. The following magnetite mineralisation assemblages are recognised from cores, reverse circulation (RC) drill cuttings and pit mapping of the south-east magnetic body: higher-grade magnetite-haematite ¦ goethite and magnetite ¦ pyrite and lower-grade, recrystallised magnetite-quartz (BIF), magnetite-carbonate, magnetite-talc and minor magnetite-bearing mafic schist. Disseminated specularite is locally present in theassemblages. Talc-schist and massive pyrite occur along the footwall contact. Magnetic susceptibility measured from drill chips within the magnetite-enriched zones reveals an apparent susceptibility values range of 0.2 to 1.3 SI. Preliminary results from Satmagan and Davis tube recovery analysis shows that the magnetite content in these mineralised zones correlate well with existing geophysical data and magnetic susceptibility measurements.

Jan 1, 2009

By J P. Evert

Didipio gold-copper mine operation is situated in the island of Luzon, approximately 270 km north of Manila in the Philippines, in an area of high seasonal rainfall. The hydrogeological water flow model implied that there would be high connectivity between regional structures and underground operations. This model predicted that underground mine groundwater inflows were expected to quickly rise as the decline progressed to a peak of 510 L/s. Designing a capital pump station to deal with 510 L/s has its own challenges, however developing the decline down to the required level, always dealing with 300 L/s of water and constructing the pump station is extremely challenging and required a robust water management plan and mine design. When dealing with expected high volumes of water, underground mine design and scheduling plays a key role in protecting electrical infrastructure, equipment, secondary pumps, and the decline from flooding. A good drainage system and controlled dewatering plan is essential for safety and progress. This paper details the dewatering techniques and mine designs required to accomplish decline development with high water inflows as used in the Didipio project. It will describe the learnings and outcomes that are achievable with a flexible design, as new structures are mapped, and water intersections are increased. It also highlights the potential for adaptability in mine planning to provide evolving improvements or to evade problems that are expected from the constant reconciliation of data recorded during development.

Mar 29, 2023

By L Mikhael Gurieff, D Baas

The Phu Kham Copper-Gold Operation (Phu Kham Operation) is located in the Lao People's Democratic Republic and is owned and operated by the Lao-registered company, Phu Bia Mining Limited (PBM). Australian-headquartered copper and gold producer, PanAust Limited holds a 90 per cent interest in PBM; the Government of Laos owns the remaining 10 per cent. The Phu Kham Operation was commissioned in 2008 with an initial concentrator nameplate throughput of 12 million tonnes per annum (Mt/a). Subsequent improvement projects, including the Phu Kham Upgrade Project (PKU), completed in 2012, and the Phu Kham Increased Recovery Project (IRP), completed in 2013, increased the design throughput to 18 Mt/yr. In 2016, the actual mill throughput exceeded 19 Mt/a, this throughput is budgeted to be maintained until the end of 2020.The concentrator flotation circuit upgrade, completed during the IRP, called for a non-selective bulk sulphide concentrate to be generated from the rougher circuit. This in turn caused the mechanical flotation cells in the cleaner circuit, particularly those in the second cleaner bank, to become volumetrically overload. The overload reduced the cleaner circuit performance to approximately 92 per cent copper recovery at a 23 per cent copper concentrate grade, below the expected 95 per cent recovery. This bottleneck restricted copper units entering the plant to approximately 14.5 tonnes per hour (t/h) due to uncontrolled recirculating load build-up in the mechanical cleaning circuit.Maintaining the operating methodologies would have led to a copper production shortfall beyond 2016, to address this shortfall the Phu Kham Operation looked to optimise the Jameson Cell and mechanical cleaner circuit performance. The work included fundamental application of flotation practice and modelling, mineralogical analysis, bubble size analysis, plant surveys and test work. The results were used to develop and implement an innovative automated control system strategy incorporating flotation theory and operating strategies. The automation has the ability to quickly adapt to disturbances in the circuit and maintain optimised performance with little or no intervention by flotation operators.Upon completion, cleaner recovery increased to 95 per cent at a final concentrate grade of 23 per cent copper, and copper units entering the plant increased to 17.5 t/h.CITATION:Baas, D and Mikhael Gurieff, L, 2018. Developing flotation circuit control and automation for the Phu Kham Copper-Gold Operation concentrator, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 37–58 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

By H-S Yang, H Park, S-J Kim, Y-H Ko, H-S Kim, S-H Cho, J-K Kim

An investigation was undertaken to devise a new method for reducing dust spread during blasting demolition utilising water tube and detonating cord. Modelling of smooth particle hydrodynamics (SPH) with AUTODYN software was initially completed to determine the expected diffusing behaviour of the water tube. The actual behaviour was then captured with high speed videos during each experiment, and each result analysed in detail. Water mist diffusion was generated and analysed by changing three key variables. In sequence, these included changing the location of detonating cord in the tube, the charge quantity and the tube diameter.As a result of experiments and simulation, optimum design for ideal diffusion behaviour was suggested and each behaviour of water mist was classified by diffusing shape of water tube as the design criteria.CITATION:Ko, Y-H, Kim, J-K, Kim, S-J, Park, H, Kim, H-S, Cho, S-H and Yang, H-S, 2015. Mist diffusion experiment and evaluation of water tube for blasting demolition dust control, in Proceedings 11th International Symposium on Rock Fragmentation by Blasting, pp 809–814 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 24, 2015

By D Brown, Z Tabor

Projects must be flexible to account for the rapid development of new technologies and changing stakeholder expectations. Coupled with calls for bleeding-edge solutions, customers, shareholders, and regulators demand robust, safe products and systems-of-systems. Developing and integrating these solutions is becoming increasingly complex and maintaining the flexibility required to ‘pivot’ to effective solutions can be a serious challenge. The necessary flexibility is fundamental to the Agile ethos, and this family of methodologies therefore offers a potential solution to this challenge (Beedle et al, 2001). These have traditionally been delivered with systems engineering applied through a Waterfall methodology. Agile Systems Engineering combines both approaches and presents a means to achieve these goals without compromising flexibility, quality or safety. A robust methodology for the application of Agile Systems Engineering is required to enhance practical outcomes and reduce risk for real-world mining projects.

Sep 1, 2024

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

The building is a lofty, well-ventilated one of hardwood frame, with galvanized-iron walls and roof, and consists of five spans running north and south, covering a total length of 236 ft. Each span is composed of nine bays of 1:3-ft. centres, making the total width of the building 117 ft. The refinery is situated conveniently at a distance of 100 yds from the smelters. Through the third span of the building runs a 5-ton electric overhead travelling crane, of a 3-motor type, with a span of 29 ft. The crane runway extends over a railway line, which connects the smelters to the refinery. This crane is llsed for handling bullion, coal, melting kettles, lead pumps, &c. A 3-ton crane of similar type, but with a 50-ft. span, runs through the fifth span of the building and also extends over the railwav line alreadv mentioned. This crane is used to load the soft lead into railway trucks, or to stack lead awaiting shipment in the area covered by the crane's operations.

Jan 1, 1918

By W G. Rowley

The Fortescue Metals Group story began in 2003 with a vision to establish an infrastructure project that would connect the stranded iron ore deposits of the Pilbara region of Western Australia with the steel mills of Asia. Following exploration successes in the Chichester Ranges using their new exploration model, Fortescue established significant iron ore resources at Cloudbreak and Christmas Creek during 2004 and 2005. By May 2006 the definitive feasibility study for mine, rail and port was completed, many of the key government approvals had been obtained, product development and market acceptance were complete and 1.07 Bt of total proved plus probable iron ore reserves were defined to support a 20 year mine life from the Cloudbreak and Christmas Creek deposits. Project construction commenced in September 2006 following a successful $3.2 billion capital raising. By April 2008, the mine and processing plant at Cloudbreak were completed along with the Herb Elliott port facility at Port Hedland and 256 km of heavy haul railroad linking the mine with the port. Mining of overburden commenced at Cloudbreak in late 2007 and by 15 May 2008 the first shipment of iron ore had departed for China. In the first 12 months of operation total shipments amounted to 24.6 M wet metric tonnes with weighted mean composition of 58.9 per cent Fe (64.4 per cent Fe calcined), 4.3 per cent SiO2, 2.0 per cent Al2O3 and 0.047 per cent P. Exactly 3.5 years between the Cloudbreak discovery hole and commercial production. The project success depended on many technical breakthroughs including a new exploration model, application of the surface miner as the main mining production unit, design of a new marketable fines product called æRocket FinesÆ, a highly efficient ædesandÆ flow sheet for upgrading of 2.4 per cent alumina run-of-mine to 1.9 per cent alumina Rocket Fines, 40 t axle loads for the heavy haul railway and a high capacity-highly automated port facility.

Jan 1, 2009

By Robertson AC

Studies by Tennent, Isokangas Pty Ltd (TIP) have indicated that underground quarrying of backfill may be a cost competitive option for providing backfill for specialised situations in underground mining. Situations where suitable bulk fill material may not be available on the surface, and where the total cost of setting up a fill distribution system are prohibitive, could favour the mining of fill material underground adjacent to the stopes being mined. Considerations include environmental impact, scheduling, surface constraints and total costs. The examples quoted in this paper, and the case studies are based on the authors' personal observations and experience.

Jan 1, 1998

By L Bergin, D J. Williams, S Islam, T A. Vangsness

The flooding of open strip coal mines in the Bowen Basin and Hunter Valley Coalfields of Eastern Australia has the potential to soften the spoil and floor materials to produce “mud”. This mud can act as a slip plane or weak zone when spoil is dumped into it, resulting in geotechnical instabilities. Once mud has formed, typical handling techniques include its costly removal by mechanical means, or its isolation and capping.There are little data available on the moisture state and shear strength of the capped mud. To investigate the effectiveness of isolation and capping, research has been conducted using a large slurry consolidometer (150 mm in diameter by up to 410 mm in height) to simulate capping in situ. Once consolidated, the mud was subjected to shear strength testing in a direct shear box measuring 60 mm by 60 mm by about 20 mm high. The shear strength of the consolidated mud was compared to that of competent, fresh spoil, a mixture of spoil and mud, and to completely degraded spoil (mud alone).These results have been used as inputs in stability calculations using the commercial computer program Slide 7.0, which demonstrates the strong influence of consolidation of the mud on overall low wall slope stability. The results provide insight into the design and construction of capping to isolate in-pit mud.CITATION:Vangsness, T A, Williams, D J, Islam, S, Smith, A and Bergin, L, 2018. Consolidation and shear strength testing and stability analysis of coal mine spoil degraded to mud, in Proceedings Mine Waste and Tailings Stewardship Conference 2018, pp 97–109 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 23, 2018

By Reichman J. P

Extensive use is made of a small scale computer (IBM 1130), in the calculations of ore reserves for Western Mining Corporation's nickel mine at Kambalda, W.A. All surface drilling data such as assays, density and location information, are stored on disk files at the Company's Technical Computing Centre at Perth, W.A. The computer is used to search through the data, select significant ore intersections, calculate the area of influence of each intersection and perform the necessary calculations to arrive at an estimate of the ore reserve. Comparing the computer-assisted ore reserve calculation with an entirely manual operation, it is estimated that a saving of 40 percent in time is achieved together with

Jan 1, 1973

By G Lumley

PlannersÆ optimism (or maybe commercial necessity) means that most mine plans use equipment rates that are rarely achieved (Lumley and Beckman, 2009). This lack of understanding of what equipment actually moves is causing erroneous equipment forecasts, leading to incorrect mine development plans and economic evaluations. Compounding this problem is a downward trend in actual equipment performance in some areas. Consequently, the presentation of realistic mine plans that are actually achieved in practice is not a common occurrence. However, rational, fact-based mine planning is available to those who want it. Hundreds of millions of cycles of data from open cut mining equipment has been collected from mines around the world since 1992. This unique and highly valuable databank is growing at an exponential rate and is being used by a number of our big miners to support rational and fact-based decision-making. However, neither the use nor the appreciation of the value of this data is universal. There is a challenge to everyone in the mining industry - how do you access value from it? The databank was drilled into and the results analysed for, the Australasian Mining and Metallurgical Operating Practices (AMMOP) publication (Lumley, in press). For this paper the analysis has been extended to include interpretation of trends for draglines, shovels, excavators and trucks. It investigates trends between coal and non-coal mines and across geographic areas. It is known that mining equipment performance in most sections of the industry is falling. This paper attempts to quantify the fall and provide explanations. The trends are analysed to extract the reasons behind the changes and most importantly, what can be done about it.CITATION:Lumley, G, 2012. Understanding trends in performance of open cut mining equipment, in Proceedings Project Evaluation 2012 , pp 203-224 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 24, 2012

By P D. Munro

On the occasion of the 14th Mill Operators’ Conference and marking 40 years since the first one was held in Mount Isa in 1978, it is fitting to review the history of the Conference and its development over that time.The first 10 Conferences were irregularly held at three to four year intervals, with 9 of these in regional centres of Australasia. It is only since 2012 that the Mill Operators’ Conference has become a regular biennial event, alternating with the MetPlant Conference.The number of people attending the Conference has more than doubled to 470 delegates at the 13th one in 2016. It has outgrown its regional beginnings.Papers presented to the previous Conferences have been analysed according to commodity, country of origin, technology and theme plus the affiliation of the authors to discern any trends that may assist in planning the future events.Suggestions are made as to how the AusIMM might wish to arrange its mineral processing/metallurgical conferences.Recent changes to the structure of the Conference providing a more meaningful experience for the delegates and increasing their interaction and involvement should be vigorously pursued.CITATION:Munro, P D, 2018. Mill Operators’ conferences – a 40-year retrospective and a vision for the future, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 5–14 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

By S Girard, L Rowland, V Lawson, Y Shields

Since 1948, ValeÆs Matte Separation Plant has been successfully using magnetic separation and froth flotation to separate the copper sulfide, nickel sulfide and Ni-Cu metallic alloy contained in Bessemer matte for downstream processing. Though some equipment upgrades have been performed over the years, the flow sheet has generally remained unchanged since the early 1970s. The need to improve metallurgical performance led to the trial of a scalping flotation column to produce a final copper concentrate ahead of the cleaner circuit feed to take advantage of a high degree of copper mineral liberation, reduce cleaner-recleaner circulating loads and decrease the associated loss of selectivity. Plant results indicated that 50 per cent of copper contained in the rougher concentrate could be recovered at final grade target. Results indicate that up to a 1.5 per cent increase in copper recovery to copper concentrate was achieved during the scalper trial due to a reduction in the generation of fine chalcocite which has historically been observed to report to flotation tailings due to surface contamination. Deficiencies are currently being addressed and a long-term trial is scheduled to confirm the benefits of copper scalping.CITATION:Girard, S, Rowland, L, Shields, Y and Lawson, V, 2012. Copper scalping at ValeÆs matte separation plant, in Proceedings 11th AusIMM Mill OperatorsÆ Conference, pp 299-308 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Oct 29, 2012

By A Giblett, S Hart

"In 2015 operations under the ownership and/or management of all Newmont Mining Corporation subsidiaries (Newmont) produced 5.7 Moz of gold and 619 Mlb of copper from mining operations in five countries, with well over 100 Mt of ore processed by various grinding technologies. Processing methods used in the extraction of metals include flotation, oxidation, conventional cyanidation and heap leaching. The grinding technologies applied in milling operations feeding metal recovery processes include conventional wet grinding semi-autogenous grinding (SAG), rod and ball, dry grinding, concentrate regrinding and ultra-fine grinding, and ball milling of high pressure grinding roll product. SAG/ball (SAB) configurations represent the dominant comminution flow sheet within the company and the circuit configurations employed include SAB, SABC-A, SABC-B and single-stage (SS) SAG milling, with SAG mill feed ranging from run-of-mine (ROM) ore through to secondary crusher product. The collective experiences earned from designing, operating and debottlenecking these various comminution circuits provide many lessons that can be applied to the design and optimisation of future operations. This paper provides an overview of Newmont’s diverse comminution circuits, discusses recent performance and offers some insight into optimisation and design considerations based on recent experience in both endeavours.Citation:Giblett, A and Hart, S, 2016. Grinding Circuit Practices at Newmont, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 293–302 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By D Flint, O Rindriatmoko

PT FreeportÆs Deep Ore Zone (DOZ) Mine is the latest block cave mine within the East Ertsberg Skarn System (EESS).Issues with undercutting and stress concentrations at the extraction level were experienced, leading to reduced pillar strength.The extraction level-related issues became more pronounced, leading to local panel drift collapse, in an area that was over 100 per cent extraction. A review of ground conditions, panel collapse descriptions, and factors contributing to panel collapse are presented in this paper.

Jan 1, 2005

By Z Li, J Pan, D Zhu, W Zhou

In order to enhance the roasting behaviours and metallurgical properties of hematite pellets, which have the problems of high roasting temperature and low compressive strength, a process of producing Brazilian hematite pellets by adding high sulfur magnetite was developed in this paper, and process parameters have been optimised. It is shown that the roasting temperature decreases from 1320¦C to 1200¦C by adding 30 per cent of high sulfur magnetite. New Fe2O3 crystal oxidised from Fe3O4 is more active, which is beneficial to induration of pellet. When the ratio of magnetite increased to 50 per cent, only about 90¦C of the roasting temperature was decreased. Higher ratio of high sulfur magnetite causes more porosity of pellets because of oxidative desulfurisation, which is harmful to the strength of roasted pellets. The reduction disintegration index (RDI), presently RDI+3.15 of product pellets is aggrandised from 87.79 per cent to 99.54 per cent and 97.55 per cent, and the reduction swelling index (RSI) is lowered from 36.25 per cent to 12.50 per cent and 6.25 per cent respectively, by adding 30 per cent and 50 per cent of high sulfur magnetite. The compressive strength of roasted pellets is elevated obviously by adding high sulfur magnetite, which resists the inner stress of pellets during reduction process, so as to enhance the RDI and reduce the RSI of product pellets. In addition, the inner porosity may be filled by the swelling during the reduction process, which can also lower the RSI. The process provides a low power consumption of making hematite pellets that high sulfur magnetite can decrease roasting temperature significantly and improve the metallurgical properties of hematite pellets dramatically.CITATION:Zhu, D, Zhou, W, Pan, J and Li, Z, 2013. Study on improving roasting behaviours and metallurgical properties of Brazilian hematite pellets by adding magnetite with high sulfur content, in Proceedings Iron Ore 2013 , pp 525-530 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 12, 2013

Upgrading of Indonesia's Bauxite by Washing Method There were eight bauxite samples used in this research, three samples from Kijang contain total SiO2 18.36 - 29.16 per cent, Al2O3 40.12 - 48.36 per cent, Fe2O3 4.27 - 5.13 per cent, one sample from Tayan, contains total SiO2 4.69 per cent, Al2O3 38.95 per cent, and Fe2O3 19.67 per cent, and four samples from Mempawah contain total SiO2 33.5 - 44.8 per cent, Al2O3 29.8 - 35.9 per cent, Fe2O3 7.29 - 9.88 per cent. All of those bauxite ores have not fulfilled the requirement for Bayer process yet; therefore simple up-grading using a rotary drum scrubber is needed. The scrubbing process was carried out with time variable up to 60 minutes with solid percentage applied was 50 per cent and rotary speed was set up 30 rev/min. The bauxite was washed by following steps: scrubbing, screening, drying, and finally it was analysed to show chemical content. The washed bauxite produced has size fraction that is retained on the 1.7 mm of screen opening. The result of the research shows that the higher alumina content of the raw bauxite, the longer washing time is needed moreover the higher quality of the washed bauxite is produced. The highest alumina content of the washed bauxite was 53.67 per cent with the alumina recovery was 89.66 per cent and the concentration ratio of 84.80 per cent was achieved within 20 minutes of washing time of the raw bauxite (Al2O3 48.36 per cent). The washed bauxite resulted from this research is suitable as a raw material for Bayer process.

Sep 13, 2010