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By C Killip

Working in Australia’s harsh climate can have a significant impact on the health, safety and productivity of our teams, but is our working environment expected to be more prone to heat stress in the future? Climate modelling suggests that we are likely to encounter more frequent heatwaves and higher apparent temperature. Does this mean that our teams will be at greater risk of heat stress, and are we prepared to deal with the changes in our future climate and the potential impacts on our working population? This paper will review the recent research on climate and projected changes to all meteorological parameters that are important in understanding the likelihood of heat stress. The paper will also describe the challenges encountered in the management of heat stress in a workforce, and then outline a systematic approach to heat stress management that will allow you to assess your own risk and manage your day-to-day operations into the future.CITATION:Killip, C, 2015. Future climate – is heat stress a real risk for the future and how can we better manage it?, in Proceedings Third International Future Mining Conference, pp 181–188 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 4, 2015

By B Taylor

Although the underground mining environment is arguably safer now than at any time in history, as underground mining operations across the globe increase in-depth, magnitude, and complexity, protecting workers from harm becomes increasingly challenging. In deep, stressed, seismic mines the development face is one of the most hazardous work areas. The active face is usually the furthest extent of the underground workings, so ventilation can be difficult to maintain, exposing workers to high temperature and humidity while working on foot and doing manual labour. While mechanisation has made many tasks easier in modern times, the reality of underground mining is that development charge-up workers still spend long periods directly exposed hazards at the face. In 2019, Orica and Epiroc partnered to co-develop the world’s first fully mechanised development charging unit using fully wireless initiation, called Avatel™. Built on Epiroc’s M2 Boomer carrier platform, the system is designed to allow one person to charge a development face from the safety of a fully enclosed cabin, thereby reducing exposure to hazards at the face. The system was prototyped in Europe before entering commercial introduction in 2022. This paper reviews earlier attempts to mechanise underground charge-up and describes the development journey and engineering challenges of building a mechanised development charging machine.

Mar 29, 2023

By Kam KM, Tran B

Statistical techniques of Box and Jenkins (1976) have been used to assess the existing control schemes and determine the dynamics of flash smelting furnace at the Kalgoorlie Nickel Smelter. Pertinent process variables, such as, oxygen flow, flux flow, matte grade and iron to silica ratio in slag, were considered in the analysis using routine operating data collected over two periods of operation. Results indicate inadequate control of some of the important variables. Dynamic characteristic parameters (dead time and response time) between a set of input and output variables were identified to improve optimisation of the existing thermodynamic model used for flash furnace control.

Jan 1, 1996

By R Minnitt

Two methods of calibrating the parameters K and Alpha for use in Gy’s formula for the fundamental sampling error were investigated. Approximately 480 kg of broken ore from Harmony’s Target gold mine in South Africa was used to compile the replicate samples for two experiments. The duplicate series analysis (DSA) and segregation free analysis (SFA) methods differ in terms of their approach to recovering the sized materials required for the calibration procedure. In this experiment the DSA method split off six more-or-less equal masses of material from a 75 kg lot that was successively crushed to finer and finer fragment sizes. The sublots so formed were split into 32 samples and fire assayed for gold. The SFA method used approximately 250 kg of broken ore crushed to 95 per cent passing 2.50 cm, which was then passed through successively finer screens until a sublot of less than 0.0075 cm was obtained. Each of the 15 sublots obtained in this way were split using a riffle splitter into 32 samples that were fire assayed. A total of 672 fire assays were used in these experiments. The sampling parameters K and Alpha were used for the compilation of a nomogram and to calculate the gold liberation size of the ores. While there are no definitive results in terms of the actual gold grain sizes against which the calculated sizes can be compared, it appears that the DSA method produces more acceptable results.CITATION:Minnitt, R, 2014. A comparison of two methods for calculating the constants K and alpha in a broken ore, in Proceedings Sampling 2014 , pp 165–178 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 29, 2014

By A N. Parry

In May 2018 Kasbah Resources Limited (“Kasbah”) completed an ore sorting test work program which was a precursor to releasing in July 2018 an updated Definitive Feasibility Study (“DFS”) for the Achmmach Tin Project in Morocco, which it is proposing to develop along with its joint venture partners. The testwork program evaluated ore sorting as a pre-concentration option to achieve early elimination of gangue and the low-grade component of ROM feed, thereby potentially:  Significantly upgrading the head grade of tin to the downstream processing plant.  Significantly reducing the required throughput capacity (and projected capital expenditure) of the downstream processing plant.  Reducing total consumables, power and water requirements in downstream processing.  Increasing the recovery of tin in the gravity and flotation circuit due to the higher feed grade achievable with ore sorting.  Reducing tailings tonnage, tailings cost and environmental footprint.  Using sorter rejects for mine backfill or road base applications. Key aspects of the design of the metallurgical testwork program centred around the need to ensure that samples representative of ROM ore feed (including projected mining dilution) were selected for the ore sorting testwork. The design and implementation of the ore sorting bulk testwork program is described, as well as a summary of the test work results and a discussion of the enhancement of the project economics reported by Kasbah, which led the company to adopt ore sorting as part of the proposed processing circuit in the updated 2018 DFS.

Nov 10, 2020

By D Brereton, C J. Moran

In this era of rising focus on the social and environmental costs and benefits of mining operations, the valuation methodologies used to assess such impacts become increasingly important. Within an industry dominated by an engineering culture that places emphasis on net present value (NPV) calculations using high discount rates, difficulties often arise when attempting to justify projects with longer-term, harder to quantify benefits. This is particularly so when these benefits fall in the social and environmental domains and involve other stakeholders. In this paper, we summarise the results of a recent literature review on this subject, which focused on the valuation of æBeyond ComplianceÆ initiatives in the mining sector. We discuss a range of approaches including the quantification of hidden internal costs, financial methods of incorporating risk into calculations, the integration of quantitative and qualitative information, and also the valuation of æexternalitiesÆ or costs and benefits borne by others. We then use a series of examples relating to the management of water in the minerals industry to illustrate how some of these approaches could be applied. There are high-level commitments from both individual companies and groups such as the ICMM to incorporate sustainable development criteria into decision-making processes within the industry. We conclude the paper by arguing that, to meet these commitments, there is a need for the industry to adopt a broader range of valuation methodologies than appears to be the case at present.

Jan 1, 2006

By I T. Cameron

The commercial production of copper metal involves a sequence of purification stages. One step of this process eliminates bulk quantities of iron and sulphur from matte Cu2S(FeS to produce blister containing 95.5 per cent copper. This task is traditionally performed in the Pierce-Smith converter, a cylindrical vessel in widespread use throughout the copper industry. Typically, multiple Pierce-Smith converters are arranged along an aisle, simplifying material transfer from vessel to vessel. Materials are moved through the aisle in pots and boats, using overhead cranes. In terms of the overall process, the converter aisle represents a critical processing unitùit contributes significantly to the value added nature of the metal. The aisle is subject to significant process disturbances. Thus, improvements in the operationÆs modes and conditions have a direct impact on process profitability. As with any commercial operation, improvements are always sought to increase process performance. The general approach involves process modelling, followed by an application of control and optimisation theory to this model. The results of such a study are then applied to the real process, leading to improved performance.

Jan 1, 1998

By W Polkowski, M Tangstad, M Wallin, J Jiao

Fe-26Si-9B (wt per cent) alloy has been identified as a potential high-temperature phase change material (PCM) due to its attractive properties, such as its high latent heat of fusion and low volumetric change during solid/liquid transition. For the successful utilisation of this alloy into thermal energy storage (TES) systems, the development of a cost-effective production method is essential. Presently, the Fe-26Si-9B alloy is produced by mixing FeSi alloys with either pure boron element or FeB alloys. However, the use of pure boron is financially prohibitive, and the carbothermic reduction results in high greenhouse gas emissions and high energy consumption in the production of FeB alloys. In this regard, our study proposes a silicothermic reduction method to produce Fe-26Si-9B PCM by using FeSi alloys and B2O3-based oxides. Accordingly, the influence of various parameters on the production process was investigated, including operating temperature, holding time, B2O3 content in the added oxides, and initial Slag/Metal (S/M) ratio. Based on the experimental results, the optimal parameters for producing FeSiB alloys with over 9 wt per cent boron were determined. Consequently, it was documented that the FeSi alloys and the added oxides enriched with 50– 65 wt per cent B2O3 should be subjected to temperatures ranging from 1550–1650°C, maintain an initial S/M ratio exceeding 1, and ensure a holding duration beyond 1 hr. Moreover, the energy consumption of this process was estimated to be ~1.86 MWh/t metal and the mass loss was lower than 7 per cent. Therefore, silicothermic reduction offers a sustainable approach for producing FeSiB alloys with a boron content above 9 wt per cent.

Jun 19, 2024

By J Manuel, A Trudu

Regulations on the emission of particulates from sinter plant stacks are becoming increasingly stringent and reducing these emissions by improving gas cleaning systems is a significant cost to the sinter plants. This paper describes an investigation into the emission of particulate matter from an iron ore sinter bed during the sintering of a Japanese Steel Mill (JSM) style ore blend in a 300 mm diameter pot grate test facility. Several techniques were trialled to determine a reliable method to sample the quantity of dust emitted and determine the mechanism of dust emission from the sinter bed. The nature of the dust was also examined using chemical and size analysis as well as optical and scanning electron microscopy. The paper discusses the techniques used to carry out the program as well as results on dust loading measured during sintering and the nature of the dust captured.

Jan 1, 2002

CONTENTSThe significance of values givenINTRODUCTIONTHE ORE1. DATA SECURED FROM THE MILLING PLANT AS OPERATING BETWEEN 1938 AND 1942(a) Mill Recoveries(b) Mill Flow Sheet(c) Scheelite-Garnet Association(d) Detailed Examination of Mill Performance during 1942Crushing UnitsCoarse Rolls DischargeFine Rolls DischargeFeed to Huntington MillsFinal Ground ProductProduction of -200-mesh Scheelite SlimeSummary of Information on Crushing and Grinding Circuit(e) Detailed Examination of Mill Performance During 1942Concentrating UnitsLocation and Nature of Scheelite LossesSize Distribution of Scheelite LossesDistributor Spigot ProductsSummary of Information on Concentration Circuit(f) Detailed Examination of Mill Performance During 1942 Gravity Plant Feed2. EXAMINATION OF MINE SAMPLES TAKEN DURING 1942(a) Introduction(b) Nature of the Ore(c) Sampling of Mill Feed(d) Testing Technique(e) Minus 1/8-inch Ores-Naturally Broken Fractions(f) Recoveries from Plus 1/8-inch Fractions-Crushed to Minus 1/8-lnch(g) Probable Recoveries Obtainable from Weathered Ores140 Contour120 Contour90 Contour(h) Examination of an Ore Sample from the 90-foot Adit(i) Run-of-Mine Ore(j) Evidence of Maximum Sizes of Scheelfte Present in Run-of- Mine Ore(k) Summary of Information on Liberation and Recovery from the Ores as Mined in 1942 and from the Mill Samples

Jan 1, 1944

By S Bourke, R Stone, B Hill

Since Jameson Cell flotation technology was first installed in a coal flotation application in 1988/89 at Newlands Coal Handling and Preparation Plant (CHPP) there have been fundamental improvements to its design which has led to its current status as the leading technology in Australia for fine coal flotation. These improvements, which include key hardware modifications, consist of the re-development of the orifice plate to produce considerable increase in wear life and reduction in power consumption for a given air entrainment and a significant increase in the amount of air that is entrained. Modifications to the downcomer allow maximisation of residence time and air entrainment while changes to the feed and air distribution system allows a reduction in installation cost and a reduction of solids ingress into the air line. Additionally, operational improvements such as the use of recycle to maintain constant flow to the cell feed are discussed. The recent installation at Hail Creek in the Bowen Basin, which consists of three B6000/20 Jameson Cells (6 m diameter bottom-fed distributor with 20 downcomers) will be reviewed as a case study. The latest design and operability of the cells are summarised and compared against one of the original designs at Riverside CHPP also in the Bowen Basin.

Jan 1, 2005

By I Jabouri

There are many physical factors that can affect the self-heating rate of coal. The presence of seam gas has often been referred to as inhibiting coal self-heating due to the limited access of oxidation sites created by the presence of the gas adsorbed on the coal pores. Similarly, the presence of bed moisture in the coal also acts as an inhibitor of oxidation by blocking access of air into the pores. Gas drainage of a coal seam prior to mining removes both gas and moisture from the seam. Bulk coal self-heating tests in a two-metre column on both gassy, as-mined and gas-drained, dried high volatile bituminous coal show that removal of gas and moisture from the coal accelerates the rate of self-heating to thermal runaway from 8.5 days to 4.25 days, from a start temperature of 30¦C, with an airflow of 0.25 L/min. The corresponding gas evolution pattern for each of these situations is different. Therefore, it is necessary to take this change in coal condition into consideration when developing a spontaneous combustion management plan.

Jan 1, 2005

By T Tan, C P. Holmes, C E. Hartford

Transportation of iron ore from the mine to the plant is critical to business success. Ore from the mine may have to be transported across states, countries and even continents to get to the processing plant or export facilities, and ultimately to the client. Numerous transportation steps may result in potential logistical difficulties. Companies are continually seeking ways to increase production rates, decrease delivery times and reduce operating costs. Transportation cost is a major component of the total cost of mining iron ore and therefore requires effective use of transport systems.Bottlenecks in iron ore transport systems, due to material handling issues, can result in loss in profit in the order of millions of dollars per hour. Bottlenecks can be seen anywhere in the transport system where the desired flow rate cannot be achieved. These bottlenecks occur for various reasons such as increasing throughput in a transport system originally designed for a lower throughput resulting in plugged transfer chutes, changing material characteristics (eg finer material, increased moisture content), changing to a new type of material or blend that again alters handleability, or changes in operational philosophy due to equipment availability or process utilisation.Stockpiles may have limited live capacity such that an adequate amount of ore may not be readily reclaimed when required (eg to fill a complete train’s railcars). In bins and hoppers, material may discharge through a central flow channel resulting in the formation of a stable rathole, which can then collapse causing material to flood the downstream system and cause significant downtime for clean-up (eg railcars beneath train load outs). In transfer chutes, bottlenecks can be caused by pluggages or downtime required for the change-out of liners due to excessive wear. In ship loading, long settling or de-aeration time, or material exceeding its transportable moisture limit (TML) may result in further bottlenecks. These bottlenecks all have associated costs because of the need to address their causes and because of the lost opportunities for throughput.This paper will discuss how bulk material technology and proper understanding of material flow characteristics can be applied to mitigate bottlenecks. It will discuss how to predict potential bottleneck locations through a scientific method of analysis and evaluation to determine if an increase in throughput of an existing transport system is possible, as well as whether or not a new material will flow reliably through an existing system.CITATION:Hartford, C E, Holmes, C P and Tan, T, 2015. De-bottlenecking iron ore transportation from mine to plant, in Proceedings Iron Ore 2015, pp 393–398 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

By Lloyd F, Arnold D. A, Hagan T. O

This paper investigates the problems that are encountered in mining at extreme depths. It looks into the rock mechanic aspects, especially the high stress levels that will occur, and the hazard of rockbursts. Furthermore, environmental problems are discussed, with refrigeration and reduction of neat loads being major methods of maintaining ,sorkable conditions. The paper concludes that it will be of tmost importance to have a planning team of Tne highest quality to ensure that conditions are maintained so that work can be carried out safely and under reasonable conditions.

Jan 1, 1986

By A Hatt

This paper presents a case study of characterisation work undertaken at a greenfield exploration project to provide engineering and OH&S inputs for the design of a ventilation system. The paper discusses how comprehensive early characterisation of the ambient surface and underground environment including aspects related to heat, dusts, strata gas, and geologic/mineralogical factors enables incorporation of the right ventilation and non-ventilation controls at a study level to mitigate the risks identified.

Oct 12, 2022

By H Weitz

Bateman Engineering provided process technology and engineering design to China Yunnan Metallurgical Company (CYMCO) for a 30 MW DC furnace for the production of high-grade titanium dioxide slag.Following the successful commissioning of the furnace during the latter part of 2009 and the first quarter of 2010, a period of adverse circumstances resulted in having to operate the furnace without feed and at a low power input for a period of time. When normal feed resumed, a layer of solid material was detected on the slag-iron interface during sounding measurements. The condition of the iron was also significantly altered. The iron temperature was much higher than the design value, but the carbon content had decreased to such an extent that a large amount of iron solidified in the furnace, which made iron tapping very challenging. The slag temperature was increased in order to melt the solidified iron. However, severe sidewall damage resulted, which finally led to a burn-through. A number of samples were taken from the slag that remained in the furnace. These samples were analysed to determine the chemistry and phase profile throughout the slag bath. The mechanisms of formation of the high melting-temperature phase on the slag-iron interface are discussed, as well as procedures that can be applied to prevent a recurrence of this phenomenon. Some recommendations are made for instances when furnace feeding is interrupted for an indeterminate period.

Oct 5, 2011

By W Mahoney, F Clement, E Saraiva

Prefabricated waterproofing sheet membranes are extremely complicated to install in underground sections with complex geometries and, despite being already subjected to quality tests in the factory, the installed membrane often exhibits leakages due to different reasons. Main sources of leaks are the required high amount of welding seams and damages caused during installation of reinforcement, as well as overstretching and poorly installed secondary concrete linings. Also the design of the tunnel lining is strongly influenced and limited by the use of prefabricated waterproofing sheet membranes. The use of sprayed waterproofing membranes for more than a decade has contributed to durability and serviceability, as well as to increasing sustainability of tunnel linings. The presented sprayed waterproofing membrane MasterSeal 345 is an advantageous alternative to prefabricated waterproofing sheet membranes under typical tunnelling conditions, especially in geometrically complex areas, such as in lay-by niches, cross passages and crossover caverns, where installation of conventional waterproofing membranes is inherently difficult, and locating leaks is challenging. This membrane has been successfully used in underground projects with different waterproofing design concepts and under diverse hydro-geological and environmental conditions for over a decade. It provides tunnel designers with different options and optimisation for the design of the tunnel concrete lining. Additional advantages to owners, contractors and designers from the use of the sprayed membrane include flexibility in the design, increased productivity and flexibility in working programming, as well as improved logistics, resulting in significant program and cost savings and reduced long-term maintenance costs. This paper describes the key features of this sprayed waterproofing membrane, its application range and limitations, the waterproofing concept, design options and related benefits. Further, guidance for membrane application and quality control and a summary of two recent project references in the United Kingdom and in Switzerland are provided.CITATION:Saraiva, E, Clement, F and Mahoney, W, 2014. The use of sprayable waterproofing membranes in underground structures – concept, design options, benefits and limitations, in Proceedings 15th Australasian Tunnelling Conference 2014 , pp 323–332 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 17, 2014

By H S. Smit, P Lotz

Gold mining companies who are signatories of the International Cyanide Management Code (visit www.cyanidecode.org for further information) are required to measure WAD cyanide on-line and destroy WAD cyanide in excess of specified limits. Weak acid dissociable (WAD) cyanide refers to those cyanide species liberated at a moderate pH of 4.5 such as HCN(aq) and CN-, and the majority of Zn, Cd, Cu, Ni and Ag complexes with low dissociation constants. It is potentially toxic to humans and animals. Recognising and in response to the gold mining industryÆs need for an on-line WAD cyanide measurement device, Mintek recently developed the WAD Cynoprobe. The WAD cyanide analysis technique is based on the use of a ligand exchange reagent that liberates WAD cyanide from metal-cyano complexes. The ligand exchange reaction is represented by the following chemical equation: Metal(CN)X + yLigand <-> Metal(Ligand)y + xCN- The plant filtrate is treated with a ligand exchange reagent, to liberate WAD cyanide, before measuring the free cyanide concentration via amperometry. The instrument proved to be accurate and reliable in the laboratory as well as under industrial gold plant conditions during various trials. It has gained wide-spread commercial acceptance both locally and internationally. However, itÆs recent exposure to complex ore types have called for refinements to the analysis technique. It has been further developed to improve its precision and accuracy and to remove reagent and thiosulfate interferences. Its compatibility with the most commonly used destruction oxidants has also recently been investigated. The WAD Cynoprobe may be configured to measure both free and WAD cyanide concentration. Its fast analysis time, approximately 5 min, makes it suitable for use in the control and optimisation of the cyanide destruction and recovery process. Proper oxidant dosage control and monitoring of effluent concentration levels will ultimately result in less cyanide and post-destruction salts discharged into the environment.

Jan 1, 2008

By K Devencorn

The development of robust, economical transport infrastructure has been identified as a key driver to sovereign economic growth. Notwithstanding the value of undeveloped mineral resources, unless they can be brought to market they are of little value. Within a global context, the continent of Africa probably faces one of the most significant transport driven economic development programs as countries strive to unlock their much sought after resources.The UN’s Africa Review Report on Transport (United Nations Economic and Social Council, 2009) provides an excellent context for the issue facing African countries and the potential for investment in transport to solve many of the intrinsic problems they are confronted with. With little exception, economic development in Africa is very likely to be driven ‘off the back’ of transport development – and more specifically from heavy-haul rail as a means by which economic wealth can be derived from export of the continent’s vast natural and mineral resources to the world. The report found:transport is a key driver of economic development and poverty reduction;road transport is the most dominant mode in Africa;the ‘Cost to Market’ of African goods is hampered by the reliance upon road transport;the cost of road transport is not just economic – 19 per cent of the world’s road fatalities were recorded on African roads;African railways are seen to be disjointed and under-utilised;Africa’s ports are key to export trade - yet only six ports (three in Egypt, and three in South Africa) handle about 50 per cent of the continent’s total container traffic;the cost of transport is increasing making African trade even less competitive; andsignificant negative impacts of Africa’s reliance on road transport – health, and greenhouse emissions.We understand that mining the resource is only part of the solution – it has to be put to market at a competitive landed cost.Most African countries face huge costs associated with transport development and ongoing operation – in many cases beyond their available resources.The Australian rail industry has faced and solved many of these challenges.

Nov 22, 2011

By J Jardine

An improved ground support method for development intersections, wide spans and stope brows was implemented at Kanmantoo mine. The method uses a jumbo to simultaneously drill and install self-drilling anchors (SDAs) to depths from 4.5 m to 7.0 m. Resin is subsequently pumped into each SDA using a specially designed integrated tool carrier basket, with plating occurring within 10 mins due to rapid resin cure. This methodology means that SDAs can be installed rapidly due to reduced process steps and wait times with reduced hazards to personnel. Cablebolts are used extensively in underground mines to reinforce the ground in wide spans, such as at intersections and stope brows. The flexible cablebolt tendon allows for a long, continuous and high-capacity reinforcing element to be inserted into the rock. A common cablebolt installation practice at Australian underground mines that do not utilise a mechanised cable bolter, is for cablebolt holes to be drilled by a jumbo or longhole rig, hand installation and grouting by a service crew, then plate tensioning following a grout curing wait time of typically 12 to 24 hours. This process involves multiple separate labour-intensive work processes and results in reduced availability of priority headings. This paper discusses the development history of vertical SDA use in wide spans at Kanmantoo mine. The installation process is fully described, including aspects such as reliable in-hole coupling of SDAs, resin selection and pumping aspects. A cost benefit assessment, and a case for ground stability are presented to compare cablebolt use to SDAs in development intersections.

Mar 29, 2023