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Shane is enjoying his new work. Six months ago, he was stocking shelves at his local supermarket and decided to make the big move to a job in mining with more challenge and, of course, more dollars. He's been through his inductions, received his training tickets and is now working in a crew of eight underground at a fly-in, fly-out (FIFO) operation. There are many more systems and processes here than in his retail job, and Shane's comfortable that his safety is being looked after. He is enjoying the continually changing work and conditions, it makes the job interesting. It's taking some time to get used to the roster and he is worn out by changeover, but he gets more time with friends and family during R & R.   Generally, the mining industry has a maturing safety culture and well developed systems. This sometimes lulls people into a false sense of security. Safety systems cannot anticipate every possible situation, nor can they replace people's perception, thinking and decision-making. To manage safety, it's critical to find the right balance between dependence on systems and a healthy fear and respect of risks we face.   As safety standards are raised, systems tend to get more thorough and complex. When a new person joins a mining crew, we induct and train them to provide the information they need. As labour availability again becomes short, and many new people join our industry, we shouldn't assume they know the fundamentals. We need to explain not only what they are expected to do, but why doing what we ask and expect will keep them safe. We must equip people to deal with both the routine and the unexpected.   This presentation explores the challenges of balancing a structured, systematic approach to safety with the need to also equip people to deal effectively with risks everyday in dynamic and extraordinary situations.   Session purpose Introduce participants to a way of looking at risk from a different perspective, as a force for change and progress, if managed well. Demonstrate that risk is something we need to engage with emotionally as well as physically, if we want our risk management efforts to be successful. This purpose will be achieved through an entertaining and engaging presentation, using photos and case studies. The session will initiate interest to explore new ways of thinking about risk and generate discussion about the balance between people and systems. What is the right balance and why getting it right enhances the safety culture, while getting it wrong can impact on safety, business performance and sustainability.

Jun 1, 2010

By B McFadyen, Y Potvin, K Woodward

The Australian Centre for Geomechanics (ACG) held two workshops in 2019—one in Australia and one in Canada—to discuss processes and methods currently used in the mining industry for stope design and reconciliation. In practice, this work strives to optimise stope performance and aims to maximise ore recovery (minimise underbreak), while minimising dilution (overbreak). One of the key findings from the workshops was that current stope design practices, almost exclusively, rely on some versions of the empirical Stability Graph methods developed in 1980s. Although robust and useful at the feasibility study stage, there are a number of inherent shortcomings with this approach. The Stability Graph’s limitations first lie in that it cannot assess underbreak, which is a very important measure of performance. Furthermore, the method doesn’t consider a number of factors which often have a critical influence on stope stability, for example, drilling and blasting or the presence of faults. Given the current industry standard practice, there is a great opportunity to reinvent the stope design process to optimise performance. A finding of the workshops was that every mine quantifies stope performance in terms of volume reconciliation with a focus on dilution and ore losses, and reconciling metal tonnes recovered from the mill. Many mines further investigate stope performance by looking at individual stope faces and the causes for the deviations between the planned stope shape and the measured cavity. Recent research at the ACG has shown that investigating overbreak and underbreak at a higher resolution is a powerful way to identify the root causes of overbreak and underbreak. Finer scale assessment is achieved using an octree analyses, which effectively divides the relevant stope volume into cubes on the scale of a metre and produces many tens of thousands of data points. The octree data structure and subsequent analysis underpins a data-driven stope design methodology. The ACG is currently developing a design approach based on multivariate modelling methods that can account for the many variables that influence stope performance and forecast stope overbreak and underbreak results. Back-analysing stopes based on octree reconciliation results provides a rich database for training the model. Once the model can achieve reliable forecasting of overbreak and underbreak, an interactive drill-and-blast design will allow for the assessment of different firing strategies to optimise stope performance.

Mar 15, 2021

By G Byrne

Long-term water management is typically ignored in mine closure planning. A review of 73 mine closure plans dating from 2007 to 2013 shows that, on average, relinquishment is proposed to be achieved in 11 years. A separate review of 57 mines in actual closure shows that only five have so far achieved relinquishment with an average closure period of 14 years after production cessation. The remaining 91 per cent of sites in closure have an average closure duration to date of 21 years - and still going.A common issue among those sites in closure is water management, with a further common issue being acid and metaliferous drainage (AMD). Of the closure plans that were reviewed only one site had allowance for long-term (>50 years) of water treatment. Of the sites in actual closure 25 per cent have reported that they expect such long-term water treatment, with many acknowledging that in perpetuity treatment is probable.Clearly there is a gap between what is being allowed in closure plans and the reality of closure. There are a number of factors leading to the optimism of the closure plans, including unrealistic assumptions, pressures to reduce closure cost provisions and the technical complexity of many AMD issues.Long-term water management is a reality that needs to be acknowledged and addressed. If addressed early in the mine life cycle the impacts for mining companies can be reduced.CITATION:Byrne, G, 2013. Long-term water management - the forgotten legacy of mine closure, in Proceedings Water in Mining 2013 , pp 163-168 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 26, 2013

Optimisation of the Advanced Automation System at Inmet Mining's PyhSsalmi Mine, Finland

Sep 13, 2010

Project-finance risk assessment is mature and approached systematically. Mining industry due diligence remains fragmented with specialists addressing different aspects of the project such as reserves/JORC, environmental impact, commodity market, even financial analysis/ modelling. Each professional has a natural tendency to believe that the risk factors they have examined are the key ones necessary to be reviewed, as if their review will stand in isolation from others in the way a project materialises. By first laying out the project risk categories and risk matrices, this paper examines the due diligence process with a keen eye to the risk assessment and overlap/interaction. Some cross fertilisation of due diligence techniques from other industry sectors is placed into the mining context. Six case studies are then presented with regards to due diligence features in each projectÆs feasibility review or financial information/ offering memorandum. A power case first shows the differences between the due diligence expectations of banks versus bond financings. Then some Australian and Indonesian mining development cases are analysed to see the due diligence learning points. Some of these were project/due diligence failures. The conclusion focuses on the value of a systematic risk assessment for project evaluation, all from the project-finance perspective.

Jan 1, 2007

By S M. Jowitt, G M. Mudd

"The mining industry is the source for the vast majority of the metal, mineral and energy resources we use on a daily basis. New deposits are discovered over time and are developed into mines before being rehabilitated – a sequence that when repeated can help contribute to the noble notion of ‘sustainable development’, despite the generic concept of mining being the unsustainable consumption of non-renewable resources. The scale of the modern mining industry is immense – from iron ore and coal to base and precious metals, modern mines are sometimes hundreds or thousands of times bigger than their long lost historic ancestors. We also live in a world with emerging and increasing demands for so-called technology metals (aka ‘critical’, ‘e-tech’ or ‘specialty’ metals) that are needed to feed the rapid growth in renewable energy (especially solar photovoltaic panels and wind turbines), consumer electronics, sophisticated military technologies and super alloys, amongst other uses. These elements include the rare earth elements, indium, germanium, tellurium, rhenium, selenium, gallium and many others, most of which had few or no known uses in the recent past. Although the mining industry has been successful in developing ever larger mines and increasing the scale of production, the key issues underlying the future of the industry are declining ore grades, increased tailings and waste rock generation, the presence of toxic or other impurities, balancing the economics of primary and secondary products, stricter environmental conditions, more difficult exploration, increasing community expectations, as well as the processing of more complex or refractory ores, let alone the recent volatility in world commodity markets. Here, we synthesise our recent research on many of these various issues, focusing on the need to link all areas within the mining chain from mineral resources through mining to environmental performance in order to ensure we obtain the most out of our modern mining effort. The paper presents a unique and detailed assessment of the sustainability challenges and opportunities facing modern mining – and geometallurgical thinking is at the heart of this conundrum.CITATION:Mudd, G M, Jowitt, S M, 2016. From Mineral Resources to Sustainable Mining – the Key Trends to Unlock the Holy Grail?, in Proceedings The Third AusIMM International Geometallurgy Conference (GeoMet) 2016, pp 37–54 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Jun 15, 2016

Water is required as a key strategic resource in most mining and metallurgical processes and, in some countries, it has become a limiting supply for the development of mining activity. During the last years, mining industry efforts have been successfully focused on water use efficiency in the different processes. However, these efforts will not be sufficient to compensate for the growing demand of mining products and the decrease of ore grades. New efforts should be oriented to the search for alternative water supplies such as sea water, with or without desalinisation, or water harvesting. But to survive this growing pressure and to get a social licence to operate, the mining industry can also assume a proactive attitude and pursue a prominent role in water management at regional and local scale. This paper reviews some of these emerging issues, particularly in the context of the Chilean copper industry.

Jan 1, 2009

By F Grobler

Many projects fail because project performance in unfavourable economic conditions was not anticipated at the investment decision stage. This type of failure may have been avoided through the selection of a strategy that enables the project to perform well under a range of possible future economic conditions (a ærobustÆ strategy); rather than an æoptimalÆ strategy for expected future conditions that will never eventuate. This paper describes a method of rapidly generating mine plans for a number of project strategies, and then evaluating it against a representative range of equally likely economic conditions. The key performance indicators derived for each strategy are the mean value and the distribution of values (variance). A prudent investor will identify prospective strategies not only on the merit of highest mean values (as a proxy for economic reward), but also on the probability of not meeting specified investment hurdles (a proxy for risk). A robust strategy will achieve its financial objective even under adverse economic variations. This paper focuses on the effect of commodity price uncertainty; particularly around the choice of mining and processing capacity levels. Results from enumerating 2000 prices scenarios against 63 strategy combinations show how processing and mining capacity can be manipulated to manage the risk-reward trade-off.

Sep 26, 2011

By M Player, R Klug, N Schwarz

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

Jul 1, 2021

The Tom's Gully gold mine is located 90km ESE from Darwin, in the Northern Territory of Australia. The orebody is the auriferous portion of a large sulphide rich quartz reef, hosted in the Wildman Siltstone Formation of the Early Proterozoic Pine Creek Inlier, at the NH extremity of the Mount Bundey granite-syenite intrusion. It was discovered by Carpentaria Exploration Company Pty Ltd on November 17th, 1986, using stream sediment geochemistry.The reef is 800m long at surface, strikes E-H and dips approximately 300 to the south, becoming progressively less steep. Only the eastern half of the reef is auriferous, with gold grades averaging 9 g/t plus anomalous silver, base metals and arsenic.The enclosing siltstone is a dark grey banded carbonaceous and pyritic metapelite, showing areenschist regional metamorphism and thermal effects from the adjacent pluton. Local folding plunging gently SW is cut by a south dipping fault, probably a thrust, in which the reef was later formed at about the time of the granitic intrusion. The main sulphides in the reef are pyrite and arsenopyrite, with gold occurring as microscopic particles in...

Jan 1, 1990

By M Barkh, F X. Spachtholz

The mining industry faces significant environmental challenges in managing tailing ponds and wastewater treatment, including the risk of contaminated water, breaches of tailing dams, and energy-intensive treatment processes. Traditional methods involve pumping water to secondary treatment facilities for neutralisation, which is costly and poses operational and environmental risks. In response to these challenges, the Professional Mine Water Action Plan (PMAP) introduces a revolutionary approach that combines cutting-edge AI technology and environmentally friendly reagents for in situ neutralisation of acidic wastewater. PMAP leverages magnesium-based slowrelease reagents and AI-driven intelligent dispensing systems to optimise treatment processes within the tailing pond itself. The unmanned smart dispensing vessel (USDV) conducts bathymetry to gather data on water quality and hydrography, allowing the system to determine the appropriate reagent quantity and injection strategy. This approach transforms the tailing pond into virtual reaction columns, enabling individual and simultaneous water treatment while optimising efficiency. PMAP’s novel reagent demonstrates exceptional efficacy in removing critical metals like cobalt, nickel, and copper, as well as reducing harmful metals such as mercury and manganese to undetectable concentrations. Unlike traditional lime-based treatments, PMAP’s reagent prevents gypsum formation and reduces waste volume significantly, improving reagent utilisation and solid waste handling. Furthermore, PMAP technology offers benefits beyond environmental stewardship. By reducing water treatment costs and improving resource management, it enhances operational efficiency and aligns with broader corporate sustainability goals. Additionally, PMAP expedites permitting processes by eliminating the need for traditional water treatment infrastructure and mitigating risks associated with hazardous reagent transportation. Integrating PMAP as a pre-treatment for existing lime facilities provides further benefits, including optimisation of treatment operations, reduced reagent consumption, and the recovery of valuable metals from generated sludges. Overall, PMAP represents a groundbreaking advancement in mining wastewater management, showcasing the transformative potential of AI and environmentally friendly solutions to foster sustainable and responsible mining practices globally. Its inaugural project in the Yukon Territory aims to demonstrate its capability to remove contaminants from mine water, paving the way for widespread adoption in the industry.

Sep 1, 2024

By Wright JK, Turner RE, Batterham RJ, Morrison AL

Simulation can play an important role in the design, optimization and control of complete industrial processes, the most appropriate method depending on the particular application. Most commonly, process models or simulators are means of representing the process which are either purely mathematical or physical. Mathematical models, however, almost invariably need to be based to some extent on experimental data or require experimental verification before they can be used with confidence. Ways in which experimental and mathematical modelling techniques can be combined to best effect are discussed, with reference to the simulation of iron ore induration and direct reduction processes. A novel method is presented for the simulation of direct reduction shaft furnaces. Small scale apparatus has been developed in which ore or pellet samples are subjected to the changing environment of the industrial process. The time dependent conditions (solid temperature and gas compositions) are provided by a mathematical representation of heat transfer and the conservation of mass and energy in the process Simulated.

Jan 1, 1986

By H Arvidson, V Chamberlain, J Joughin, N Pollock, F Cessford, T Flitton, T Rowl

Environmental, social and governance issues (ESG) have become a defining feature in the marketplace to differentiate preferred investments. With the sustainability commitment and reporting landscape anticipated to evolve exponentially, it is now imperative to rapidly develop the approach taken by mineral companies to adequately identify and address ESG risks and opportunities in the reporting of Mineral Resource and Mineral Reserve (MRMR). MRMR cannot be effectively reported as technically and financially assured and realistically executable, if ESG is not integrated into the strategy, business model, input assumptions and process that defines and drives robust MRMR public reporting. Regulatory reporting codes across the globe are presently in various stages of being updated and modified to ensure ESG factors are appropriately covered as a key part of diligent and transparent disclosure. Security exchanges are making it clear that companies must not omit ESG risks from reports to investors. This paper discusses associated challenges for MRMR reporting and suggests avenues for improvement. Key themes include: the importance of procedure rather than prescription and checklists; how ESG criteria impact Modifying Factors and determination of Reasonable Prospects for Economic Extraction (RPEE); the need for financial models to account for material ESG commitments; the uniqueness of each mineral asset; the need for education, upskilling and accreditation of both ESG experts about MRMR reporting and equally Competent Persons in ESG matters; and the need for clear and balanced reports that meet the needs of end users. (RPEE is adopted here for simplicity and consistency, recognising that some reporting codes still include ‘Eventual’ in the term (ie RPEEE). Whilst RPEE and RPEEE are subtly different the intent is to point to the process of assessing ESG factors in determining reasonable prospects.) The principles of transparency, materiality and competence remain paramount when considering the impact of ESG matters on MRMR reporting, and this necessitates an inclusive, cohesive, and integrated approach to assessing ESG issues to ensure the necessary expertise and diligence is applied.

May 24, 2023

By S N. Donaldson, B L. Hollis, K Wynn, L Potts, M Evans

A real-time load-haul-dump (LHD) dispatch optimisation tool has been deployed at Panel Cave 1 and Panel Cave 2 at Newcrest’s Cadia Valley Operations. The tool, known as ORB, is the first known successful implementation of an optimisation-based, autonomous, real-time dispatch tool, custombuilt for underground mining operations. ORB can co-ordinate the optimal dispatch of LHD’s in a block cave to achieve a range of objectives while adhering to draw compliance and geotechnical constraints. It is an example of highly automated short-term interval control. This paper starts by outlining the pre-existing business planning process, detailing the simple logic that produced the daily draw order. Next, the motivations for a real-time dispatch tool are presented, drawing comparison to the limitations in existing planning processes and how these can be overcome through an optimisation-based, autonomous, real-time dispatch tool. Subsequently, the paper details the Ratio Bogging Draw Strategy, through which tonnes targets are expressed continuously on draw bells or draw points as a ratio of total cumulative cave draw. This signifies artificial planning boundaries are removed and that draw targets are linked within a cave; such that tonnes are unlocked by bogging other parts of the cave, instead of as a function of time. This creates incentive within the target mechanism for fixing and bogging struggling draw areas whilst allowing uncapped progress if all draw targets are progressing within compliance. Furthermore, the optimisation tool developed is outlined, including the data it uses and the objectives it optimises. Finally, detail on the improvements to operations the implementation of this tool has brought, and the business process change it has facilitated are presented using Newcrest’s Cadia Valley Operations as a case study.

Mar 15, 2021

By N Voller, A Ishmurzin, G Hackl, M Wu, A Kharicha, M Chintinne, C M. G Rodrigues, A Ludwig

Slag fuming (SF) is a critical process for recycling zinc-containing slags, but the corrosive nature of molten slag poses challenges to the reactor durability. The freeze-lining (FL) technique offers a solution by forming a protective layer on the reactor wall. It requires intensive cooling using watercooled jackets, which can stabilise the FL while compromising the energy efficiency of the process. This study presents a computational fluid dynamic (CFD)-based model to optimise the SF process by considering FL formation and its impact on heat transfer and reactor wall temperature. A volumeof- fluid (VOF) model is coupled with a mixture continuum (MC) solidification model to capture the intricate multiphase flow dynamics within the SF furnace. Two FL types are considered: FL solidifying on the reactor wall in the slag bath region; and FL solidifying on the reactor wall in the freeboard region. The FL of the first type forms when the slag temperature drops below liquidus temperature. The FL of the second type only forms when a splash-induced slag droplet collides with the freeboard wall and solidifies. A series of splashing events are necessary to coat the freeboard wall. The simulation was run until a global energy balance was reached. This means that the heat losses from the water-cooled jacket, bottom wall, outlet and fuming balance the heat gains from the hot gas injected through the submerged plasma torches. The increase in FL thickness, due to its low thermal conductivity, reduces the heat losses through the reactor walls. The calculated FL thickness and heat fluxes were in good agreement with industrial data, validating the model’s credibility. The simulation results provided valuable insights into the fuming process, including slag bath temperature evolution, slag splashing dynamics, FL formation patterns, local heat fluxes through the reactor wall and overall energy balance. These findings can inform process optimisation strategies to enhance the energy efficiency and sustainability of SF operations. The authors have built a prior version of the model framework and applied it to simulate FL formation in an electric smelting furnace (ESF). The results from both the ESF and the current SF highlight the applicability of such model framework to a range of industrial processes involving FL formation. This model framework can ultimately contribute to more energy-efficient and sustainable industrial operations.

Aug 21, 2024

This paper aims to address the issue of the public's image of the extractive minerals industry. What is it about the industry that incites such negative feelings and are they justified? Are we really the 'rapists of the land' that many would have us believe? Has the industry really not improved since the old gold boom days?   I believe that the fundamental cause for the public's view is lack of knowledge and understanding of the industry as a result of the dislocation of the end production from its source. There are few people who look at a house, car, record, toilet, tooth-brush, bottle of coke or pair of glasses and see the mine site that supplied the source material. But the mine site and its products should be inseparably linked. This is one area where we should be educating the public û it is all very well being anti-development but the population as a whole is not really prepared to live without its 'mineral'-derived necessities. It is very easy to say that we do not want minerals development in New Zealand but are we prepared to live with the consequences, ie go without its products? We have a duty as a global citizen to develop our own resources rather than expect Third World nations desperate for overseas investment, often with governments who are not prepared to constrain or control their development, to be exploited. New Zealand is not the only 'beautiful' place in the world and we should be aware of the impact that our demands for resources have on the countries who supply us. We have a duty to be a good global citizen.   So how does the industry improve its public image? The key here has to be to educate. This does not have to be high powered or expensive but can be as simple as getting a few local kids' hands dirty panning, and gaining some firsthand knowledge of the industry. The industry also needs to be more pro-active in the public arena. Yes, the industry has skeletons, but the industry should be publicly displaying them û admit that things have gone wrong but let's do it ourselves and not leave it up to the environmental groups to accuse, point the finger and put the industry under public scrutiny. The industry should also be publicising its successes, inviting the local press, councils, etc to view the latest area rehabilitated. But more than anything else we must tell the public what the minerals industry means to New Zealand. Can they really live without us?

Jan 1, 1991

By M Sebbag, T Taimre

Barrick Gold Corporation is proceeding with development of the Buzwagi Mine in the Lake Victoria Greenstone Belt District of Tanzania. The Buzwagi orebody occurs in the Nzega Shear zone within the Greenstone Belt and is hosted in a K-Feldspar rich granite in contact with mafic volcanic. The orebody presents 2.6 M ounces in 41 Mt of reserves, at 2.0 g/t. Over the ten year mine life, total material movement will be 261 Mt. The feasibility study was completed in 2006 and presented several technical challenges. Two principle challenges are grade control and the impact of dilution on the economic viability of the project. The principle challenges for grade control will be quality control and quality assurance in the sampling of the massive coarse grained granite, which comprises 70 per cent of the deposit. The principle challenge with dilution will be with the selective mining of the narrower mineralised zones contained within the mafic volcanics. This paper will focus on the mine planning methodology which has been applied including selective mine unit (SMU) and dilution estimation, net smelter revenue (NSR) calculation and the effects of cut-off grades to the project economics and mine schedule.

Jan 1, 2007

By B Rouvray, R Bertuzzi

The development of a design-and-construct tunnelling project in Australia from its concept to its construction requires designs to be prepared and reviewed at several distinct stages prior to documenting ‘for construction’. On recent projects the post-tender stages have been variously called 30 per cent—70 per cent—100 per cent; or concept–substantial–final; or system definition–preliminary–critical. The design is reviewed at each stage by the designer’s internal reviewer, the contractor and its independent advisor(s), the owner and its independent advisor(s), the project’s independent certifier, proof engineers and often third-party stakeholders and their advisors. Documentation for each stage often dominates the design effort, at times distracting from design. This paper presents the authors’ experience of this design-and-review process. Comparisons of design budget and actual design spend and design program implications are presented. It is postulated that a subtle change has occurred in our industry that has diminished the value of the design dollar. Is there a better process? An alternative is suggested.CITATION:Bertuzzi, R and Rouvray, B, 2014. Reducing the cost of tunnel design in Australia, in Proceedings 15th Australasian Tunnelling Conference 2014 , pp 501–506 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 17, 2014

By O Bøckman, E Thisted, K H. Esbensen, U Thisted

Process industry measurement systems, once installed, are often interpreted as static black boxes delivering correct values as long as not proven otherwise. After first implementation and set-up with a distinct sampling frequency, they often run ‘forever’ without checking if this frequency is still appropriate with respect to changed raw materials characteristics, different process conditions or changed customer specifications. Failure detection is based on operator experience and skills (often close to an art form) and/or from control measurements of reference samples. This may well be too late for many industrial process contexts. An appropriate sampling frequency is a critical success factor for valid monitoring and control.Based on the methodology of variographic analysis we here illustrate how to design/re-design/optimise an industrial measurement system in terms of sampling frequency, discretisation and accuracy based on customer specifications. We also show how variographics can be used to monitor for deviations. We use experience from process industry to show how these methods can be used not only for product characterisation, but also for monitoring input factors, process indicators and measurement of these. The information hidden in the vast amounts of data that is continuously created in modern process industries can be utilised to cut costs in the measurement activities and at the same time contribute to early error detection. We illustrate by case examples from production processes at a nickel refinery, supporting the Lean and Six Sigma methodology. This will provide a standard operating procedure for monitoring the stability of measurement systems, and provide a basis with which to discuss how a variographic approach can be integrated with the Lean and Six Sigma approach as an online tool to map, characterise and validate measurement systems and thus avoid more cumbersome measurement system analysis in full detail.CITATION:Thisted, E, Thisted, U, Bøckman, O and Esbensen, K H, 2017. Variographic case study for designing, monitoring and optimising industrial measurement systems – the missing link in Lean and Six Sigma, in Proceedings Eighth World Conference on Sampling and Blending , pp 359–366 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2017

By J Holdsworth, L Sutton, A Lavrinec, D Ilic

Air quality is a big topic of discussion in regional mining communities as well as urban environments situated close to port terminals handling bulk solids. Community perception of poor air quality can significantly affect the reputation of the mining operation and handling facilities. Dust monitoring for regulatory compliance relies on using a handful of accurate but very expensive sensors, usually situated at the boundary, relatively far from the activities that generate the airborne dust. These reference monitors measure dust leaving the site but dust mitigation and management on-site largely relies on operator judgement. At a fraction of the cost, small wireless solar powered units can be used to supplement reference monitors in real-time. Due to their compact nature, portability and low price, these units can be implemented on a mass scale to increase spatial resolution of dust measurements and, more importantly, in much closer proximity to both the dust generating activity and the sources of dust. This can provide valuable insights into the origins and timing of dust generation thus producing datadriven decision-making while minimising subjectivity. Similarly, light detection and ranging (LiDAR) is another supplemental technology that can be used to increase the spatial resolution of dust measurements in near real-time, however, the cost of commercial systems even exceeds that of regulatory monitors. LiDAR also presents difficulties in quantifying dust plume concentrations. This study presents learnings of implementing both technologies for dust emissions management. Several low-cost sensor units and a fast-scanning custom-built 3D LiDAR system operating at a range of 1.5 km with a resolution of 1.5 m were deployed on a surface mine to monitor dust emissions from different activities. The project explores the use of real-time sensor data to quantify LiDAR measurements in parallel with integration into mine planning. The approach can assist in prioritising dust mitigation activities thereby reducing instances of emissions exceedance and minimising water use through databased and targeted application. Demonstrated is an opportunity for a step-change in industry best practice as well as commercialisation and operationalisation of the method across different industries, including future mineral extraction.

Sep 18, 2023