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The complete life cycle of a production facility has many phases requiring many different skills and many different personalities. It is not unlike the life cycle of a person and many parallels can be drawn from it. I leave some of these analogous situations to your fertile minds. The author, having worked in operations, plant design, plant commissioning, marketing and many other interesting situations through the industry has drawn from this experience and examples given by many associates in the industry.The phases seen are as follows: Concept Studies û someone has a bright idea of how to make a dollar. Scope Studies û what possible processes/options that could make a dollar. Prefeasibility Study û the æviableÆ scope options are studied to develop feasible options. Feasibility study û defines the concepts that should be designed to make a viable project thus enabling financing and project commitment to be made. Detailed Design û an intermediate step that consolidates the inputs to give a robust plant that can be constructed.Construction û people can see what they thought was going to occur and start to understand the plant. Commissioning û the hand-over of æownershipÆ from the conceiverÆs to the operators. Operations û the ætoyÆ has become reality and money must be made. De-commissioning û the plant has seen out the useful life of the ore deposit, it now goes through a further process required by society.Across these phases of plant design run several countervailing management requirements that can influence the outcome of the plant design. Some of the management rigours that have to be applied to the various phases are as follows: costing basis of the various phases; operational and maintenance reviews; sustainable development; risk assessment; reliability reviews; equipment availability; commissioning time; and environmental review.This paper endeavours to awaken people to the phases that projects require for a successful outcome and the management rigour that has to be applied throughout the phases to ensure the correct intellectual horsepower is applied at the right time to ensure the best outcome.Many of you would be parents and realise this is not unlike the development of children, teenagers, adults, retirees and ongoing.

Jan 1, 2002

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

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

Sep 1, 2024

By Bhattacharyya AK

With increasing demand for more efficient production from the underground coal mines in the Southern Coalfields- of New South Wales, their design and operational aspects are constantly being reviewed and improved. One key area in such pursuits is the reliable design of stable and yielding pillars. The current designs of pillars based mostly on experience leads to unnecessary sterilisation of coal or strata control problems. To explore such mine design problems, computer based modelling is increasingly being applied. In the study described in this paper, the object was to determine the particular width of pillars separating three roadways in a panel at which the pillars yielded completely and their loads largely transferred to the unmined coal at the flanks of the panel. This was approached through a computer simulation of the behaviour of the strata around a panel, in which the three roadways were separated by pillars of progressively decreasing width. A computer program called FLAC based on the finite difference method was used to simulate the relevant strata behaviour in vertical sections. The appropriate in situ values of the deformability parameters relating to the coal seam, roof and floor were determined from the back analysis of some displacement measurements in such a panel. The process involved successive modelling of a vertical section through such a panel,starting with realistic values of the parameters and varying them until the measured and the modelled displacements agreed closely. Based on the results of the numerical modelling, the width of a yielding pillar for the given conditions is Suggested.

Jan 1, 1992

By A Torpy, N C. Wilson

Improvements in electron optics, field emission gun design, and X-ray detector technology have led to the development of a new class of microanalysis tools. By combining multiple wavelength dispersive (WD) spectrometers, spectral energy dispersive (ED) spectrometers and cathodoluminescence (CL) data sets, a wealth of information can be collected during routine electron beam mapping and analysis. In this paper, data collection on a field emission electron microprobe equipped with five wavelength dispersive, two silicon drift energy dispersive X-ray spectrometers and a wavelength dispersive linear array optical spectrometer has been automated with the optical, electron and X-ray signals being collected in parallel. To analyse the large hyperspectral data sets we have implemented an autoclustering strategy that can be used to produce a quantitative chemical phase map. The cathodoluminescence spectra can be deconvoluted to produce peak intensity maps, which are then converted into elemental speciation images with quantitative sensitivity down to parts per million levels. Both methods are illustrated using typical mineral processing examples, firstly a Ni-laterite sample is investigated with the fine-scale distribution of Ni examined in detail. Secondly, a scheelite sample with rare earth zoning in mapped and rare earth levels quantified.

Jan 1, 2008

Coal Mining machinery has undergone enormous changes in design and complexity of controls in the past 10 years. Specialised, high productivity equipment has been manufactured in Australia, in sufficient volume, to satisfy the local mullet needs.Local manufacturers face greater challenges from overseas competition, as well as increased customer demands to improve machine performance, productivity, quality, reliability and safety. In order to meet these demands now and in the future, it will be necessary to review work practises, and restructure production and quality systems to incorporate the latest principles and philosophies.

Jan 1, 1991

The ore reserves of the Frieda porphyry copper prospect in Papua New Guinea have been estimated using kriging and an alternative method. Only very erratic variograms could be obtained from the raw data and thus it can be expected that kriging variances will be unrel- iable. The frequency distributions of the two sets of estimates show expected differences and the resulting mineable reserves show similar expected differences. More drilling and the use of disjunctive kriging are needed to produce reliable estim- Ates.

Jan 1, 1979

Who Macraes Mining Company Limited is can be summed up by the following statements: +         We have been New Zealand's largest gold producer for seven years +         We have one of the lowest market capitalisation per reserve ounce of the gold producers in the  Australian Gold Index +         We have a resource finding cost of less than NZ$l0 per ounce +         We have a large land bank with proven reserves +         We have an Operating Cash Margin of approximately NZ$200 per ounce +         We have reduced our Dry Milled Tonne Cost by 34% since 1992   Our Mission is to continually grow our gold business, through maximising cashflow and focusing on our value drivers being: +         Increasing reserves +         Increasing cash operating margins +         Increasing production   The real challenge is the reduction of operating costs and the optimisation of revenue, particularly in the current gold price environment.   The Company has as at 31 December 1996 total mineral resources of 6.1 million ounces and reserves of 3.4 million ounces. This together with our current cash position of approximately NZ$15 million and strong hedging book of approximately 800,000 ounces places the Company on a sound financial footing whilst positioning itself to aggressively pursue its growth strategy when gold price and market conditions improve.

Jan 1, 1997

By D J. Williams, A Shokouhi, A Naderian

Extracting alumina from bauxite involves the production of fine-grained waste known as red mud. The highly alkaline red mud is usually neutralised by applying sea water, thickened to between 25% and 30% solids by mass, before disposal to a Tailing Storage Facility (TSF). Hydraulic sorting, settling, self-weight consolidation, and desiccation are the processes contributing to the overall volume change of the red mud after deposition. Investigating the effect of these processes on the volume change behaviour of the fine-grained red mud is an important step in the estimation of the required storage volume of the storage facilities. This paper presents the results of a series of laboratory consolidation tests in a slurry consolidometer, and comparisons are made with field testing and observations.CITATION:Shokouhi, A, Naderian, A and Williams, D J, 2018. Assessing the volume change behaviour of red mud through laboratory and field testing, in Proceedings Mine Waste and Tailings Stewardship Conference 2018, pp 309–316 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 23, 2018

As we look back through the Proceedings of our Institute, we find few papers dealing directly with education and recruitment. Apart from papers prepared in the earlier decades of this century, there was little written discussion on the subject until the 1950s, and mostly this was by the professionals, the professors and lecturers who staff the various mining schools of Australia and New Zealand.I use the term "mining school" in its fullest and widest meaning, to cover all aspects from ore to metal, and not in the narrow meaning that the word might imply. At the same time, in restricting the parameters of this address to "ore to metal" I recognize that I am excluding the very important fields of physical metallurgy and materials science; this I do because there is a limit to the quantum of any paper, and in fact these subjects are more closely allied to the use rather than the production of metals.However, the lack of education papers does not mean that education has been regarded lightly by The Institute. Sir Maurice Mawby in his presidential address in 1968, reminded us of the original objectives of The Institute, one 'of which was, "To promote the arts and sciences connected with the economical production of the useful minerals and metals ...". Our present Royal Charter is more specific when it says that one of the objects of The Institute is, ". . . to encourage the study of engineering with special reference to mining and metallurgy ...". If we recognize that in itself membership of our Institute is one means of continuing our education, it is true that education has been a concern of The Institute since it was first founded.Occasionally in recent years, an intrepid president has ventured to tell the academics what the industry needs, and he generally does this in a "no-question" situation! However it is encouraging that those entrusted with mineral education have always accepted this; they keep coming back for more and ask us to tell them what we want, and they will provide it.In 1948 a considerable dialogue on education was initiated when a standing committee was established by the Council of The Institute. In the period 1949 to 1951, three papers were prepared under the chair...

Jan 1, 1974

By T QUINLAN

A resource estimate uses data obtained by sampling an orebody. An example is described in which a random drilling pattern did not provide a representative set of assays, and the estimated resource was significantly less than the mine production. It is believed that a better estimate would have been made if the exploration holes had been drilled on a regular grid.

Jan 1, 1992

By M I. Pownceby, N A. S Webster, R Pattel, N Ware

The decrease in quality of Australian iron ore, coupled with the demand for more efficient energy use, necessitates closer monitoring and optimisation of process conditions for iron ore sinter production. Sinter properties are correlated with the mineralogical content and traditionally, quality control has relied on methods such as Fe2+ determination, point counting via optical microscopy and automated electron beam techniques such as QEMSCAN; these can have a typical turnaround time of several days between sampling and reporting of results. As well, there is additional uncertainty around quantifying some of the complex mineralogical phases in sinter such as silico-ferrite of calcium and aluminium (SFCA) and SFCA-I, which are key phases influencing sinter quality. There is a clear need for the implementation of alternative analytical methodologies that offer a turnaround in hours or even minutes to provide information to accurately maintain production conditions.X-ray diffraction (XRD) is a technique widely used for the quantitative mineralogical phase analysis (QPA) of ores and processed materials in the iron ore industry. Partial least squares regression (PLSR) analysis methods have recently been suggested as an indicator of sinter Fe2+ content from powder XRD data without the need for rigorous and often time-consuming mineralogical analysis by the operator. In this study we provide results from the implementation of PLSR to predict the strength of iron ore sinter. Results are sourced from a well-constrained data set comprising strength properties (as quantified by a tumble index (TI)) from a series of compact laboratory test samples. Using this data set it was determined that PLSR has potential to be used as a method for calculation of sinter TI from powder XRD data and, therefore, process control.CITATION:Webster, N A S, Pownceby, M I, Ware, N and Pattel, R, 2017. Predicting iron ore sinter strength through X-ray diffraction analysis, in Proceedings Iron Ore 2017, pp 331–334 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 24, 2017

The mining industry is facing tremendous economic challenges. Fluctuating and depressed commodity prices, the ever-increasing pressure from environmental legislation and the competing global opportunities for capital investment are placing enormous strains on every aspect of the mining business. At the same time, mines are generally becoming older and deeper with all the logistical and rock mechanics difficulties that this entails. In the face of these new challenges the industry looks to technological advances to make operations more efficient and profitable. One approach is to develop and implement highly automated and computerised equipment as part of a trend towards major reductions in the underground workforce. This approach requires more capital investment rather than less and requires a more sophisticated and well-educated workforce with skills which are generally in high demand in society as a whole. It is difficult to see how the benefit that can be gained from such technology can justify the expenditures necessary to make it operate reliably underground on a daily basis. Nor is it easy to foresee how the mining industry, based as it is often in very remote areas, will be able to hire and retain sufficient numbers of people to maintain such fleets of equipment. Another approach, and the one which I favour, is the implementation of much greater control over the whole of the mining process. Mining is essentially a very simple process - we break rock and move it. The most cost-effective means of moving and processing the mining product depends entirely on the way it is broken - it depends on primary fragmentation by blasting. I propose that the way forward for the industry in the face of our present difficulties, is not new technology but is to utilise the level of technology which currently exists in ways which have traditionally been regarded as too difficult or too inflexible - improved fragmentation and the use of conveyors. The technical success of this approach depends on the complete re-design of the ore handling system from the face or stope drawpoint to surface. The fundamental issue which determines the success of this approach is designed fragmentation.

Jan 1, 1995

Instantaneous outbursts of coal and gas have occurred in Australia in the Sydney Coal Basin since 1895 and in the Bowen Coal Basin since 1954. The largest has been about 500 tonnes of coal and so their magnitude and character have not approached those experienced in some other countries. The occurrence of CO2 with some Australian cases provides some similarity with the worst affected areas in France and Poland.The proneness of seams depends on coal rank and seam gas composition, among other factors. The proneness of places depends on depth, structure, intrusion, tectonism and other factors affecting the geometric, physical and chemical uniformity as well as details of mining. As a phenomenon due to gas and stress, prevention can be achieved by relief of high gas and/or stress condition. Alternatively, controls can be applied to render mining safe for personnel. Unfortunately day-to-day prediction is not widely and reliably achieved to allow selective use of prevention or control. The initial rate of desorption is the most promising day-to-day indicator.Various researches include gas conditions and parameters, stress and failure conditions and parameters, coal variables and geological variables in relation to prediction, prevention and control. Some assistance in research may derive from study of analogous phenomena of instantaneous outbursts of salt and other rocks and gas. It is concluded that in the Sydney and Bowen Basins, any coals with less than 30 per cent Volatile Matter (VM) ash free dry (afd) at depths over 200 m could be prone. Proneness increases with depth, with lower volatile content, with geological disturbance including faulting, intrusion and recent tectonics, with increased CO2 in seam gas, with narrow work and with other factors. Much more research is needed.Unfortunately outbursts are needed too, to provide the research with realistic data. With the problems of mechanism and prediction still being unsolved much research remains to be done. No present aspect of research is satisfactorily resolved.

Jan 1, 1983

By H Plewes, A Bur, L Murray, J Pottie

Water recovery from tailings for reuse in mineral processing is essential to operation of mines in the Atacama Desert of Chile. With annual rainfall of 5 mm, the prudent and efficient use of available water resources is a major issue for the Escondida Mine and other mines in the area. The Escondida Mine is located at an altitude of 3100 m, in a very arid, seismically active part of the Atacama Desert of northern Chile. The site is located about 170 km from the coastal city of Antofagasta. From 1994 to 2002, tailings were discharged into the Hamburgo Tailings Facility, which comprises a series of æpaddiesÆ located near the open pit and mill. Because water in the region is only obtainable from groundwater sources, the paddy system incorporated a number of design features with the aim to maximise water recovery from the tailings. As part of the recent mill expansion to 237 500 metric tonnes per day, a new tailings facility, the Laguna Seca Tailings Facility, projected to be one of the largest tailings facilities in the world, was commissioned in 2002. Extensive studies were conducted for the design of the new facility to predict water recovery from the conventional wet disposal of tailings. The predictions were calibrated against the performance of the Hamburgo Tailings Facility and subsequently re-calibrated against actual performance during the first year of operation at the Laguna Seca Tailings Facility. Initial operation of the Laguna Seca Facility was marked by a coincidental change in tailings characteristics from design, which highlighted the need for thoroughly understanding tailings behaviour during deposition, and the parameters and deposition techniques that could enhance water recovery. Systems have been put in place to manage the tailings deposition and respond to changes in key parameters such that water recovery targets can be reliably achieved. This paper describes the background studies that were conducted to evaluate evaporation and tailings behaviour, summarises the water balance and then presents some observations from the commissioning and start-up of the facility.

Jan 1, 2003

In the last 40 years nuclear energy has taken its place as a major source of electricity worldwide. It now produces 17 per cent of the world's electricity and could conceivably produce a higher proportion, to displace some six billion tonnes of carbon dioxide emissions per year. Concerns about global warming and environmental quality now underline the virtues of nuclear electricity among alternative sources of energy. Global electricity demand is rapidly increasing as a proportion of total energy usage. The proportion has doubled since 1960 and the demand is expected to increase at least 75 per cent between now and 2020. The source of this extra capacity, and the replacement of present capacity, raise questions with major resource and environmental implications. Today nuclear energy is a mature technology. Over 1200 nuclear reactors have been built and operated, some of these have been decommissioned, and among the 440 reactors in commercial operation the first advanced reactors are now entering service. Some 8000 reactor-years of operation have, with the sole exception of Chernobyl, shown nuclear energy to be extremely safe and reliable. High-level wastes are being managed properly and in different parts of the world two strategies are applied to this. Australia has a major role as a long-term supplier of uranium, since it holds almost 30 per cent of the world's reserves. This, along with an impending sellers' market for uranium, is making it an opportune time to develop new mines here. However, after several decades of concern about civil nuclear energy contributing to the arms race, we now have uranium liberated from nuclear weapons stockpiles being diluted for use in civil reactors, which will supplement ex-mine supply. The public acceptability of nuclear energy remains the critical factor in its future and hence in ours.

Jan 1, 1997

By D Caffrey

To demonstrate the advantages of using electronic delay detonators over pyrotechnic detonators, a trial using the DNES Dynatronic System was conducted at the KCGM Mount Charlotte operation in 1998. The trial clearly demonstrated that accurate control over the firing delay time between blastholes can lead to fragmentation improvement and ground vibration energy control which are two important issues for the Mt Charlotte underground operation. Excellent fragmentation was achieved by employing a 12 ms delay sequence. Detailed fragmentation analysis has shown a 10 to 20 per cent passing increase for the rock fragment size from 0.1 to 0.4 m compared with the pyrotechnic detonator firing. There was no increase in ground vibration level on the surface with the electronic detonator firing even though the electronic detonator firing had a much shorter blast duration than the pyrotechnic detonator firing. In fact, our energy calculation has clearly shown that much less energy had been propagated to the surface from the blast using electronic detonator firing.

Jan 1, 1999

By G McSpadden

At September 2001 the beneficiation plant at BHP Billiton Iron OreÆs Mt Whaleback mine is set to treat 9.5 million tonnes per annum (Mtpa) of iron ore, 40 per cent better than original design. This paper describes the steps, decision-making processes and innovations used to increase capacity at minimum cost. The plant was designed in 1979 to operate at 1133 t/h for 6000 hours per annum, treating 6.8 Mtpa. Sufficient suitable contact ore was unavailable and feed was finer than planned. The plant was designed with minimum surge capacity between multiple process units. It had never reached design capacity. In 1993 a study by Fluor Daniel to treat increased tonnage resulted in modifications to improve plant operations. Efforts to expand production by increasing reliability did not achieve the desired capacity. NJ Morrow (Pty) Ltd (NJM) conducted a technical audit in 1996 with process evaluation by Mineral Processors. Replacement of operator interface and PLC logic in 1997 made plant operation and diagnosis easier. Involving operators in logic development enhanced their plant knowledge. Fluor Daniel Simulation developed a simulation model of the process. Mineral Processors and NJM reviewed the model findings, recommended metallurgical improvements and developed preliminary designs and costs. BHP Engineering produced a detailed design with a cost estimate of $A34 million. After analysis and revision of the design, a $A10.4 million upgrade to 8.5 Mtpa was carried out. Detailed modifications to the process units, particularly the HM drum plant, allowed significantly higher capacities and improved metallurgical performance. The target capacity was achieved in June 2001. Further modifications are progressing to treat lower-grade ores.

Jan 1, 2002

By B P. Banerjee. S Raval, P M. Ranasinghe

Simultaneous Localisation and Mapping (SLAM) is an important technology that enables autonomous robots to navigate independently and create detailed, real-time maps of their surroundings. This capability is crucial in underground mining settings, where it enhances operational efficiency and significantly strengthens safety in these subterranean environments. SLAM algorithms typically rely on identifying and using distinct geometric features, such as plane and edge features, to understand the spatial layout of the environment and to track how it evolves as the sensor moves through it. In underground roadways, the scarcity of noticeable edge features, coupled with the repetitive nature of walls and corridors, poses a significant challenge, making it difficult for these systems to distinguish one area from another. Furthermore, the absence of global navigation satellite system (GNSS) signals in underground adds more challenges, leading to the accumulation of errors in both the mapping and localisation.

Sep 1, 2024

By Firth B. A

The flotation of fine coal (minus 0.5 mm) often requires the addition of an insoluble hydrocarbon collector to apparently promote the adhesion of coal particles to air bubbles. A series of experiments was conducted using a radiotracer and narrow size fractions of clean coal to determine the effect of particle size distribution, collector addition rate, desliming of feed and emuIisification of collector on the distribution of collector between the different size fractions. The concentration of collector per gram of each size fraction was found to be approximately proportional to (average particle size)-2 except if the collector was emulsified prior to addition, the dependence altered to approximately (average particle size)-1. Mechanistic consequences are discussed.

Jan 1, 1982

By U Briem, R Verreet

The level of wire rope technology used in mine hoisting applications has a significant effect on the overall efficiency of the hoisting system. This paper discusses the effect that a reduction in rope mass per unit length and an increase in rope breaking strength can have on rock skip capacity and hence mine shaft output. A 20 per cent reduction in rope mass per metre for a typical 48 mm hoisting rope, while maintaining the breaking strength, increases the skipÆs capacity by circa 30 per cent at a suspended rope length of 3000 m. Such gains in shaft output, without any significant changes to the shaft or winder design, can have major implications for the feasibility of future deep mine projects. The technical challenge for rope manufacturers is how to get rid of 20 to 30 per cent of the rope mass while keeping the breaking strength and modulus of elasticity of the whole rope constant. CASAR are currently developing steel wire rope constructions where the steel IWRC has been replaced with high strength, high modulus fibres such as Kevlar«, Spectra« and Dyneema«. One of the key aspects of such composite rope designs is to ensure equal load sharing between the different rope components, ie in proportion to their area. If there is a significant difference in modulus between the fibre core and the steel outer strands, the core may not carry its proper proportion of the load and the outer strands would be overloaded. Some technical aspects of the design of composite steel wire ropes are discussed. A design and operational issue that needs careful consideration is the safe non destructive testing (NDT) of composite ropes. Traditional magnetic NDT would only be capable of inspecting the steel wires. Techniques therefore need to be developed that would give operators a reliable indication of the condition of the load bearing fibre core. This paper also discusses possible solutions to this very important NDT question.

Jan 1, 2005