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By S Wright, W Bruckard

The current status of battery collection and recycling schemes in Australia are explored in light of current developments in product stewardship and increasing pressure to decrease materials going to landfill by originating equipment manufacturers. Used consumer batteries, both single cycle and rechargeable contain a mixture of valuable metals and potentially toxic materials that may become a resource/revenue stream to offset the cost of disposal/recycling. Although the volume of batteries discarded in Australia is modest compared to other global population centres, the expected increase in battery use with increasing equipment portability and future developments in the automotive industry, provide an opportunity to recycle. The requirements for a battery recycling facility in Australia and the most promising processing platforms that may exploit the resource with enough flexibility to cope with battery developments and market trends, are explored.

Jan 1, 2006

By S M. Stewart

Building and Maintaining Community Relationships   In mining terms, the town of Waihi is distinctive with the Martha mine situated right in the heart of the town. MarthaÆs central location and other mining activity nearby means there is an increased community focus on the happenings at the mine and the effects and impacts of mining. While WaihiÆs proximity to the mine is unique, all mines have a community context that they operate within.   Issues of proximity simply heighten awareness and emphasise the need for building and maintaining good community relationships. In the three years we have been working alongside the Waihi community, we have worked together with concerned and supportive residents, representatives of Newmont Waihi Gold and representatives of Hauraki District Council, to develop a collaborative framework for addressing the economic, social, environmental, cultural and spiritual wellbeing of the people of Waihi. This could not have occurred without the genuine commitment of all participants.   This collaborative focus has resulted in some tangible progress in Waihi which, in part, stems from people taking an interest in the town because the town is taking an interest in itself. As we have worked and learned within the process of building and maintaining a collaborative and sustainable community environment, we have tried to adhere to a philosophy and a set of basic principles. We believe that this approach, combined with a teachable skill set, helped to create the opportunity to develop a truly collaborative community environment which continues to grow. Our paper will describe this philosophy, these principles and the skill set that we have applied.   The application of the process in Waihi has resulted in a series of outcomes unique to Waihi. These outcomes include formation of the Waihi Community Vision committee, the Vision Waihi Trust and the subgroups set up to further the interests of particular groups, for the collective benefit of all the community.   Based on our experience of other situations, and on the way the Waihi process has developed, we believe that the identified principles and skills can be transported and used in other cultures and contexts. While the resultant outcomes may differ, the underlying principles will still apply. Progress will come from creating a sustainable environment within which the community (including residents, industry and regulatory authority) can determine its own internal relationships and the vibrant growing sense it has of itself.

Jan 1, 2006

By T O&apos, Sullivan

Reconciliation of metal production from a sublevel cave (SLC) mining operation is a complicated process. SLC reconciliation is unlike reconciliation for open stope operations, where a tonnage of extracted ore can be assigned to an exact volume of in situ ore, and a direct comparison made between the estimation of contained metal and actual metal production. In SLC operations the ore extracted from a particular SLC drawpoint will be composed in part from the parcel of freshly blasted in situ material, in part from varying components of ore material (from cave stocks) flowing down from other previously mined areas vertically above the current draw position and in part from external dilution. This leads to difficulties in reconciling production grades against estimated grades. The problem is that we know how much metal we have produced but we can not precisely say where it has come from. Metal production reconciliation is fundamental in assessing ore reserve estimation accuracy and performance and in determining a draw management strategy for SLC mining. In terms of contained metal, differences in extracted metal compared to in situ metal represent changes to cave stocks. To generate local estimates of the cave stocks, differences in metal for each ring are treated as additions to or subtractions from a series of vertical columns of stocks extending throughout the height of the cave. The sum of metal differences (extracted versus in situ) for each vertical column results in a residual metal map at any particular mining level. The metal maps show areas where the metal production has been greater than or less than expected. The maps also highlight areas in the cave where residual metal is located, areas where targeted overdraw can reduce cave stocks.

Jan 1, 2006

By T Niitti, J Turunen, P B, A Rinne

In todayÆs marketplace, with high metals prices, many operations are faced with the challenge of improving recovery in the particle size ranges which are normally difficult to recover. This presentation focuses on the various methods used to alter the flow dynamics in a mechanical flotation cell, thereby improving metallurgical results. Modern computational fluid dynamics (CFD) tools have been used in the design phase, with subsequent validation at the plant. Some of the validated variables include mixing profile, power draw and local air hold-up. This presentation underlines how modern CFD analysis can be used to screen and select different approaches before commencing costly trial-and-error experiments at plant scale. Two methods of affecting flow dynamics are discussed û firstly, by altering the geometry of the rotor-stator area and, secondly, by fitting additional features in the tank. The rotor-stator area can be modified to provide more concentrated turbulent kinetic energy or, respectively, to provide more pumping efficiency with less attrition. The tank can be fitted with various additional features, aimed to create different particle suspension profiles. The benefit of both methods is that they can be applied not only to newly installed flotation technology, but also to existing plant cells, thus enabling potential improvement in the mixing profiles, solids suspension, tank sanding and metallurgical performance. Results of several sitesÆ tests are discussed in terms of flow variables measurement as well as metallurgy. This paper demonstrates the effects of different flow dynamics on the mixing profiles and metallurgical results of existing mechanical flotation cells.

Jan 1, 2006

By E Hondros

Innovation and Business Skills Australia (IBSA) commissioned The Boston Consulting Group (BCG) to undertake a study into how the role of AustraliaÆs senior managers is likely to change between now and 2020 and to identify the skills and attributes that will be needed to respond to those changes. This report builds on a previous study prepared by BCG in the early 1990s for the Industry Taskforce on Leadership and Management Skills (Karpin Committee), which provided a snapshot of the Senior Manager in 2010. The following powerpoint slides summarise the 2020 Vision û The Manager of the 21st Century û outlining how the role of AustraliaÆs senior managers is likely to change between now and 2020 and to identify the skills and attributes that will be needed to respond to those changes. The presentation is summed up in the following quote from Jon Nicholson û Senior Vice President of BCG: We believe that to succeed in the years up to 2020, executives will need to master a range of hard and soft skills. Amongst other things, they will require to manage multi-generaional teams, the creativity to measure staff performance on outputs rather than inputs, and a high degree of technical and functional expertise in addition to their general management credentials. This paper is available as a PowerPoint presentation only.

Jan 1, 2006

The mine manager is one of the oldest jobs in the world. Over many centuries the fundamentals of how this job was approached did not change much. However since the later part of the 1980s there has been a dramatic shift in the expectations and role of the mine manager as the pressures of globalisation and consolidation have increased the size of companies and the production levels of mining operations. The changes have been dramatic, with demanding requirements on mine managers to continually improve the skill levels of people, to apply and develop rapidly changing technologies and to consider far broader business issues that need to be managed in a truly globally connected world. This paper will attempt to outline some of the issues, the complexity surrounding them and some of the approaches that have been made to manage them. There is not a single correct answer or approach, but there are many key success factors that have led to some amazing levels of performance being achieved as we go deeper, broader and literally move mountains to meet the customerÆs needs for today and tomorrow. This contrasts with many mining operations in developing countries that still have a traditional approach to how they mine. Society is the river of life that continually flows and changes the environment that surrounds it. The pressures from the customers and world growth, shape and force alterations to be made in an industry that has to live with the far greater primal and uncompromising forces of the earth we mine. This has led to some paradigm shifts in how we accept what we manage. TodayÆs mine manager must manage a far broader range of issues, than just how do we get tonnage out of the mine and product out of the ore. These include but are not limited to technical, commercial, product quality and end use understanding, employee and community issues, environmental and the ever increasing complexities of sustainable development. Organisations will have to look at how they structure their management of the business to manage functions to meet the complexity of different stakeholders needs û the business, the employees, the customer and the broader community within an environment that is becoming more attuned to the harm impacts to the world in which we operate. The attraction and retention of skilled people that contribute to the value and worth of the corporation, will become critical to sustain a companyÆs growth. One of the fundamental elements of successfully doing this will always be the skills of the mine manager and his/her extended team with the continued development and support that they will need to meet these demands.

Jan 1, 2006

By B Manda, K L. Sandvik, K Musiwa

Mining and processing of pyrite ore at Iron Duke Mine, north east of Zimbabwe, generates large quantities of acidic mine water as a result of the oxidation of iron sulfides on exposure to air and water used in the drilling and blasting operations. The acid mine drainage (AMD) contains elevated levels of dissolved Fe, Al, Mn and sulfate and has characteristic pH values ranging from about 0.50 to 3.00. Handling and disposal of such a drainage places significant impacts on the economics of the mining operation due to the corrosive nature of the drainage on infrastructure, the limitations placed on water reuse and discharge to the environment under a new law governing effluent discharge. Treated sludge at Iron Duke is chemically unstable, changing pH from ~7 to ~3 within four days after deposition in the evaporation ponds. The effluent does not meet the permitted level of neutral pH, 500 mg/l sulfate and less than 2000 mg/l total dissolved solids. Excessive acid seepage from the evaporation ponds has resulted in contamination of the ground water below the ponds area, which shows high mean annual levels of iron (368.67 mg/l), sulfate (1702.89 mg/l) and low pH (2.86) in addition to other pollutants. This poor quality seepage infiltrates into the nearby Yellow Jacket River, contaminating the public water source. Furthermore, a deterioration of the land area and vegetation adjacent to the tailings dump is also observed. Understanding the controls on the neutralisation of acidic drainage and long-term sludge stability after placement in evaporation ponds is essential to minimise costs of closure requirements and for the protection of environment and human health. This study examined the effects of the master variables pH, redox potential, acidity and alkalinity on acid neutralisation. The results indicate that ferrous hydroxides are not as stable as ferric hydroxides and that proper oxidation of iron also leads to better sludge stability, higher treatment efficiency and a manageable sludge viscosity. Metal hydrolysis and secondary mineral formation at the evaporation ponds under a wide range of pH and redox conditions is responsible for equilibrium shifts in metal reactions, resulting in high potential for metal leaching and mobility. Mechanisms of metal attenuation are also discussed.

Jan 1, 2006

The Golden Cross is the first large precious metals mine to be both commissioned and closed in the æmodernÆ era in New Zealand. This paper discusses the life cycle of the Golden Cross mine, with emphasis on the closure process and post closure management.   The closure process has generally been very well managed, and successful, but in spite of that some on-going issues remain unresolved. Nearly nine years after the end of mining the mine owners are still actively managing the site, with no immediate end to that in sight.   The site has been described as atypical, due to the identification of a deep seated landslide below the tailings and waste rock storage facilities. However that should not be given too much emphasis when addressing the overall closure and post-closure management issues, which could well apply to other existing and future mine sites in New Zealand.   The Golden Cross can provide valuable lessons for other miners, and the issues arising at this site should be watched closely by the industry as a whole.

Jan 1, 2006

Mining projects have long since presented challenges for the protection of the water environment. Lessons learnt from historical pollution incidents and increasingly stringent environmental controls have significantly improved the environmental performance of mines in developed countries. In contrast, water protection legislation and guidance in the Former Soviet Union (FSU) countries, based on the æpolluter paysÆ principle, has not promoted the prevention of water pollution, and examples of poor environmental performance in mining still exist. However, there is now evidence of emerging legislation encouraging the protection of the water environment. This paper provides an overview of water protection legislation in the Russian Federation and Armenia and highlights some of the challenges facing international mining companies developing projects. A mining case study is described, which highlights how communities in Armenia increasingly value their water environment. Here, greater public participation in development projects is playing a vital role in influencing water protection legislation. It is considered that public opinion and emerging legislation will increasingly present challenges for the development of mining projects.

Jan 1, 2006

By W Boughton, L Gilbert

The Australian Water Balance Model (AWBM) has found widespread use in Australia in estimating the streamflow behaviour of catchments. It has been used at the Ridgeway Gold Mine, in central west New South Wales, to estimate streamflows in creeks potentially affected by loss of spring-fed baseflow due to mine dewatering. The AWBM estimates are used to assess the effect of mining on streamflows and the need to provide compensatory flow releases, which would be drawn from mine water supplies, into the creeks, in compliance with regulatory consent requirements. The monitored flows in some of the creeks exhibit non-typical behaviour, with streamflows increasing in autumn months despite a lack of significant rainfall. This behaviour is believed to be due to the combined effects of discharge from rock fractures and the effects of evapotranspiration in the riparian zone. A modified version of the AWBM has been developed which much more closely simulates the observed flow behaviour and which will be used in ongoing flow assessments for the mine. This paper outlines the difficulties involved in modelling low flows in small catchments that are subject to a number of influences (other than mining), describes the development of a refined model to improve simulation of low flows and baseflow in small headwater catchments and highlights the need for good baseline data to calibrate such models.

Jan 1, 2006

By M Hino, Y Sasaki

Sustainable handling of municipal waste and sewage sludge has an important goal to recycle resources without supply of harmful substances to humans or the environment. The gasification mechanism of phosphorus from municipal waste and sewage sludge during the incineration process has been investigated to develop a phosphorus recovery system. Quadrupole mass spectrometer coupled to an electric furnace is applied to study the vaporisation behaviour of phosphorous gas phases from municipal solid waste (MSW) incinerator ash of sludge during solid-state reduction by carbon. Measurements are carried out in vacuum conditions of 2 x 10-6 Torrs and furnace temperature range 573 - 1773 K, at a heating rate of 7.22 K/minute. It has been found that most of the phosphorus is vaporised as PO2, P2 and P4, in agreement with thermodynamic estimation despite a shift in the temperature regimes.

Jan 1, 2006

RME has a vision for a new mill operational paradigm made possible by RMEÆs fast, safe Mill Relining System. This vision can be moved forward into reality at any time with or without guidance from recent development in measurement and predictive modelling tools.Some new liner designs can degrade SAG mill performance because of mill volume loss, ball strike (rotational speed limitations) and other issues often brought about by optimising liners for life and without a backward glance at metallurgical consequences. Freshly relined mills can initially produce as little as 80 per cent of their maximum throughput, that maximum occurring toward the end of the linersÆ wear life. RMEÆs proposition is to design new liners for maximum commercial performance. This may mean more frequent changes of liners but with liners designed to yield optimum grinding, metallurgical and profitability performance. In other words, mill liner profiles and mill relining speed become key operational controls and not simply æmust doÆ maintenance functions. Taken to the extreme, liner profiles may prove capable of ætuningÆ a grinding plant for maximum profitability in any metal price environment. This paper provides an update regarding RMEÆs fast, safe Mill Relining System technologies and outlines RMEÆs vision of a æliner profile versus profitabilityÆ model as a function of metal price, developed intuitively or by using a combination of new measurement and modelling technologies. These new measurement and modelling tools provide the opportunity to predict the optimum commercial outcome, off-line in the virtual world, before committing to an expensive liner experiment.

Jan 1, 2006

By M Lund

Due to operational and regulatory practicalities, pit lakes will continue to be legacies of many open cut mining lease relinquishments. Unplanned or inappropriate management of these significant geographical features may lead to a short-term liability to all stakeholders during mining operations, or to ongoing liability to the local community and environment following lease relinquishment. However, the potential for pit lakes to provide benefit to companies, communities and the environment is frequently unrecognised and yet may be a vital contribution to the sustainability of the open cut mining industry. Improved remediation technologies are offering more avenues for pit lake end use than ever before, at the same time mining companies, local communities and regulatory authorities are also becoming more aware of the benefit these water resources have to offer. Sustainable pit lake management aims to better minimise short- and long-term pit lake liabilities, and yet also to maximise short- and long-term pit lake opportunities as well.

Jan 1, 2006

By E Widijanto, A Srikant

PT Freeport Indonesia operates a copper-gold mine located in the remote highlands of Papua, Indonesia, about 3500 km east of Jakarta. Currently, the district produces about 240 000 tonnes per day (tpd) of which about 45 000 tpd come from the DOZ Block Cave and the rest is mined from the Grasberg Open Pit. Over the next ten years, ore production from large block caves in the area is expected to reach about 200 000 tpd, replacing a large part of the production from the Grasberg Pit. Block cave mining alters the hydrological characteristics of the area being mined and when the cave expresses itself at the surface in the form of subsidence, it increases the entrapment area for surface water. Operating a large block cave mine in a region with an average annual rainfall of 5500 mm in steep mountainous terrain and complex geological and hydrological features presents a challenging scenario for dewatering or depressurisation of the area. The high rainfall infiltration and entrapment in stacked mines operating within an essentially single orebody, coupled with the presence of fine-grained and clayey material within the draw points of the block cave, creates mud rushes or wet muck spills, which can endanger the personnel and interrupt production. This paper outlines the problems caused by high water inflow into the DOZ Block Cave and the efforts undertaken to ensure the safety of the miners and continued achievement of desired production rates from underground mining in the district.

Jan 1, 2006

By A G. L Pratt, J R. Grant

Mining companies face the ongoing challenge of sustaining and growing production. This paper outlines business investment concepts to grow reliable returns on investment from a portfolio of choices by:improved visualisation, diagnosis and tune up of the investment pipeline (pipeline management); good corporate decision making (governance) to select the right project mix, risks and sequence; and delivery strategies to enhance and reliably execute projects.

Jan 1, 2006

By G Muller, P Larrondo, M C. Godoy

The categories of Mineral Resources and Ore Reserves that may be used for public reporting in Australasia are defined in the current JORC Code (2004). Most internationally accepted codes emphasise the principles of transparency, materiality and competence in classifying resources. They also provide some guidance in considering the impact of data quality. There is no method recommended in the JORC Code to classify a Mineral Resource into the allowed categories of Measured, Indicated and Inferred for public reporting. A clearly defined procedure is desirable for many reasons, including consistency, repeatability and auditability. The demonstrated use of geological knowledge in the classification method is desirable. In deposits with abundant historical data there can be large variations in data type and quality. Quantification of the error of the estimates may also be considered. Ways to formally incorporate such information into the resource classification process are presented as a first step towards establishing an objective, repeatable methodology that allocates resources into appropriate categories based on defined criteria of accuracy and precision.

Jan 1, 2006

By Y Gu

The Mineral Liberation Analyser (MLA) employs the technologies of scanning electron microscopy (SEM) and energy dispersive X-ray analysis (EDX). The use of backscattered electron images to define phase boundaries produces very high resolution image analysis and subsequently detailed and accurate particle images and data output. The mineralogy, elemental deportment, grain size, liberation characteristics and mineral associations of a large number of samples can be described. The MLA uses a comprehensive set of analysis methods to meet a wide range of applications. The data from ore characteristion projects completed during feasibility studies are important aids for effective plant design. The MLA can be used to establish variation in the mineralogy of an orebody, identify and quantify the deportment of deleterious elements, and provide valuable information to support comminution and flotation test work. In established plants the MLA data is an important component of plant survey work and monthly composite samples. Changes in feed characteristics and/or operating conditions can be monitored and solutions to any deterioration in recovery and grade performance found. The MLA has extensive applications in the minerals industry. Rare and precious metal samples can be accurately measured using high-resolution grey-scale images. Several new measurement techniques have been developed to perform rapid searches of a large number of samples to provide efficient and accurate analyses of fine-grain, low concentrate material. Quantifying the mineral variability in mineral sands operations is essential to maximising grades and recovery. The MLA produces particle-based data on density, mineralogy, size and shape and has developed measurement techniques to provide the elemental quantification required for the characterisation of these deposits. Nickel sulfide ores can be analysed to provide modal mineralogy, elemental deportment and liberation and locking data. The low-grade and variable nickel mineralogy of these deposits makes the use of quantitative mineralogy an essential component of maximising returns. Coarse particle measurements preserve the in situ textures of ores and support flotation and breakage test work for feasibility studies. The deportment of penalty and bonus elements can be quantified and the association and grain-size data can be used to identify potential separation issues.

Jan 1, 2006

ITSL Technology group employs around 100 people at Mississauga in Canada. Its long and proud history as a driving force for the worldÆs nickel industry continues, progressively adapting to meet IncoÆs ongoing development needs. The nickel industry, unlike many others in the minerals processing world, has not evolved into one or two narrow technology paradigms. Rather, each process requires a degree of optimisation to meet the characteristics of the ore. Without a competent team to address this complexity, the uncertainties that arise can greatly increase the risk (and costs) associated with the nickel industry developments. The development work carried out at ITSL Technology ranges from milling and metallurgical processing of ores through to development of value added products for the battery and electronics industries. It covers routine evaluation of ores for exploration (mine planning and greenfield), and provides on the ground support to bring specialist technical perspectives to site-based projects. In recent years, ITSL Technology has had as its particular focus the process development and commissioning support for IncoÆs major projects. Over the next several years, Inco will commission its Goro laterite operation, design and construct the further processing facility for VoiseyÆs Bay, undertake major upgrades at Sudbury, Thompson and PT Inco, and bring forward some additional resources currently in the exploration stage. The appropriate mix of both internal and external resources to effectively manage this project portfolio will prove critical to success. The key to ITSL Technology meeting these development challenges has been in working closely with its internal customers to ensure alignment of the value proposition, to identify the critical issues to be managed, and to understand the deliverables required. This paper discusses examples to reinforce these principles in the definition and development for two different projects; processing of VoiseyÆs Bay ores and concentrates and resource optimisation at Thompson.

Jan 1, 2006

By C Hertle, B Goebel, R Fabre

The mining industry maintains a ælove-hateÆ relationship with water. Dewatering, aquifer, water disposal, irrigation, process water, tailings water, run-off water, seepage, leachate and sumps are all terms that are used on a daily basis in the mining industry, highlighting the numerous water usages on site and their associated quality. According to the Australian Bureau of Statistics (2001), each year the mining industry consumes over 530 000 ML of water. The increasing recognition of water as a limited and valuable commodity, and the associated environmental concerns with the management of water disposal to the environment has led the industry into improving on-site water management. Progressively, water balance models and water reuse strategies are being developed, incorporating more sophisticated water treatment processes. By way of example, membrane technologies, once restricted to industries such as the pharmaceutical industry or the drinking water industry, are now entering the mining world with the aim of producing clean water of suitable quality for ore processing or for advanced treatment prior to release to the environment. This paper will provide a review of the threats and opportunities linked to water use and recovery/reuse in the mining industry in Australia. It will open with an overview of current water usage and associated quality for various mineral industries and continue with identifying the threats and limitations associated with the quality of available water. It will then present how newly developed water treatment technologies and assessment tools can be incorporated into the system to enhance the recovery and reuse of water on site, reduce the risks associated with securing long-term water supply and further improve production, environment and safety (health risk control).

Jan 1, 2006

Sampling of CIL/CIP circuits is typically done by compositing samples of feed and tails over eight or 12 hour periods. As the residence time in the leaching tankage may be approximately 20 hours, the tails from any period being derived from material entering the circuit 20 hours earlier do not correspond to the head from the same sampling period. Moreover, mixing in the series of tanks in a circuit also modifies correspondence between input and output. A special purpose simulator has therefore been developed to allow for the mixing and delay in the tankage and permit estimation of the head assays corresponding to any tailings sample. Thus more accurate assessment of the day-to-day recoveries of gold and silver follows. The model, programmed in Excel, assumes that the tanks are perfect mixers. By inputting the sequential head grades and considering that no leaching has occurred, the head grade which corresponded to the tailings for each period could be estimated. Allowance is made for variations in feed rate over the sampling period by computing the average flow rate of slurry and thus the residence time of each increment of the tailings. This simple model and its application have been found to be subject to some limitations, which are discussed in the paper, resulting in some unresolved variability in results. However, for a typical circuit even the simple model was able to greatly improve consistency of recovery data with variations being approximately halved by eliminating much of the anomalous variation arising from the lack of correspondence between head and tail when changes in head grade are occurring. Therefore, this permits genuine variations in metallurgy to be identified with greater confidence and thus operational shortcomings can be identified and addressed more quickly.

Jan 1, 2006