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By S J. Loach

Geological reconciliation is an indispensable part of BHP Billiton’s Western Australian Iron Ore (WAIO) operations. Since 2009 our reconciliations have been calculated in a single, centralised sequel-server database. This system draws data from across our operations and calculates a hierarchical sequence of reconciliation factors that span the company from the smallest grade control (GC) block to the whole of WAIO. It then presents the results using sophisticated graphical reporting tools.The initial motive for developing WAIO’s reconciliation system was to meet corporate compliance and public reporting requirements. The ability to validate our resource and reserve models by comparing their estimates of tonnes and grade with production figures remains the system’s principal function; however, as the system has matured, we have significantly developed its ability to support the improvement of various technical activities within the business. For example, the system can now calculate and report reconciliation factors for different resource classifications, short-term planning models and geometallurgical estimates.More recently, great emphasis has fallen on the system’s ability to detect and warn of possible geological issues that may pose a risk to either production schedules or product quality. We envisage a future where automated analysis of our large historical data set will enable high-risk conditions within future mine plans to be detected and highlighted.In all of these ways geological reconciliation plays an important role in contributing to this company’s financial and operational resilience.CITATION:Loach, S J, 2017. The development and future of BHP Billiton’s Western Australian iron ore geological reconciliation system, in Proceedings Iron Ore 2017, pp 415–422 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 24, 2017

By P Hodkiewicz

Recent structural interpretations based on historic stope shapes were used to develop a rapid and innovative method to domain and simulate structurally complex, high-grade gold veins at depth in the Edna May deposit. This involved ‘implicit’ modelling of drill hole data using Leapfrog software, which allows complex wireframe domains to be built and updated rapidly, compared to ‘explicit’ manual wireframing methods that are too subjective and time consuming. Conditional simulation was used for resource estimation, in order to simulate the highly variable gold grades associated with the veins. Similar modelling methods could be used to determine the mining potential of other historic gold deposits that are receiving renewed interest because of the high gold price.Gold at Edna May is hosted in the Edna May Gneiss, which is a WNW-striking tonalitic intrusion along a shear zone that dips approximately 45° towards the NNE. Gold occurs in multiple 0.5 - 5 m thick arcuate quartz veins that plunge steeply towards the west. Two phases of historic underground mining at Edna May (1911 to 1922 and 1935 to 1947) produced 360 000 ounces of gold at an average grade 19.5 g/t from seven ‘reefs’ to a depth of 240 m. This established Edna May as one of the highest grade gold mines in Western Australia at the time.Recent drilling by Catalpa Resources confirmed the potential for down-plunge continuity of high-grade veins. New structural interpretations, based on historic level maps and wireframe re-constructions of the arcuate stope shapes, were used as ‘structural trends’ in Leapfrog to model the mineralisation. The resulting wireframes capture the complex distribution of gold in the deposit and were used as domains for resource estimation.Conditional simulation using the Turning Bands method was used to simulate the expected variability of gold grades associated with this mineralisation style and the median of the 100 realisations was used to report an inferred resource. Results of this modelling method are being used to target vein extensions at depth, to consider different underground mining scenarios, and to assess the risks associated with developing and mining this high-grade and high-nugget gold deposit.

Aug 22, 2011

By B P. Banerjee, S Raval

In the recent past there have been dramatic advancements in the development of remote sensing platforms (satellite, aircraft and unmanned aerial vehicles – UAVs) as well as sensor systems (multispectral, hyperspectral, thermal, light detection and ranging (LiDAR) and radar). However, selection of the appropriate remote sensing technique for a mining application is complex and requires scrutiny on multiple scales including spatial, temporal and imaging capabilities. This presentation highlights various conventional and emerging remote sensing approaches over a mine’s life.CITATION:Banerjee, B P and Raval, S, 2016. Applications of advanced remote sensing systems during a mine life, in Proceedings Life-of-Mine 2016 Conference , pp 116–120 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jun 28, 2016

By J K. Claflin, S R. La Brooy, A M. Claflin

Rotary kilns have been in service in the gold industry to regenerate carbon for 65 years. At the time oxide ores with gold head grades of 8 to 10 g/t were being treated. Carbon could be regenerated adequately at 650°C and solution losses were less than 1%. Forty years ago, research indicated that heavily fouled carbon from flotation circuits had to be held at 750 to 850°C for ten to twenty minutes for full reactivation (Avraamides and La Brooy, 1987), gold head grades were typically 5 g/t and solution losses typically 0.02 ppm – still less than 1%. In 2017 it was determined (Claflin et al., 2017) that a residence time of less than 1 minute at 750°C can be adequate to reactivate carbon fouled with organics sufficiently to achieve 0.005 ppm solution losses in a flotation tailings leach plant.With the potential for discovery head grades to drop below 0.6 g/t, solution losses of 0.02 ppm represent over 3% loss. Tight operation of the whole carbon circuit is required to keep gold solution losses below 1% going forward.There are alternatives to a rotary carbon kiln, e.g. vertical kilns of which the Minfurn, Rintoul and Combustion Air kilns are examples. The alternative kilns can be heated using electrical heating elements, induction, and microwave. These kilns can operate successfully under the right conditions, however, they are almost exclusively for small carbon throughputs and are not suitable for the large carbon advance rates that are required to process low head grade ore deposits. Large throughput carbon kilns are are almost exclusively fossil fuel fired rotary kilns and the subject of this paper. In the view of the principal author, a fossil fuel fired vertical carbon kiln is preferred to a rotary kiln, however, it is not currently used in the industry.Thermal regeneration of activated carbon has a major impact on gold recovery in the carbon circuit. The carbon kiln and associated equipment constitute 3 to 5% of the capital cost for an oxide processing plant and up to 10% of the capital cost if flotation tails are leached. Despite the capital cost and impact on recovery, the carbon kiln is often poorly selected, operated and maintained.Six years ago Ausenco embarked on the Carbon Kiln Initiative to reduce solution gold losses. This body of knowledge has been published in a series of papers culminating in this paper on how to:1. Select a kiln appropriate for the flowsheet;2. Maintain the kiln to achieve design operation; and3. Operate the kiln to minimise costs and maximise reactivation.CITATION:Claflin, J K, La Brooy, S R and Claflin, A M, 2018. Carbon kiln selection, operation and maintenance, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 251–274 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

By P Cavieres, R Dunlop, S Gaete

El Teniente Mine started the exploitation of the primary rock in the beginning of the 1980s decade, using caving methods. Since the beginning the mining activities have induced seismicity including some occasional rockbursts. Owing to the relevant damages, the mining operations were stopped in some production sectors. This paper describes the concepts that have been used in order to control the induced seismicity based on the strategies for controlling the rockmass breaking process, which depend on mining parameters. It also presents the main concepts applied in the Teniente Sub6 sector design and the experience collected during its sector exploitation.

Jan 1, 2000

By S Juras

The terms measured resources and proven reserves denote the highest level of estimation confidence in all of the major classification schemes. But what do they really bring to today’s project or mine with respect to production planning and expectations? Initial reserve declaration does not need measured resources, just indicated resources. Economic viability of a project is assessed on total reserves with nary a bonus for the amount of proven reserves. Production plans are based on grade and tonnage goals that may only coincidently correspond to proven reserves. So are the measured and proven categories still relevant? Historically, and almost exclusively in underground mines, companies only allowed mining in areas of proven reserves. Some companies still follow that philosophy. But many others will mine a mixture of probable and proven reserves without hesitation. Also what of the undeveloped project in a new district – what is to be made of their declared measured resources and proven reserves? Measured resources are commonly set either by some type of proximity to data scheme or a matter of ‘feel’ based on the qualified person’s experience. The parameters for reserve conversion focus on the project as a whole and then a portion becomes classified as proven reserves almost solely based on whether the resource category is measured. So should the mining industry continue to use these categories of resource and reserve classification? This paper will present arguments about making these categories once again more relevant. A more disciplined usage of these categories may re-introduce their relevancy in public disclosures of resources and reserves. As well a more consistent usage in operations may lead to increased confidence in managing production targets and costs.

Aug 22, 2011

By J Safarian, D Hariswijaya

Treating bauxite residue as an alternative source of metals for iron and aluminium industry is an approach to promote circular economy in metal industries. Reduction of metal oxides with H2-based process is an important step on decarbonisation of metal industry. In this study bauxite residue pellets were prepared and were reduced with different H2-H2O gas compositions at different temperatures which yielded with various degrees of reduction. The bauxite residue pellets were made from a mixture of bauxite residue and Ca(OH)2 powders and sintered at 1150°C. Hydrogen reduction was carried out on the oxide pellets using a resistance furnace at elevated temperatures in controlled reduction atmosphere of H2-H2O gas mixtures which resulted in reduction of iron oxides in the pellets. Unreduced and reduced pellets were subsequently heated to 1400°C to study their smelting behaviour using differential thermal analysis (DTA) and thermogravimetric analysis (TGA) technique to investigate the evolution of phases related to slag formation via smelting. Equilibrium module of Factsage™ ver 8.1 was utilised to analyse results of thermal analysis. It was observed that Tricalcium phosphate-β (CaP2O8), Bredigite (Ca7Si4MgO16), Rankinite (Ca3Si2O7), and calcium alumino ferrite (Ca[Al,Fe]6O10) were formed during thermal analysis as intermediate phases. The initial slag formation for sintered and reduced pellets occurred at 900°C which mainly contains calcium and small amount of strontium component. The slag formation rate increases significantly starting from 1100°C when iron oxides started to form initial molten slag phase which then followed by other oxides dissolution in the system. Gas formation was observed at 1180°C and it was found that the gas to be released from unreduced pellets is O2 meanwhile the gas to be released from reduced pellets is SO2 gas. Gas formation rate for both pellets start to increase at 1280°C when the remaining chemically bonded gas start to be released from the system.

Jun 19, 2024

In October 2005 Phelps Dodge mining, a US based company, visited several Australian mining companies and mine sites to ascertain the current applications of risk management methods in the organisation. The results of this review, documented by the author, indicated a ælayeredÆ approach from high level site or major hazard analysis through to face level, æstop and lookÆ, methods. The approaches of several companies were summarised in one simple layered model. This model is helpful to other sites and companies to identify potential improvements but also offers an image of best practice that may assist with the governance of OH&S by both company boards and community regulators. The issue is particularly relevant as we discuss national consistency in mining regulation. This paper examines the layered model, the company and site approaches that helped define the model, as well as the suggested implications of the layered model to governance.

Jan 1, 2006

By D Liang, L Zhang, X He

The sulfurisation-flotation process was unsuccessful when initially applied to the oxidised Pb-Zn ore in Lanping County of Yunnan Province China. A comprehensive mineralogical study indicates that the problem is caused by the soluble salt gypsum in the Lanping oxidised ore, which produces a large amount of Ca2+ cations. The Ca2+ cations react with S2- anions (from sodium sulfide) in preference to Zn2+ and Pb2+ forming calcium sulfide, and make it difficult to form zinc and lead sulfides on the surfaces of the respective oxidised Zn and Pb minerals. In addition, the calcium sulfide formation consumes a large quantity of the available sodium sulfide, further inhibiting the sulfurisation process. The efficiency of the sulfurisation of oxidised Zn and Pb minerals has been improved greatly by the pretreatment removal of gypsum, with the added benefit of the required dosage of sodium sulfide being substantially reduced.

Jan 1, 2008

By P Hucker, E Hall

Harmony Gold operates the Mount Marion underground gold mine near Kalgoorlie, Western Australia. The mine consists of two ore zones, East and West, and mining of these zones is currently conducted using the sublevel caving method. When mining commenced in the Western zone, the span was insufficient to induce caving of the country rock above. Dyno Nobel, together with Harmony and 360 Drilling, developed an innovative drill and blast solution in order to promote cave propagation and improve the safety of personnel at the operation. The solution involved a series of shallow angle drill holes up to 90 m into the hanging wall of the West zone. These were charged with Titan« 7000 underground bulk emulsion and the HotShotÖ electronic initiation system. The blast used over seven tonnes of emulsion and 46 detonators and achieved the desired result without damaging nearby mine infrastructure.

Jan 1, 2007

By Neill B. K, Fander H. W, Wong K, Dunlop G, O&apos

Commercial interest in refractory gold is increasing rapidly. This trend is supported by the work patterns of Amdel, where, apartfrom routine process- ing of free-milling and refractory ores, the majority of testing now includes biological and pressure oxidation studies to enhance gold recoveries. Central Mineralogical Services have examined, among other ores, an apparently unique type of refractory coating. A summary is given of experience at Optimet Laboratories, Pty., Limited. Research into nitric acid pre-oxidation, underway at the South Australian Institute of Technology since 1987, has shown significant improvements in gold recoveries, and in some cases, large reductions in reagent consump- tions. Three final-year student research projects were undertaken in 1990, jointly between the University of Adelaide and the S.A. Institute of Tech- nology. These projects involved biological pre-oxidation, pressure leaching, and Scanning Electron Microscope examination of refractory ores, and the resultant pre-oxidation and cyanidation products.

Jan 1, 1991

The use of ammonium nitrate/fuel oil explosives is.now well established in most open cut mining operations. Its use. is extending to underground mining. This has been due in a large measure to improvements in the nature of the ammonium nitrate made available from various sources. The addition of surface active agents and water in controlled amounts to the fuel oil has been found to increase the sensitivity of the ANJFO mixture with consequent better explosive properties. It is considered that the surface active agent increases the bond between the ammonium nitrate and fuel oil giving a more, intimate physical and chemical mixing of the oxidising and reducing agent. This results in increased sensitivity and a faster rate of reaction. The increase in sensitivity has been accomplished without any diminution of safety. Tests which demonstrate the safety of this type of explosive are given in the appenuix.

Jan 1, 1964

By D M. Weedon

This paper introduces a novel roll crusher design, which incorporates non-cylindrical crushing rolls. The use of non-cylindrical rolls enables the crusher to achieve a greater reduction ratio than is possible with conventional roll crushers. Referred to as the NCRC (non-cylindrical roll crusher), the new crusher incorporates two rolls comprised of an alternating arrangement of plane and convex or concave surfaces. The two rolls are complementary and arranged so that when they rotate the convex and concave surfaces of each roll are substantially opposed. With the rolls rotating in opposite directions at the same speed, this arrangement produces a gap between the rolls that remains approximately constant. Discontinuities on the roll surfaces provide improved angles of nip, which increase the probability of larger particles being drawn into the crusher. Initial tests on a scale prototype of the NCRC have indicated that reduction ratios exceeding 10:1 are achievable.

Jan 1, 2000

By Favreau RF

Over the last 20 years the blasting industry has progressed from the stage of being artform to a science as it is today. The use of computers to simulate blasting results has allowed blasting engineers to accurately pre- dict blast results and to optimise their blasting. This paper describes the computer blast simulator called BLASPA and its various applications in blasting. BLASPA allows the blasting engineer to predict blast results given known details of explosive properties, their distribution, rock type and properties, hole size, burden, spacing, collar and subdrill. The simulator runs mathematical situations and outputs numerical estimates of fragmentation and muckpile results. The paper discusses results which show that the mathematical outputs correlate very closely with actual results seen in the field, thus confirming the validity of the simulator. BLASPA can be used to help improve blast design by predicting stress levels in the rock mass and consequent rock breakage.

Jan 1, 1986

By Finch W, Dunne R

Understanding how liberated and unliberated minerals behave in comminution and classification circuits is of vital importance to ensure that maximum liberation occurs without unnecessary and costly overgrinding. This paper presents the results of a study carried out by the Julius Kruttschnitt Mineral Research Centre and Newcrest Mining of the liberation performance of Newcrest Mining's New Celebration grinding circuit. Using data from surveys of the circuit, together with QEM*SEM analyses of individual streams, a detailed picture of the liberation and classification of gold-associated pyrite is presented. In addition the relationship between the QEM*SEM analyses and results from laboratory leach tests are also discussed. Using the survey and QEM*SEM data, mathematical models were constructed of the performance of the ball mill and cyclones, and simulations carried out to investigate ways of improving the performance of the circuit. The results from the more promising scenarios are Reviewed.

Jan 1, 1993

By O Dominguez

Mine value chain reconciliation (MVC) is a necessary procedure to evaluate a mine’s performance against the assumptions and models used to plan mining and processing operations. Using nomenclature from Parker (2012), F2 reconciliation is the ratio between material received at the mill, compared with material sent to the mill, commonly reported in terms of tonnes, grade and metal. Measurements of material sent to the mill can be estimated in many ways, including: fleet management system (FMS) records, truck counts, or volume reduction. Most time-based reconciliations (for example, month-end reconciliation) use short-term model depletions of in situ rock measured by periodic topographic scans or surveys.

Mar 22, 2022

By M R. Drumond

The present work presents a new theoretical interpretation of the flotation process, which can also be applied to other mineral processing physical unit operations. This interpretation is part of the æModelo OperacionalÆ (Operational Model) that was developed as an attempt to establish a new theoretical basis for mineral processing unit operations. In the case of flotation, a book was edited by one of the authors in Brazil (Mass Concentration by Froth Flotation, in Portuguese and Spanish).The model establishes a link between a natural phenomenon (migration of particles from the pulp to the froth) and a real industrial phenomenon (mass concentration by operational interference). In this model, flotation is viewed as a phenomenon of macromolecular mass transport (of particles) between froth and slurry phases. Mechanisms for mass transport and particle flow between phases as a function of the hydrophobic potential in each phase are discussed. By establishing the so-called equilibrium distribution curve between phases it is possible to calculate macroscopic balances that are related to metallurgical results, which in turn are a function of the operational line that is required by the process itself. The number of cleaning stages and their efficiencies can also be determined by simple laboratory-scale experiments.

Jan 1, 2005

By J W. Glatthaar, M Mavotoi

The occurrence of fluorine in the copper/gold concentrates produced by Ok Tedi Mining Limited has provided a series of challenges to metallurgists since 1988. Although fluorine is distributed throughout the gangue minerals contained within Ok Tedi ores, itsÆ presence in talc and phlogopite (naturally floating fluorosilicates) has proven to be the predominate sources of fluorine in the final concentrate. Initial treatment for the fluorosilicates consisted of the use of a carboxy-methyl cellulose depressant added to the flotation cleaners. This was superceded in 1998 with the installation of a fluorine reverse flotation process for the removal of naturally floating fluorosilicates from the final concentrate when the fluorine content of the final concentrate exceeds smelter-defined trigger points. The fluorine reverse process is similar to by-product molybdenite concentrate production in that sodium hydrosulfide is used to depress copper/gold flotation whilst allowing the fluorosilicates to float. The process was installed in two parallel modules (to match the existing grinding/flotation modules at Ok Tedi), each consisting of a closed rougher/cleaner circuit configuration. Both rougher and cleaner cells are Jameson Cells from MIM Process Technologies, with the selection based on both processing characteristics and available construction space. This paper discusses both the nature of fluorine in-, and its removal from-, Ok Tedi copper/gold concentrates.

Jan 1, 2003

By V O’Brien

The suitability of magnetic surveys flown at low altitudes to identify buried heavy mineral (HM) strands has long been accepted. This is despite the low intensity magnetic response often obtained from such strands. The fundamentals of the magnetic survey method dictate that the closer the instrument is to the source the stronger the response. As such the optimal elevation for the magnetometer is at or near the surface. Iluka sought to use a ground based magnetometer to aid in the exploration target generation process and allow accurate targeting of exploration drill holes. Following the initial trial Iluka recognised the potential additional application of data obtained by a ground based magnetometer over known strand deposits. The detail of the ground magnetic images can confirm the assumed strand continuity between cross-sections of close spaced drilling and can aid in the definition of the geometry of different generations of mineralisation. The ability to confidently determine that the deposit has not been truncated by post emplacement erosion of the mineralised deposit may enable reductions in drilling requirements as well as assisting mine planning activities. Iluka intends to investigate advanced modelling of the magnetic data to determine the level of strand geometry and HM content resolution that can be achieved from the ground magnetic survey data and its potential application in the mining grade control process.It is anticipated that the surveying of Iluka’s known resource deposits will provide the ability to correlate the magnetic response from new exploration targets with those from known deposits for a given depth, HM grade and mineralogy suite.

Oct 5, 2011

By Innes J. A

The structural variations occurring in pellets of finely divided mixtures of iron ore and coke breeze, metallized by firing at elevated temperatures, have been examined microscopically. For any given pellet composition, time and temperature are the two most important factors in determining the development of the bonding processes.INTRODUCTIONThe success of sintering and pelletizing processes in the agglomeration of fine iron ores for blast furnace use has brought about rapid changes in thinking relative to methods of preparing furnace burdens. Increases in productivity with the use of sinter emphasize the advantages of a stable, uniformly sized furnace feed. Current practice is to produce a self-fluxing sinter containing most of the lime requirements of the furnace incorporated as a stable medium (Figgis and Charker, 1962). The elimination of fine material from the burden allows greater stack permeability and smoother operation.Sintering and pelletizing of iron ores with or without the incorporation of fluxing compounds has conditioned operators to the extent that it is now considered possible that all components of the burden may eventually be beneficiated in one form or another. Investigations are in hand to improve the quality and sizing of coke, which occupies the major part of the burden volume (Callcott, Innes and Brown, 1961; Innes, Gregory and Worner, 1963). Interest is also being revived in methods of pre-reducing iron ores prior to charging to the furnace (Hansen, Melcher and Fine, 1961). Recent experiments in a small experimental blast furnace (Melcher, 1963) show that charging of semi-metallized pellets can give rise to a production increase of 55 per cent...

Jan 1, 1963