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By G M. Hoffmann

Utilisation of lower grade (Jigging technology has progressed to a point where SishenÆs 50 to 60 per cent Fe run of mine (ROM) material, once considered as waste, can be beneficiated to produce a saleable 64 per cent Fe product. This has been confirmed through appropriate beneficiation testwork. Consequently, Sishen can now produce saleable product from material not currently included in the resource definition, significantly increasing the resource base of the mine and ensuring higher resource utilisation. Mine planning utilised the geological models to produce detailed planning schedules, reflecting the current and SEP plants separately, optimised to comply with product specifications of both the current and SEP plants and to confirm the viability of the low-grade resources identified as SEP feed material. The SEP product specifications have been derived by optimally matching iron ore market requirements with the revised resource base. A 64.0 per cent Fe lump product and a 63.5 per cent Fe fine product are the optimal SEP products. The SEP plant will be able to produce 10 Mtpa at an average yield of 60 per cent and a lump to fine ratio of 62:38. The plant consists of five major sections: namely crushing, material preparation, beneficiation, final product handling and quality control services. Maximum integration with the current Sishen plant was considered. Kumba currently has an agreement with Transnet to rail up to 23.5 Mtpa through the Sishen Saldanha iron ore export channel (IOEC). Transnet and Sishen Iron Ore Company have signed a Definitive Agreement that deals with the expansion of IOECÆs capacity, which increases KumbaÆs entitlement from 23.5 Mtpa to 35.0 Mtpa. The detailed enviro-legal impact assessments for the SEP indicated that the project has low enviro-legal risk as a result of it being a brownfields project incorporated into the current Sishen operations.

Jan 1, 2005

By A G. Guinea

Every person in an organisation has what could be called ‘a different take’ on what it means to be a safety leader. The directors will tell you they are ultimately responsible for everyone’s safety and that they can be imprisoned as a consequence of a workplace fatality. Managers, take more of a focused approach and would explain that they are totally responsible for the safety of their teams. And then there are front-line leaders. Those that not only have the responsibility (like directors and managers) but they also have the accountability, and the ability, to influence how safely their teams work. But it is not just physical safety that leaders should be concerned with.

May 5, 2022

By Grossi M, Baiden G

This paper describes a new mine backfill method based on a newly invented binder with several years of test results from laboratory and on- site applications. The new binder has several advantages over traditional Portland and slag cement binders. One tonne of the new binder can replace two to three tonne of Portland cement when used to consolidate backfill and can result in the same compressive strength within seven days. When comparing backfill slurries of the same pulp density, the new binder attains more volume of in-place backfill mass than Portland cement because of the high crystallisation of water, resulting in tightly filled stopes. The crystallisation of the water provides for less or no de- watering in the backfill stope and easier transportation of the backfill slurry. Pastefill performance can be achieved by using pulp densities typical of a hydraulic backfill and the new binder, all the while transporting with the same ease of hydraulic fill.

Jan 1, 1998

An enhanced gravity concentrator was installed in conjunction with an intensive leach reactor at the Sadiola plant in Mali last year and commissioned in December 2007. There has been much debate over the years as to the effect of gravity concentration on overall plant performance. The late Dr Laplante suggested that for every ten per cent of gold recovered by gravity, there was a corresponding 0.1 per cent to one per cent additional overall plant recovery. The results at Sadiola are consistent with this hypothesis with an overall four per cent gain in plant recovery. With total gold recovery of 12 per cent in the gravity section, grades are increased from 3.54 g/t in the gravity feed to an average of 2 600 g/t in the concentrator feed to the inline reactor. The recovery of gold in the inline reactor is in excess of 98.5 per cent. This paper discusses the background to the project, the laboratory test work prior to the equipment selection, the operational results of the system, as well as the benefi ts of the future application of high mass yield centrifugal concentrators in base metals, sulfides and industrial minerals. Bench scale, pilot scale and plant practice examples are also presented.

Aug 1, 2010

Conventional blasthole sampling for grade control has acquired an extremely bad reputation for the last 50 years. The introduction of many sources of bias is a structural reality. Delimitation biases are devastating. Extraction biases are of great concern as well. Weighting biases aggravate an already bad situation. Furthermore, preparation biases are many. Some of these biases are due to the type of drilling machine that is used and are nearly unsolvable. Some of these biases are due to the sampling tools that are used and often unsatisfactory. Attempts to automate blasthole sampling at the drilling site have failed, not because it cannot be done, but mainly because it interferes with drilling productivity. As a result the miner most often rejects the idea after a few weeks of practice. Manual sampling of blasthole piles is a disaster for many reasons; some are related to the methodology, some to the selected sampling protocol, some to the training of operators, some to limited manpower available, and some to limited supervision. Furthermore, with blasthole sampling a time logistic problem is unsolvable as the miner wants the ore grade control geologist to make up his mind within two or three days at most; as a result not enough time is allowed for samplers, preparation facilities, laboratory, and resources department to perform a good job as everyone is working under unreasonable pressure. The economic impact of poor blasthole sampling for grade control has been vastly underestimated by mining companies. The resulting ore grade misclassification is responsible for severe reconciliation problems and massive financial losses every year. This paper suggests areas along this grim scenario where things can be greatly improved; however it is clear that too many problems are unsolvable. An alternative using reverse circulation drilling for grade control is suggested. A thorough analysis of the respective advantages and disadvantages for blasthole and reverse circulation drilling for grade control is presented in this paper.

Jan 1, 2008

By D L. Kennedy

It has always been a challenge to accelerate the underground development progress by increasing the advance rate of each development round. Surveys have shown that most of the development rounds have only been pulled 84 per cent to 94 per cent of the drilled length. Where bare detonators have been used as primers, less advance rate is expected. In order to obtain a good understanding of the influence of priming upon the advance rate in underground development, a series of high energy primer trials has been conducted by Orica Explosives in the goldfields using various types of Orica high energy Anzomex « primers. It has been shown that development face has been pulled an extra 140 mm to 420 mm by priming with Anzomex « K primers compared with conventional primers. From all the trials at different sites, we have seen that the face pulled using K primers was more square than that pulled using conventional primers. Virtually, no butts and toe were left on the face developed using K primers. Computer simulation has been conducted using either a conventional primer, a bare detonator or a K primer as initiator. The study compared the predicted crack patterns developed around the toe of the hole and it was deducted that a detonator-initiated hole would leave a butt some 200 mm longer than that from a conventional primer-initiated hole, and a K primer-initiated blasthole would give rise to stronger initial p-wave, promoting crack development around the toe and increasing the ability to pull close to the full depth.

Jan 1, 1999

By M A. Llano-Serna, D J. Williams, L Bu

Tailings dam failures continue to occur worldwide at an unacceptable rate, averaging two events annually over the last 100 years. Furthermore, tailings dams continue to grow in size, increasing the potential release of tailings and water should they fail. Tailings are generally deposited in a slurry state, with the potential to flow if containment is lost. Understanding the generation and propagation of excess pore water pressure on failure is critical to predicting the flow and run-out of tailings. This paper presents numerical modelling using the material point method indicating that tailings run-out processes may be self-enhanced by the excess pore water pressure induced during the collapse of the containment. Moreover, it is shown that geomorphological features, such as the slope and its surface roughness downstream of the tailings dam, influence the pore water pressure dynamics upstream of the advancing toe.CITATION:Llano-Serna, M A, Bu, L and Williams, D J, 2018. Excess pore water pressure induced during tailings run-out, in Proceedings Mine Waste and Tailings Stewardship Conference 2018, pp 377–383 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 23, 2018

By S Udayakumar, S Biswal, N Sarmadi, V Sahajwalla, F Pahlevani

Recent times have witnessed a notable momentum in the interest surrounding technology dedicated to harnessing waste as valuable resources, prompted by the mounting challenges posed by waste accumulation and the swift depletion of natural resources. The carbon dissolution process within a molten iron bath stands as a pivotal reaction within the metal processing sector. The current study explores the utilisation of waste graphite electrodes (WGE) (obtained after being utilised in an electric arc furnace) as a secondary resource of carbon for dissolution into liquid iron. Experimental investigations were carried out at 1550°C using the sessile drop approach. High purity iron powder was used and the carbonaceous substrates were prepared from the ground WGE. The carbon pickup was determined using a suitable carbon analyser. Furthermore, an examination of the interfacial area between the molten iron and the WGE substrate was conducted beneath the metallic droplet, which effectively represents the iron/carbon interface. This interfacial analysis was carried out on two different samples obtained after a varying period of heat treatments at 1550°C. The interface layer was investigated using scanning electron microscopy (SEM) in conjunction with energy-dispersive X-ray spectroscopy (EDS).

Jun 19, 2024

By D Felipe, G J. Harbort

In the past 40 years substantial changes have occurred in flotation machines. This has included increases in mechanical cell size to 630 m3 , significant changes to flotation column aeration design and widespread use of the Jameson cell and other pneumatic flotation cells. Over the corresponding period there has been increased used of machine characterisation measurements to benchmark and optimise flotation circuit performance. JKTech maintains a database of industrial flotation machine characterisation measurements. The database contains over 4000 entries and includes gas dispersion measurements, such as bubble size, gas hold-up and superficial gas velocity, cell dimensions and impeller tip speeds. Data comes from numerous operating sites and commodity groups, including gold, copper, molybdenum, nickel, palladium, lead-zinc, platinum, silica, phosphate, coal and iron ore. Flotation duties registered include flash flotation, preflotation, roughing, scavenging and cleaner circuits. Measurements have been conducted on a wide range of flotation machines from different manufacturers. This includes forced air machines, such as Outotec and Dorr Oliver, and self-aerated machines, such as Denver and Wemco. The database also includes substantial flotation column entries, such as the Microcel, Eriez/CMT Slamjet and Jameson cell. This paper describes the flotation machine characterisation database and discusses the variation between different types of industrial flotation machines, in operating production circuits.

Aug 24, 2022

By S Kost, R Nievergelt, F Cortes

In recent years, the use of steel fibre-reinforced concrete (SFRC) for segmental tunnel linings has become increasingly popular due to numerous advantages including durability, resistance to spalling, reduced cracking at corners and edges and significant cost-saving potential. One of the key parameters for measuring the performance of SFRC is the residual (post crack) flexural strength. A problem often faced in design and quality control of SFRC is the high variability of results obtained by standard beam test methods, with reported coefficients of variability (CoV) in the order of 25 per cent. The high test variability results in a relatively low permissible design strength relative to the average flexural strength of the material and commonly leads to non-conformances with respect to residual flexural strength during production testing.This paper presents the implementation of an alternative testing method using large round determinate panels (RDPs) for quality control testing of the SFRC used in the segmental lining of the City East Cable Tunnel (CECT) in Sydney. The alternative RDP test method was found to correlate well with standard beam tests and significantly reduce the variability of test results, minimising the risk of outlying residual flexural strength results, with zero non-compliant test results reported during the production period.This successful implementation of an alternative test for post-crack flexural strength with lower variability in results constitutes a relevant precedent to demonstrate the feasibility of this approach which contributes to the development of more cost-effective concrete mixes and minimises the risk for non-compliant results and the contractual disputes that commonly arise from these.CITATION:Cortes, F, Nievergelt, R and Kost, S, 2014. Development of a segmental lining specification for steel fibre reinforced concrete flexural strength testing using round panel tests, in Proceedings 15th Australasian Tunnelling Conference 2014 , pp 461–468 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 17, 2014

By R S. Sing, M D. Yadav, G Udaybhanu

This paper presents the results of the first part of a research project to study the effect of various inhibitors to reduce the spontaneous heating susceptibility of some highly susceptible Indian coal seams. In this investigation 11 inhibitors were chosen and applied at three, five and ten per cent of their concentrations in an aqueous solution for four coal samples collected from four different seams. The susceptibility of coal samples, before and after application of these inhibitors, was determined by carrying out crossing point temperature (CPT) analysis. The findings of this study have indicated that it is possible to retard the tendency of spontaneous heating of Indian coals to a considerable extent by the application of six of the inhibitors studied. Further, these inhibitors were tested in 1:1 combination to study their synergistic effect. Finally the economics of the application of these inhibitors has been analysed and four inhibitors are recommended for field use. These results have direct application to control fire and improve productivity and safety in coal mines.

Jan 1, 2005

By J Dyt, S Lyons

In the mining industry, crusher-related incidents have led to 15 reported deaths in Australia, New Zealand, and the USA between 1998 and 2007 (NSW Government Resources Regulator, 2024). The majority of these fatalities occurred during routine crusher maintenance tasks. A survey of quarry and mine site maintenance staff was completed to ascertain what they thought of such safety device to understand if beneficial and if so reasons if unused. Overall, findings show, staff perceived risks differently, cost, familiarity, device awareness and not front of mind, influenced adoption. This underscores the importance of asking the right questions involving maintenance and safety staff to lead to more proactive risk assessment.

Apr 16, 2024

By P Crorkan

Within the framework in which future exploitations for Codelco-Chile Divisi=n El Teniente are situated, regarding the deepening of its reserves and the geotechnical problems that affect their recovery, it becomes strategic to evolve with new variants, which make deep mining possible. Codelco ChileÆs Divisi=n El Teniente is progressing within its long-term planning the exploitation of a sector called Esmeralda, which includes its removal through the gravitational caving method (panel caving). It is planned to use pre-caving, which basically consists of developing and undermining the undercut level, without having developed the infrastructure of the production and transport levels. This is carried out in order to achieve a better redistribution of the stresses, thus obtaining higher quality in the infrastructure development of these levels as well as less risk. The extraction reserves for this area, estimated through the opportunity cost selection criteria, were determined at 348 million tons with an average grade of 1.014 per cent Cu. The project carried out geological and geotechnical studies in order to prevent the geomechanical risks of the sector to be exploited, which is a site conformed totally by primary ore. Lithologically, it occurs mainly in Andesite, located at the western limit by Brecha Braden Pipe. There are also varieties of porphyries and hydrothermal breaches of anhydrite. The Esmeralda Mine production program will increase from 4000 tpd (average) in 1998 to its 45 000 tpd rate of production estimated for the year 2005. The approved investment for the period 1995 to 1999 is $US 150 million, out of a total $US 213 million for the project. At feasibility study level and before the project, it showed a Net Present Value of $US 342 million, an Internal Rate of Return of 37 per cent and an IVAN indicator of 2.3 for a ten per cent discount rate and a copper price of 100 US cents/lb.

Jan 1, 2000

By A McCallum, J Abols, G Patrick, G Johansen

The authors challenge the traditional thinking that whole ore cyanidation followed by Carbon in Pulp (CIP) or Carbon in Leach (CIL) should be applied as a standard process in the majority of gold processing flow sheets. The concept of whole ore leaching by using cyanide can result in unnecessary environmental and capital risk. Alternative, currently available technologies can be used to provide the desired level of gold recovery at a much lower installed cost and less impact on the environment. Gravity concentration, alone or in conjunction with flotation, can produce a gold bearing concentrate that can then be fed directly to a batch or continuous intensive cyanidation unit. The In-line Leach Reactor (ILR) is an intensive cyanidation unit developed by Gekko Systems of Australia. Advantages of this technology include significantly reduced capital outlays for greenfield plants or plant upgrades and increased investor returns. Reduction of onsite cyanide and carbon inventories improves plant safety, materials handling and site security. By using direct electrowinning to treat the gold bearing solutions produced by the ILR, the need for a conventional carbon stripping circuit is removed. Potential also exists to increase grind size û saving energy, further reducing capital and operating costs and decreasing the environmental impact of a mill. Detoxification of cyanide before the release of solution to the tailings dam can minimise tailings disposal and containment requirements. When used in the right application the proposed process will have little or no impact on gold recovery and may actually increase recovery for complex ores. Areas applicable to this type of treatment include: plants in environmentally sensitive regions, lower tonnage higher grade deposits, coarse gold deposits, and preg robbing ores û some of which may not currently be economically feasible using standard processes and flow sheets. We have provided two examples of such projects, where an alternative to whole ore leach and CIP or CIL has the potential to deliver these benefits.

Jan 1, 2004

By B P. Wrench, N R. Steward, C Wu

A gold mine in southern China has transitioned from an open pit operation to a fully underground mine. An overhand mining method is used which requires the mined stopes to be filled with backfill having an unconfined compressive strength of at least 0.35MPa. Tailings from the process plant is deposited into separate flotation and Carbon in Leach (CIL) tailings storage facilities. The tailings has a high fines content and the thickener on site could only produce a dilute flotation tailings at a solids content of about 30 wt%. This resulted in two undesirable outcomes: the density of flotation tailings in the Tailings Storage Facility (TSF) was significantly lower than planned so that the TSF could not store the life of mine tailings and that the backfill product had to include a high percentage of manufactured aggregate and increased cement content to achieve the required strength. This paper presents results of a tailings study which identified that the flotation TSF would be capable of storing the remaining life of mine tailings if an amended backfill product made up of 100% of flotation tailings could be introduced. A 100% tailings backfill with the addition of 8% cement was developed by classifying the tailings and using the coarser fraction in the backfill. This backfill allowed 60% of the flotation tailings to be placed underground and only the remaining 40% in the flotation TSF. A new thickener was designed and installed to thicken the tailings and rheological testing of the tailings, using a closed loop pilot plant, provided parameters to upgrade the underground reticulation system to deliver cemented backfill to stopes throughout the mine and to deliver thickened tailings to the TSF. The revised design was implemented and has resulted in considerable cost savings. CITATION:Steward, N R, Wrench, B P and Wu, C, 2018. Optimisation of surface tailings storage and tailings backfill – a case study, in Proceedings Mine Waste and Tailings Stewardship Conference 2018, pp 454–464 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 23, 2018

By J Rayner, R P. Langmead, J A. R Coote

Gosowong is situated within the Neogene magmatic arc of Halmahera island in the Maluku province of eastern Indonesia. It was discovered as the result of a rigorous ground reconnaissance program in an area with no previous mining activity. The broad structural setting in the Gosowong District comprises an elongate dome formed by the forceful upward intrusion of magma along a deep-seated structure, resulting in associated tensional fracturing trending parallel to the long axis of the dome. Four copper-gold porphyries and numerous low-grade epithermal veins occur within this mineralised corridor, with the Gosowong Deposit being the only economic occurrence discovered to-date. Gold mineralisation is hosted within multiphase epithermal quartz-adularia and quartz-chlorite fissure veins, breccias, and stockworks. High-grade gold mineralisation is emplaced in two gently south-plunging ore shoots along a 400 m section of the north-striking, east-dipping, Gosowong Fault, the primary control on mineralisation. The Gosowong Fault is believed to be a tensional fracture associated with uplift of the dome. Lithological variation and structural intersections play a large role in grade distribution within the vein zone. Host rocks comprise a wide range of shallow marine, intermediate-basic volcanic and volcaniclastic rocks of ?late Miocene age. The Gosowong gold deposit is a classic example of a low-sulphidation epithermal gold deposit, based on the abundance of adularia and illite in the alteration assemblage, and low base-metal sulphide content within quartz-adularia veins. The indicated resource is estimated at 0.99 Mt at 27 g/t Au and 38 g/t Ag for a total of 870 000 ounces Au, using a cut-off grade of 2 g/t Au.

Jan 1, 1999

By B Dold

Western Europe is a dynamic region, with an emerging co-operation between the individual nations both politically, economically, technically and scientifically. The European Union, today with 15 member States and with a range of central European States applying for membership, is a catalyst for this Cupertino, using a combination of EU funds, for financing research initiatives, and legislation to enhance development of technology and environmental performance. Europe is a major net importer of metals but with a large potential for own production, in particular in the accession countries. The metals and mining sector is furthermore identified as having a large potential to generate wealth both in todayÆs EU and in the future, widened Union. This paper provides a chart of examples on the many research initiatives presently underway in Europe, addressing environmental issues related to mining. The list of programmes and projects does not claim to be complete; it is rather an illustration on the wideness of the approach, describing various ways for transboundary Cupertino. The approach taken by many of the programmes goes beyond the strict ARD scientific area and therefore only a limited number of the many programmes can be identified as ARD research programmes. Also national programmes, without EU funding, are operating, eg in Sweden, Germany, and UK. The picture is continuously changing with new programmes being commissioned and old ones being completed.

Jan 1, 2003

The information age has arrived. In every aspect of life, at the end of the second millennium, computers and information technology have made significant inroads. In mining there has been huge growth in the use of digitally controlled systems. From resource evaluation to mine planning to daily operations, information is being acquired, analysed, modeled and presented, using state-of-the-art information technology. Explosives, too, have moved into the information age. Computer controlled trucks and manufacturing plants have been developed and are now a regular feature on many mine benches. The next challenge for the explosives industry as a whole is to integrate blast initiation with information technology. The benefits are there, both to the supplier and to the end-user. Much has been written in the past about the potential for blast improvement but there are other significant advantages to a digital initiation system. These include security from unauthorised use, stock control and minimisation, reliability through testability and ease of use to name a few. So why is it taking so long? Surely the complexity of an electronic initiation system is far less than that of mobile phones that have been around for a long time. The answer, it seems, lies in the level of new technologies that need to be developed. There are enormous technological hurdles to be overcome in order to put into the market a cost-effective, reliable, user-friendly electronic initiation system. The most significant of these are:Safely and reliably initiating an explosive from an electronic device powered by a small capacitor. Prior to the development of electronic detonators primary initiation of explosives was by shock tube spit or by passing large currents and voltages down a pair of wires. Electronic detonators do not have that luxury. For example the energy stored in a æBeethovenÆ exploder is more than 500 times greater than that available to an electronic detonator. Communicating to a multitude of devices over very long cables installed by miners in harsh conditions. The deployment of an electronic detonator system has been likened to building a large telephone exchange in the rain and getting it to work perfectly first time! New communications protocols needed to be developed and tested. Wiring and connection systems have to be designed to survive the mining environment. In spite of these technological hurdles most of the major explosives manufacturers have persisted with electronic initiation systems and we are now, in 1999, starting to see the results of these multi-million dollar efforts. At SMI we are often asked many questions about this technology. The remainder of this paper seeks to answer those most often asked. As with any business linked to information technology todayÆs breaking news is tomorrowÆs archive and we expect the rate of development and understanding to accelerate as these technologies become accepted by the global mining industry.

Jan 1, 1999

By C E. Gawith

The Waihi underground mining operation currently mines epithermal veins ranging from two metres up to ten metres in width using a ‘Modified Avoca’ stoping method. This method consists of longhole bench stope mining at 15m to 18m sublevel spacing. The bulk of production drilling and blasting is top down with the extraction length of a typical stope panel nominally being 18m to 20m along strike. A stope panel is usually taken in two blasting cycles followed by the remote bogging of the stope ore. The panel is backfilled in-cycle using unconsolidated waste rock material which is tipped into the void from the upper level using a Caterpillar R2900 or R1700 sized underground loader. The underground mine first commenced production in 2008 and up until 2016, as was typical of many open stope mining operations at the time, an underground loader was used to place a waste rock bund at the top brow of the open stope. This rock bund was the principal means of protecting people and equipment from this hazard. In 2016 there was a fatality at the mine when a loader that had been tasked with building this rock bund fell into the stope void. Immediately post incident all mining and processing operations were suspended for a week to allow colleagues to grieve, to observe cultural protocols and to begin the investigation into this event. During this period senior operators, supervisory and technical staff developed an innovative system which used steel bollards to protect this open edge. With development over the following months this bollard system has eliminated this hazard from the Waihi underground mine.

Mar 15, 2021

By L Basnayaka, N Subasinghe, B Albijanic

"It has been recognised that the presence of clay minerals in ores adversely affect flotation performance. In this study, changes in rheological properties of the flotation pulps under normal operating conditions were studied with additions of bentonite and kaolinite clays at various concentrations. Zeta potential measurements were also carried out to determine the changes in surface charge due to adsorption of clay particles. The results showed that bentonite clay adversely affects floatability of pyrite while kaolinite clay had a lesser influence on flotation of pyrite. The addition of Ca2+ ions to the pulp containing bentonite modified the rheological characteristics and in turn improved the pyrite flotation. It was also observed Ca2+ ions suppressed the swelling properties of bentonite and altered surface charge properties of bentonite clay particles. It has been shown that the flow index affected the ultimate recovery and it may provide a means to monitor flotation performance in routine plant operations.Citation:Basnayaka, L, Subasinghe, N and Albijanic, B, 2016. Effect of Clay Rheology on Flotation of a Refractory Gold Ore, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 77–84 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016