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By R Barritt, P Scott

Across the globe, it is a common scenario that tailings storage facilities (TSFs) are being decommissioned; however, their subsequent impact on the local environment and landscape can often be overlooked during the mine planning process. In addition, the requirement of a cover system for a facilities closure may not be a priority until the latter stages of the mine/mill operation when potential cover materials may have been utilised elsewhere or, worse, buried. Developing a conceptual design and closure plan for a TSF early in a mining venture is fundamental to its success once operations have ceased. If a cover system is a planned component for rehabilitation of a TSF, it is vital that its design is appropriate to the facility and any local site constraints, such as climate and cover system material availability. It is also strongly recommended that various cover system options are physically trialled at the site by using performance-monitoring instrumentation. Through this process, an informed decision can be made regarding the most appropriate cover system design to meet any regulatory and stakeholder closure objectives and criteria specific to the site in question; however, in order for the cover system’s performance to be determined through on-site trials, it is essential that an appropriate instrumentation design is utilised. Often, little attention is paid to the data that is being obtained, and its importance may only become apparent after several years of monitoring at an expense to the venture. This should not be the case. Many sites have used an appropriate initial planning stage to understand what is required for the successful closure of a TSF, how it can be achieved and how monitoring data can be utilised to prove, or otherwise, that a cover system design will be a success.CITATION:Barritt, R and Scott, P, 2015. Cover system performance monitoring for tailings – are we doing it correctly?, in Proceedings Tailings and Mine Waste Management for the 21st Century , pp 283–288 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 27, 2015

The Grootegeluk coal beneficiation plant is situated near Ellisras in the Waterberg coal= field in the Transvaal, RSA. At this plant 15 million tons of coal bearing material per annum are beneficiated by means of two-stage heavy medium bath and cyclone plants. Because of the very low yield of 12 % coking coal product, run= ping costs are of the - utmost importance. For this reason extensive tests were carried out to establish the most effective crushing and bene= ficiation methods and suitable aquipment. At the second heavy medium separation stage, the near-gravity material (+ 0,1. g/cc) amounts to 45 % and daily plant performance ana=lysis is required to ensure acceptable plant efficiency. Beneficiation processes for the -0,5 mm coal originally considered were froth flotation, shaking tables, heavy medium cyclones and water- only cyclones. When the froth flotation route was decided upon, further test work was done to enable selection of the equipment most suitable for the particular requirements.

Jan 1, 1987

By M Armony, J F. C L Costa, J C. Koppe

Linear kriging methods fail to estimate local grades and local reserves for highly skewed variables due to three reasons: it uses only part of the available data information, it has no physical principles associated with the mathematical proceedings to minimise the problems, and it works with continuous variables while data are discrete because of the limited precision of any equipment. The techniques commonly used up to now to solve the highly skewed variables estimation problems were unsuccessful, unless mathematical rigor is abandoned. Even the method of multiple indicator kriging is not satisfactory. This paper presents a new framework, the field parametric geostatistics (FPG) that transforms noisy variograms into well-behaved variograms and justifies mathematically empirical procedures commonly used, as trimming or capping arbitrarily very high values. The method, when applied to non-skewed variables, yields similar results to classic kriging. The methodology is illustrated in a case study at a gold deposit in Brazil, and compared to results obtained by usual techniques.

Sep 26, 2011

By J Rutter, D La Rosa, P Walters, M Scott, L Keeney

Bulk ore sorting technologies, whether surfaced based or penetrative, have seen an increased uptake by the mining industry for preconcentration application. As with all technologies, going through the technology validation process is key to de-risking the operationalisation of the technologies and to demonstrate and confirm predicted value propositions. The ability to laboratory calibrate cross-belt bulk sensors is standard practise for sensor vendors, however transitioning the technology from laboratory to real-world application is a non-trivial process. The industry has taken two main approaches to trialling and validating bulk sensing technologies in operational environments, namely:  Construct an off-line pilot facility at scale, or  Install bulk sensing systems on production conveyors Each of these two approaches have significant advantages and disadvantages and require different experimental design programs and analysis methodologies. Consideration of material movement, heterogeneity degradation, logistical requirements, and financial investment all factor into which approach is most suitable for an evaluation scenario. CRC ORE in partnership with mining companies, have conducted several bulk sensor pilot trials utilising different sensor technologies employing each of the two main approaches outlined above. This paper describes the challenges faced, learnings obtained and outlines a position on how to transition bulk sensing technologies from the laboratory into the operating environment. The case studies presented cover a range of commodity types in both open pit and underground operations.

Nov 10, 2020

By P J. Handley

"Predicting how coal seams will be beneficiated through the coal handling processing plant (CHPP) has long been challenging within BHP Coal. Various coal seams from different areas are mined and stockpiled separately, often depending upon a deleterious coal quality parameter; high/low trace elements for example. These stockpiles are then fed in different ratios into the CHPP to produce the desired product/s. In understanding the washability characteristics of the feed source, mine geologists and process engineers work together to improve the beneficiation of different coal materials through the CHPP.For the majority of the BHP Coal deposits, the washability data is available for the coal seams across the deposits. However, no previous standardised modelling and prediction technique existed that could ensure the correct information was available for forecasting and refining CHPP processes. This paper will discuss the steps undertaken to implement a geometallurgical prediction tool that simplified and streamlined the washability modelling and yield estimation process. The value realised to the BHP Coal assets resulting from this process was: improved compliance to plan increased throughput increased CHPP recovery through improved efficiencies and increased revenues.CITATION:Handley, P J, 2017. Washability modelling and estimation techniques used to improve coal handling preparation plant beneficiation, in Proceedings Tenth International Mining Geology Conference 2017, pp 327–336 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Sep 20, 2017

By A Llewellyn, M Varvari

The ventilation circuit at the FrogÆs Leg Mine was originally designed to permit mining to progress down to 440 m below surface at a maximum production rate of 500 kt/a, as per the feasibility study. The FrogÆs Leg resource has now been defined down to 640 m below surface at a maximum production rate of 750 kt/a. In order to allow for this increase in production depth and tonnage, it was necessary to upgrade the ventilation circuit.This paper outlines the upgrades to the ventilation circuit that were undertaken and the underlying rationale behind them.CITATION:Llewellyn, A and Varvari, M, 2013. Ventilation upgrade at the FrogÆs Leg Mine - Case study, in Proceedings The Australian Mine Ventilation Conference , pp 95-102 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 1, 2013

By C M. Stewart

Lithium battery electric powered vehicles and machines (BEVs) continue to gain traction inunderground mining use, with predictions they will dominate the underground light and heavy vehicle fleets for some mines within the next decade. There are clear advantages for ventilation systems through reduced heat output and the elimination of harmful exhaust gases and diesel particulates. However, the risks and effects of BEV fire emergencies for underground personnel and ventilationsystems are still largely in the early stages of analysis and understanding. This paper conducts an industry review of a selection of lithium battery fire incidents and research.A research paper review on lihthium fire behaviour, intensity and toxicity will be analysed and comparisons made with equivalent diesel machinery fires for context. Guidelines for mine firemodelling parameters will be offered to assist in predicting the behaviour, heat and emissions from BEV fires, and recommendations and conclusions will be drawn on the specific hazards of lithium battery fires compared to conventional diesel powered machines.

Oct 12, 2022

RME has a vision for a new grinding plant operational paradigm made possible by RMEÆs fast, safe Mill Relining System. Some new liner designs can degrade SAG mill performance because of mill volume loss, ball strike (rotational speed limitations) and other issues often brought about by modifying liner design for maximum life and without a backward glance at metallurgical consequences. Freshly relined mills can initially produce as little as 80 per cent of their maximum throughput, that maximum occurring toward the end of the linersÆ wear life. RMEÆs proposition is to see new liners designed for maximum commercial performance. This may mean more frequent mill relines but with liners designed to yield optimum grinding, metallurgical and profitability performance, not maximum life. In other words, mill liner profiles and mill relining speed become key operational controls and not simply æmust doÆ maintenance functions. Taken to the extreme, liner profiles may prove capable of ætuningÆ a grinding plant for maximum profitability in any metal price environment. Following the introduction, the first section of this paper provides an update describing recent and significant developments within RMEÆs range of Mill Relining Systems, the enabling technologies which permit more frequent liner exchange without incurring additional downtime imposts. The second section outlines RMEÆs vision of a æliner profile versus profitabilityÆ commercial model, developed either intuitively or by using a combination of new measurement and modelling technologies. These new measurement and modelling tools provide the opportunity to predict the optimum commercial outcome, off-line in the virtual world, before committing to an expensive liner experiment.

Jan 1, 2007

By K Mayank, A N. Mainza, I Govender, M Narasimha, A Mittal

In mineral processing industries grinding is the most energy-consuming process. A tumbling mill is an essential grinding equipment widely used for particle size reduction. Power consumption, impact forces and trajectory paths are critical parameters for characterising a tumbling mill to determine grinding efficiency. The effect of lifters and mill speed plays a vital role in such parameters. However, most of the studies ignore the impact of the lifter and do not investigate the effect of slurry dynamics on charge motion. The focus of the present work is to prepare a computational model that can accurately predict the complex multi-phase dynamics of charge particles, air and slurry inside the mill using a model that couples computational fluid dynamics (CFD) and the discrete element method (DEM). The details of impact forces with lifter profiles and mill speed variations will be refined even further using the CFD-DEM coupling approach. The slurry-air free surface is modelled using the volume of fluid (VOF) method, and the charge motion is modelled using the DEM. The phases are coupled using the interface momentum exchange between the charge and the fluid slurry. The coupled model is validated against experimental results from the positron-emitting particle tracking (PEPT) data. The validated model compares the effect of slurry content on charge dynamics with the dry DEM model. The presence of slurry is observed to dampen the tangential and shear contact forces.

Aug 24, 2022

By E Beltran, S Ngunz, F Orrante, F van Zyl, M Westcott

"The primary control objective of the project is to achieve milling optimisation by ensuring that the energy available for rock breakage is used as efficiently as possible. This is achieved by increasing the level of mill filing until a process constraint is reached. Stable operation against this limiting constraint is then maintained to ensure long-term optimised operation.Semi-autogenous grinding (SAG) mill control optimisation presents a number of challenges. SAG mills have multiple inputs that are used to control multiple outputs (MIMO process). Secondly, the SAG mill loading process is a ‘high inertia’ process that can be approximated as an integrating process. This means that it is open-loop unstable. The hybrid control strategy presented implements an advanced ‘load stabiliser’, which transforms this integrator process into a more manageable first order process, which can be steered stably against the constraints. This SGS hybrid Expert control strategy implemented on both SAG mills at the Porgera concentrator therefore consists of two integrated parts responsible for:stabilising the mill load to a targetdriving the mill load target to the maximum determined by the process constraints (eg maximum power draw) to maximise efficiency and throughput. A comparative study is done between the operation of the plant for a period of a month before and a month after the implementation of this strategy. The results indicated a significant improvement in the SAG mills’ stability and operation as well as a reduction of overload situations leading to a loss of throughput.Citation:Ngunz, S, van Zyl, F, Orrante, F, Beltran, E, Westcott, M and Wilson, S, 2016. Simplified Hybrid Semi-autogenous Grinding Mill Control - Explanation and Practical Results at the Porgera Concentrator, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 313–320 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By M Pyle, R Ch, T Vizcarra, ramohan, G Lane, G Ballantyne

Preconcentration, through gravity separation (Wallace et al, 2015), magnetic separation and particle size (Clout, 2013), has been used in many historical projects to convert low grade material into ore. More recently, pre-concentration technologies such as bulk sorting (Kurth, 2017), screening (Bearman, 2014) and coarse particle flotation (Vollert et al, 2019) have also demonstrated their ability to progressively reject waste through the value chain. These technologies can not only deliver stepchange improvements to the economics of mining operations, but can transform the environmental and social aspects by minimising water and energy consumption and significantly reduce the quantity of fine tailings produced. However, implementing progressive waste rejection requires technologies and approaches to be combined and applied in the right way to capture the value. From a technical perspective, progressive waste rejection introduces challenges related to the orebody, equipment performance, engineering and understanding the value chain from the resource through to final product. From a management perspective, the key issues are related to people and processes, in particular; motivating the business, challenging the paradigms, and introducing new ways of operating within the constraint of existing management structures to manage risks and minimise lost opportunity costs. This combination of technical and management issues means that progressive waste rejection is a complex undertaking for mining companies, yet the reward for the business and other stakeholders is potentially high and should not be ignored. This paper presents how progressive waste rejection can offer step-change improvements to the business case for high and low grade greenfield and brownfield projects based on case studies completed by Ausenco. The paper then outlines different implementation approaches from concept studies to execution to address the various technical and management challenges outlined above.

Nov 10, 2020

By I Grewal, B Klein

The Knelson Continuous Variable Discharge (CVD) is a continuous centrifugal gravity concentrator for high-mass yield recovery applications. It has four operating variables that enable control of mass yield, product grade and recovery namely: fluidisation water, bowl speed, pinch valve open time and pinch valve closed time. Plant testing of a pilot scale Knelson CVD6 was conducted to evaluate the effects of operating variables on mineral separation. The analysis of operating variable effects has provided a framework for the development of operating guidelines for the CVD.

Jan 1, 2001

By R Pozo, F Reyes

Codelco Chile is currently developing the El Teniente û New Mine Level Project (NMLP) in order to increase ore production by seeking to mine the ore deposit located under the current operational orebody. Reserves of 2000 million tonnes (Mt) have been quantified, which will be extracted as from the year 2017 by using the panel caving and progressive sinking method. Codelco and SKM Minmetal (SKM) jointly developed the project prefeasibility stage (PFS), closing these studies in March 2008. The first part of the project approach is to replace mine production currently feeding the Colon concentrator facilities with 137 000 tonnes per day (t/d), focusing attention on a production increase from the year 2026 up to 180 000 t/d. Project efforts have also been centred on maximising the contribution of new technologies for both construction and operational phases of the New Mine Level, together with selecting the best mine infrastructure to keep El Teniente operations going on for the next 50 years. Implicit in this is the inherent improvement of a variety of current Mina El Teniente process and management practices. The plan is to reduce actual mine operational risks and take advantage of new opportunities afforded by the project, which is in effect a greenfield project with respect to the implementation of fundamental changes in the labour and business environment. In addition, issues related to human resources, maintenance and management, materials handling, establishing centralised operations and accesses, automation and remote operations control and power efficiency could also be addressed. The project, beyond the New Mine Level exploitation, considers the mineÆs future potential, with a second deeper exploration in prospect named Deep Level. Finally, the project identifies features that would add value to the mine operations, in an initiative named æSpace for Future TechnologiesÆ. This will allow the eventual implementation of new electrical equipment and the application of mechanised technologies and other process improvements for the mine development.

Jan 1, 2008

By L D. Redden, M G. Nelson

Mechanical flotation machine design is typically based on hydrodynamic analysis, with scale-up calculated by geometric proportionality. End users often specify and purchase machines on the basis of retention time, characterised by the æ$/m3Æ approach; they may also consider the manufacturerÆs installed base. In some applications, end users also consider specific energy and the impact of energy consumption on operational costs. In other cases, a decision may be based on machine type (forced-air versus self-aspirating) and perceived metallurgical or operational advantages of one machine type over the other. With regard to metallurgical performance efficient bubble-particle contact is very important and is primarily influenced by two factors:the concentration and size distribution of bubbles in the machineÆs contact zone (the volume enclosed by the disperser); and the number of times that slurry is pumped through the contact zone. The second factor is a function of the machineÆs pumping rate and its retention time. Field data show that pumping efficiency is independent of aeration rate. In this paper, a new dimensionless number for the characterisation of flotation efficiency is presented. The contact frequency number (CFN) is defined as the number of times a given volume of slurry passes through a machineÆs active contact region, and is given by: CFN Qp/Qf, where:Qpis the pumping rate through the contact regionQfis the volumetric feed rate to the machine

Jan 1, 2005

By R Dimitrakopoulos, R Goodfellow

One of the primary objectives when optimising a mining complex is to maximise its value for the primary stakeholders. In order to achieve this objective, it is necessary to holistically optimise all aspects of the mining complex, including decisions of when to extract materials from the available sources, how to blend or stockpile these materials and how to best use the available processing streams to satisfy customer demand. Existing methods for global, or holistic, optimisation ignore the compounded effects that risk has on the performance of a mining complex. Over the past decade, several stochastic optimisation approaches have been proposed to integrate various forms of uncertainty into the open pit mine design and production scheduling. These methods, however, are limited in their ability to simultaneously optimise the production schedules for the portfolio of mines, material destination policies, the use of the available processing streams and the various products that are produced at each location of the mining complex.This paper aims to discuss a new method for the global optimisation of open pit mining complexes with geological uncertainty. The proposed generalised methodology is capable of modelling and holistically optimising mining complexes, including aspects related to production scheduling, blending, stockpiling and non-linear interactions that often occur in practice, but are over-simplified in existing models. Two case studies are discussed to highlight the need for these complex, stochastic optimisers. First, a case study for a nickel laterite blending operation highlights the need to integrate geological uncertainty into the optimisation in order to ensure product quality constraints are respected. Second, a case study for a copper-gold mining complex highlights the added value when simultaneously optimising the production schedule and the stockpiling and treatment of extracted materials.CITATION:Goodfellow, R and Dimitrakopoulos, R, 2014. Stochastic optimisation of mineral value chains – developments and applications for the global optimisation of mining complexes with uncertainty, in Proceedings Orebody Modelling and Strategic Mine Planning Symposium 2014 , pp 13–22 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 24, 2014

The Graham Farmer Freeway Project in Perth, Western Australia, is the largest urban infrastructure project ever carried out in the State. At a project cost of over $360 million, it also ranks as one of the largest in Australia and is even large by world class standards. The project provides a much needed east-west freeway bypass around the CBD of Perth, linking the Great Eastern Highway in the east with the Kwinana and Mitchell Freeway system in the west. The Bypass will have 6.5 kilometres of freeway, a major bridge over the Swan River, several pedestrian overpasses and underpasses, dual use paths, interchanges and flyover bridges and a rail tunnel. The whole project is being carried out over a four-year time frame, due to be complete and open to traffic in June 2000. The project has been divided into two stages, with Stage 1 including the 1.63 kilometre long Northbridge Tunnel, the subject of this paper.

Jan 1, 1999

By J-P Franzidis

Mill operators have traditionally been forced to rely on grade-recovery curves and overall flotation rate constants when analysing proposed improvements to plants. This has led to loss in money and time when a proposed change that showed potential in laboratory scale tests failed to show improvement in the plant. Frequently, this is a result of the operators being unable to gain insight into how and why the proposed change affected the flotation performance. This is due to the classical models not including any description of the subprocesses of flotation and their individual contribution to the overall flotation performance. A new flotation model has been developed as part of the AMIRA P9 project that separates the flotation process into subprocesses and includes the contribution of both the pulp phase and froth phase to the overall flotation recovery. It is not possible to determine the individual components of this new model on traditional pilot plants as they lack the required flexibility and scale. Therefore a new pilot plant has been developed known as the Floatability Characterisation Test Rig (FCTR) that has the flexibility and features required for the determination of the flotation subprocesses. The flexibility and features of the FCTR also make it an ideal tool for investigations into many different aspects of flotation research. These include the effect of reagents, grinding, and power on the flotation performance. This paper will describe the methodology for using the FCTR in these fields of research and highlights the advantages of using the FCTR over traditional methods.

Jan 1, 2000

By C Mpodozis

Central Andean (22¦S to 34¦S latitude) Miocene giant ore deposits share common features that reveal their origin. Tectonic and magmatic features include a relation to a shallow subduction zone, an association with the waning or initiation of a magmatic episode, emplacement at the time of uplift associated with crustal thickening and formation at times of major magmatic changes along the Andean margin. Rare Earth Element (REE) signatures in magmas erupted near the time of mineralisation indicate a progressive change from equilibration at depth with a hydrous, intermediate-pressure amphibole-bearing mineral residue to equilibration with an anhydrous high-pressure garnet-bearing assemblage. These features point to a common history. First, a relatively shallow subduction zone leads to hydration of a cool mantle wedge providing a source of fluids which builds up over at least several million years. Arc magmas formed at this time equilibrate with a hornblende-bearing residual mineralogy. Second, a compressive tectonic regime leads to crustal shortening and thickening that facilitates entrapment of arc magmas in the crust. Eventually, the magma-weakened crust yields to horizontal compression causing rapid crustal thickening. Fluids required for mineralisation are liberated as amphibole-bearing assemblages break down to garnet-bearing ones and over pressured fluids are released from plutons. Mineralisation subsequently ceases in the region unless continued dehydration of the slab and mechanical thinning of the continental lithosphere causes the previous conditions to repeat. The type of mineral deposit generated depends on the pre-existing continental lithosphere and the distance from the trench.

Jan 1, 1999

By G Lane, S La Brooy

A century ago, new mines were often accompanied by smelters. In Australia, smelters were built at the Daydream mine near Broken Hill, at Kuridala and Mount Elliott near Mount Isa, Broken Hill, Mount Lyell, Mount Morgan, Mount Isa, and more recently at Tennant Creek, Kalgoorlie and Olympic Dam. Now the big miners eschew site-based processing in favour of shipping concentrate to smelters in Europe and Asia. As Chip Goodyear was in the process of vacating his leadership role at BHP Billiton, he was quoted as saying that BHP should concentrate on mining ore and leave æto others the skill set of processing that materialÆ. Yet there are times when on-site processing clearly makes sense. Few companies ship gold ore or concentrate to China for gold extraction. New smelters are being built in Zambia. Solvent-extraction and electrowinning plants frequently produce copper from oxide ores and concentrates while pressure leaching is increasingly being considered for copper sulfide ores. Some argue that on-site processing is best because the waste products can be returned to the ground from whence they came, avoiding potentially large disposal costs in more-populated areas. Copper treatment and refining charges will not remain at $45 per tonne and 4.5 cents per pound forever. This paper examines when it makes sense to use on-site pyro- or hydrometallurgical processes in todayÆs environment and comments on how current trends might alter the balance in future.

Jan 1, 2008

By C Armstrong, B Wentzinger

Upstream embankment raises often represent the lowest cost option for increasing the capacity of tailings storage facilities (TSF), but also pose the highest stability risk due to constructing on top of previously deposited tailings.This paper presents an overview of key aspects in the geotechnical investigation and design of upstream raises and some recent lessons learnt from experience across a number of TSFs in Australia. A summary of recommended field investigation and laboratory testing methods is provided with a focus on collecting quality information for design purposes. A strong focus is given in developing an accurate assessment of pore water pressures, which, if not correctly understood can have disastrous consequences on tailings strength parameter interpretation and wall stability assessment in static and post-seismic conditions.The assessment of the contractive or dilative shearing behaviour of the tailings material and rigorous interpretation of design characteristic values are presented. Some comments on stability analysis options and proposed methodology are also provided.CITATION:Wentzinger, B and Armstrong, C, 2018. Lessons learnt in geotechnical investigation and stability analysis for upstream tailings storage facility raise design, in Proceedings Mine Waste and Tailings Stewardship Conference 2018, pp 333–348 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 23, 2018