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By T Cutts

Since 1989 Kalgoorlie Consolidated Gold Mines has managed the Kalgoorlie gold operations of joint venture partners Normandy Mining Ltd and Homestake Gold of Australia Ltd. Current production from the Fimiston Open Pit is approximately 650 000 ounces per annum. The mine incorporates a multitude of narrow shear hosted, subvertical lodes, predominantly within Golden Mile Dolerite. Traditionally KCGM has used blasthole based grade control in the Fimiston pits. A single sample is taken from vertical production blastholes, drilled on ten metre benches. This process was improved with the addition of infill drilling along blasthole rows to provide additional samples across strike. However the limitations of adequately defining subvertical mineralised structures with vertical blastholes remain. In 1997 the first of two trial areas were drilled with close spaced, inclined Reverse Circulation (RC) drilling. These tests indicated that RC based grade control had the potential to provide significant advantages. These include:improved delineation of mineralised structures, particularly across strike; reliable short-term mine schedules based on the advance data available from drilling over three benches; and the angled RC drilling is capable of providing samples of near stope and stope fill material which often remains unsampled by blasthole drills due to the safety constraints around unstable underground openings. Based on the success of this initial work RC based grade control was gradually implemented across production areas commencing September 1998. Some of the many challenges faced include:development of effective procedures and systems for the planning, logging, interpretation and modelling of the RC data; obtaining adequate drill coverage due to mine scheduling constraints and restricted access around underground openings; requirement for integrated systems to handle either blast hole or RC data; and development of effective methods to evaluate the performance of RC grade control. RC based grade control is delivering significantly improved lode definition, grade estimation and subsequent ore classification.

Jan 1, 2000

The purpose of this paper is to explain the basic structure of how minerals are marketed, whilst highlighting the essential factors that mine management needs to be confident are incorporated into a mineÆs marketing strategy. The traditional mine management approach to marketing has been to defer its scrutiny to the marketing manager and take a largely passive role. It is this paperÆs assertion that mine management needs to become more proactive and provide greater strategic input into the marketing process. Irrespective of what mineral your mine produces, the key marketing principles remain constant and need to be understood and managed to extract the full benefit on behalf of the mining asset. From a mine management perspective, success is ultimately linked to understanding these marketing principles and ensuring that they are effectively addressed by your mineÆs marketing strategy. This paper will unashamedly attempt to simplify marketing by explaining how the basic fundamentals of supply and demand set market direction, the importance of a comprehensive marketing strategy, the importance of customer relationships and how contracts and prices are typically negotiated. This paper will use examples from the metallurgical coal (met coal) industry to highlight these points. The paper will also provide a template for developing the critical mine interaction that needs to exist between the marketing department and management to develop a æwhole of mineÆ approach to marketing. It is this core group that will be strategically responsible for delivering the commitments your mine has made to your customers. For mine management not to be actively involved in this process puts at æriskÆ the hard won production and cost efficiencies achieved at your mine and ignores the opportunity to maximise your current and future revenue streams. And whilst this paper recognises that is arguably unreasonable for mine management to become æmarketing expertsÆ, it also argues that it is unreasonable for a mine management to divorce themselves from the process.

Jan 1, 2006

By D McClelland, R Whittering

Minerals and Metals Group (MMG) subsidiary Lane Xang Minerals Ltd operates a single site copper and gold mine near Sepon in Lao PDR. Gold production commenced in 2002 and first cathode copper production was in March 2006. Plant throughputs for gold and copper are currently 2.5 Mt/yr and 1.4 Mt/yr respectively; use of a second tailings dam has commenced accordingly. Although the increased catchment area creates opportunities for more storage to reduce demand on other water sources, especially during the dry season, it also creates greater requirements for water treatment capacity.The water balance for mining operations in a tropical monsoon environment with dry winters presents on going management challenges. A successful mining operation depends on a careful balance of water inputs and outputs. The challenge prior to every wet season is having enough storage capacity to absorb potential rainfall. Plant operation in the dry season benefits from water captured and stored from the wet season which reduces the dependence on river water. Release of excess water to the environment is necessary to cope with the overall positive water balance and depends on suitable and effective treatment of water in accordance with the environmental guidelines.Ausenco has recently built and commissioned a second water treatment plant at the Sepon Copper Plant to process tailings decant water.  The objective of the second Sepon water treatment facility is to increase the site water discharge capacity to maintain the water balance and reduce the dependence on river water.  Decant water treatment is required to precipitate the contained heavy metals prior to discharging to surrounding wetlands.  The main metal that needs to be removed from the site water to meet discharge water quality requirements is manganese, as heavy metals are already precipitated to required levels in neutralisation before the tailings are sent to the storage facilities. A site layout provision for removal of manganese to produce a saleable carbonate precipitate is incorporated in the polishing plant design (future installation).

Jan 1, 2009

By A Radici, S Russell

The Dampier Port Upgrade was completed in 2007 and is the largest project in Rio Tinto Iron Ore's expansion program. The project doubled Dampier Port's iron ore shipping capacity over a five year period. Sinclair Knight Merz (SKM) was appointed by Rio Tinto as the Engineering, Procurement and Construction Management (EPCM) contractor to manage Phase A and Phase B of the Dampier Port Upgrade. The aim of the project was to increase the Dampier Port capacity from 74 to 140 million tonnes per annum (Mt/a). This increase in shipping capacity tripled the capacity of the Parker Point facility from 34 to 94 Mt/a, whilst the East Intercourse Island facility increased from 40 to 46 Mt/a. The Dampier port remained fully operational throughout construction and achieved record yearly export tonnages over the period of the project. The $US1.4B project was completed ahead of schedule, on budget and with an outstanding safety record. Significantly the project team set an industry benchmark by achieving five million man-hours Lost Time Injury (LTI) free. The project has been recognised by the Engineers Australia 2008 Western Australian Engineering Excellence awards as category winner in resources and the overall winner in WA, and went on to win a National Engineering Excellence award. This paper provides an overview of the EPCM project management and an insight into some of the key drivers that have delivered this outstanding project.

Jan 1, 2009

By C Chen, W J. Bruckard, F R. A Jorge

The base metal industry mines and processes hundreds of million tonnes of ore per annum to produce saleable products and large tonnages of waste by-products such as tailings. These ores usually contain less than 1 wt per cent of toxic elements (As, Sb, Bi, Cd, Se, Te, Hg, etc), which are subsequently treated with the other components in the ore during the production of concentrate through to saleable metal products. The deportments of minor elements across the various unit operations of a process flow sheet do not normally receive the attention that the major elements receive. However, these minor elements can have a major influence on the quality of the products as well as an economic and environmental impact. Therefore, a high degree of control over their deportments is a key step in reducing their dispersion in the biosphere. Ongoing work at CSIRO has been examining minor element deportments across unit processes used for smelting and refining and the options for early removal of minor elements, as well as methods for safe disposal of some toxic elements. This paper provides an overview of the R&D activities undertaken at CSIRO to develop tools and methodologies for improved management of minor elements during the processing of sulfide ores.

Jan 1, 2006

The Barmac autogenous crushing mill is one of the most successful new comminution technologies to become available to the mining and industrial minerals industries in this decade.   The Barmac autogenous crushing mill is an innovative Vertical Shaft Impactor which operates in essence like a high intensity dry ore centrifugal pump with the reduction occurring primarily as a result of high velocity rock to rock impact in a fully rock lined crushing chamber.   With applications in a wide range of mining and industrial minerals operations the Barmac autogenous crushing mill presents an opportunity to enhance reduction and liberation whilst providing many cost savings and production increases in new and existing plants.   This paper briefly describes the operation of the Barmac autogenous crushing mill and reviews its benefits.

Jan 1, 1990

By Wright D. J

Successful heap leaching depends on three major factors: 1. Chemical conditions appropriate for the dissolution of the valuable metal; 2. Contact between the leach solution and the valuable metal particles; and 3. Movement of the leach solution through, and out of, the heap. Given that appropriate chemical conditions can be provided, and the individual particles have sufficient permeability to allow solute/solvent contact, the problem of getting the solution to and from the particles remains. Non-uniform percolation of solution throughout the heap, caused by the presence of fines, is a common problem which occurs, to some extent, with all heap leachable ore. The conventional solution to this problem is agglomeration, which involves the attachment of fine particles to larger particles, effectively modifying the size distribution by preventing the fine particles from acting on their own. While agglomeration must be considered as an extremely effective technique with virtually no limit to its application from a technical point of view, its application is limited by economic considerations. A new technique has been developed which is not only a low cost alternative to agglomeration, but also has the potential for enabling the application of low cost heap and vat leach techniques to a significantly wider range of ores than current practice would suggest. The new technique, known as Electrokinetic Leaching, utilises electro-osmotic flow to enhance percolation through the heap. This paper describes and presents results of the laboratory testing, pilot heap operation and commercial application of Electrokinetic Leaching of a low grade gold ore and a tailings deposit. Comparative cost analyses between conventional and the alternative processing techniques are presented.

Jan 1, 1994

By Wu H. W, Just G. D

Australia's mineral resources boom in the two decades up to 1980 saw the establishment of about 25 new mining towns across the continent Quality housing and a high standard of community services were incorporated to attract a labour force for the major mine or mines i eing serviced. Town construction costs were high and were principally born by the private enterprise mine developer. There has been a change in the pattern in recent years and over 20 new mine developers have adopted a fly-in fly-out arrangement rather than construct new towns. Employees are drawn from a home base which is typically a large city, coastal community or established mining town and flown to the mine site for intensive work periods of about two weeks. The change has occurred for many reasons. Mining companies have been unwilling to support the high construction costs of towns, short life and smallermining operations do not justify a town, fast jet aircraft are available and there is a better perceived family lifestyle in established (coastal) communities. On the other hand reduced permanent development at new mine sites does not assist Australia's perceived need for decentralization. There have been questions as to the social problems which may develop from the artificial separation of the "breadwinner" from his family. The paper reviews a recent survey of the attitude of Australian mining companies employees, governments and unions to fly-in fly-out arrange- ments. The support for this approach is analysed and conclusions drawn that the concept is likely to be with the Australian mining industry for some time in the future.

Jan 1, 1991

Rare-earth permanent magnetic roll separators, pioneered by our group a few years ago, have distinctly different operation characteristics compared to prior art electromagnetic separators of various types. Many new applications for dry high-intensity (or better: high-force) magnetic separation have been developed in a short time period. It has also been found that the new generation of separators generally are more efficient with regards to removal of weakly magnetic contaminants in glass and ceramic raw materials with minimum loss of valuable product compared to induced magnetic roll (IMR) separators.The latest development is in the area of production of clean magnetic concentrates at high recoveries. It is likely that the PERMROLLR magnetic separator will replace cross-belt and lift-type magnetic separators as a result of this most recent advance.The paper will review the features of the PERMROLLR magnetic separator in comparison with other types of magnetic separators on the market and give examples on applications.

Jan 1, 1990

By M Dickie

During the 1980s and early 1990s low cost gold treatment plants were at the forefront of the Australian engineering and mineral processing business. This opportunity was the result of a high gold price and innovative design by emerging engineering companies in an expanding market. The low cost approach to gold plant design and project execution resulted in smaller and shorter life projects becoming viable and the multiplicity and fast track approach of the projects resulted in sharp learning curves. From the mid 1990s to the early 2000s the relatively low commodity prices and resultant reduction in minerals opportunities also resulted in innovative design in both small and large plants, albeit on a reduced scale. The innovation was associated with alleviating capital cost pressures for large capacity low-grade (eg NewcrestÆs Cadia) or small-scale (eg JubileeÆs Cosmos) projects to either improve NPV or to enable the project to be won and profitable in the competitive lump sum environment. Between 2004 and 2008 the engineering market became less competitive from an engineerÆs perspective due to the high demand for engineering services in a high price commodity market. The need for innovation remained but was driven overtly by shortages in water, power and personnel and long equipment lead times. This paper discusses some of the factors that contribute to the capital cost of a project and the scope for improving the likelihood of financing and increasing the project net present value (NPV). Case studies with recent large copper concentrator projects will be used to demonstrate how a value driven approach to project and plant layout can result in significant improvement in NPV.

Jan 1, 2009

East Otago gold deposits are hosted in Otago Schist that is the metamorphosed equivalent of Permian-Triassic Torlesse terrane greywackes. Relatively undeformed Torlesse sequences in Canterbury have <l m - 50 m bedding, with c. 500 m - l km and c. three kilometre scale units, typically either: 1) thick-bedded, massive, sandstones; 2) thin-bedded sandstone-argillite flysch; or 3) siltstone- or argillite-dominated units. Such lithological layering in Otago was intensely folded, deformed, and overprinted by metamorphic fabrics during Jurassic-Cretaceous regional metamorphism. Although primary sedimentary structures can no longer be recognised, a æghostÆ lithological variation is still present in Otago represented by psammitic (sand-derived), interlayered (sandstone-siltstone derived) and pelitic (siltstone-mudstone derived) schist. Lithological æunitsÆ in the schist are typically either 20 100 m or c.1 - 2 km thick, and are oblique to faults and shears hosting gold mineralisation at Macraes, Barewood, Nenthom, and Oturehua. Lithological variations and folds in lithological units are important in the along-strike distribution of gold in these deposits, and in the development of relatively high-grade pods and shoots at l00 m - 1.5 km scales. Ramps, flats and step-overs (known to be locally important for controlling mineralisation) are commonly located at lithological boundaries, presumably by local refraction of faults or shear zones as they propagated through folded stratigraphy. The various lithologies have also responded differently to deformation, causing variations in permeability that affected the penetration of mineralising fluids. Mapping lithological variations in barren host-rocks, either directly+ by fieldwork or indirectly by aerial geophysics, is a key to understanding and predicting the distribution of gold at mine and deposit scales.

Jan 1, 2001

By Oliver R

The Hamersley Iron ore resources are geologically complex with fluctuations in mineral chemistry. From this resource Hamersley Iron must produce consistently high quality direct shipping products and have the ability to evaluate the effects of changes in demand. In order to achieve these objectives an incremental long term planning technique has been developed. This method reduces the total geological resource statement into a simple, logical sequence of events. A logical sequence of mining increments is defined within individual areas based on a final pit and access system. Increment characteristics are derived manually and from a computer based orebody model. The end product of the technique, an optimum mining schedule, is readily developed from the incremental information. Among its many benefits, this simple technique rapidly provides management with information for policy formulation.

Jan 1, 1979

Flotation testing has been done at laboratory scale on hematite mineral and ore samples using stage additions of various hydroxamates. Chemisorption of hydroxamate species onto the hematite surface was inferred from the results, possibly involving both the undissociated hydroxamic acid and hydroxamate ion as maximum recovery occurred close to the pKa of the hydroxamic acid. Flotation testing on a specular hematite ore containing 40 per cent Fe and 42.5 per cent silica gave highest iron grades in concentrate at pH 6, in contrast to published data which suggested pH 9 as the optimum value for ore processing. Using octyl hydroxamate, a rougher concentrate assaying 67 per cent Fe at 51 per cent recovery was obtained using four stage additions of 50 g/t at pH 6. For lower grade concentrates still meeting the chemical analysis for pigment grade micaceous hematite (minimum Fe assay 60 per cent) iron recoveries of 80 per cent were possible for stage additions of 50 g/t octyl hydroxamate in the pH range 6-8.

Jan 1, 1999

Exerting the Advantages of National Key Discipline, Outstanding the Training of Engineering Capability, Cultivating Talent to be with Innovation Ability

Sep 13, 2010

By S R. Grano, M Vera

This paper deals with two separate case studies investigating the froth phase performance and characterisation of two industrial rougher/ scavenger flotation circuits. Froth phase performance was quantified using a mass balance approach to estimate froth zone recovery. Measured characteristics of the froth phase included frother solution concentration determined by gas chromatography, and the time taken for an equilibrium froth sample to decay to one-half of its original froth height. The latter measurement is referred to as the æfroth half-lifeÆ and is strongly linked to froth stability. Special methods and techniques developed to preserve frother in solution and to measure froth half-life are briefly described. The frother type in the first case study was a mixture of straight and branched alcohols, whilst the frother type in the second case study was a mixture of alcohols, aldehydes and triethoxybutane. The first case study focussed on a flotation circuit treating a low-grade ore containing only a small fraction of floatable copper sulfide minerals, while the second case study focussed on a flotation circuit treating a higher grade complex sulfide ore containing significant quantities of chalcopyrite, galena, sphalerite and pyrite. It was found that froth zone recovery of valuable mineral generally decreased down-the-bank of the two industrial rougher/scavenger circuits. Moreover, decreases in froth zone recovery significantly limit the overall cell recovery of valuable mineral achievable from the plant scavenger cells. However, the decrease in froth zone recovery could not be linked to the removal of frother from the pulp solution to the concentrate product in the preceding rougher flotation stages. Measurements of residual frother in solution suggested that, approximately, only five to ten per cent of the added frother was removed into the rougher/scavenger concentrate, with the remainder appearing in the scavenger tailings. This finding suggested there was apparently adequate frother in solution in the scavenger stages.

Jan 1, 2005

By L Brodie-Hally

In the early-1990s, Tad Golosinski, the former the head of mining department at WASM participated in a review mining engineering courses in Australia. The review team asked various industry executives what subjects they thought graduates needed to be taught. Tad made the comment to me that the more senior executives thought that history and ethics were very important. The outcome was that the mining engineering courses were required to contain at least five per cent content dealing in ethics. The course was to be modified to reflect this. Tad thought at the time the students would think that subjects dealing in history and ethics came from retirees and professionals that were over the hill. So let me talk to you today about ethics.

Jan 1, 2002

By G Lind

Bridging of production stopes in narrow vein gold deposits contributes to significant financial losses and production delays. Bridging is caused when underbreak in the stope production blast occurs, resulting in less than the designed stope blast volume breaking out during blasting. Jundee Operations in the Northern Goldfields of Western Australia extracts ore from its expansive narrow vein orebodies utilising longhole open stoping. In 2006 it experienced bridging in ten panels, or 8.77 per cent of all panels, as well as multiple bridging in 30 per cent of these bridged panels. The Jundee orebodies are west dipping with the bridged panels dipping between 44¦ and 62¦. This paper examines some solutions from the drill and blast design perspective to minimise bridging occurrences. It was found that the then current drill patterns and number of holes were adequate from a longhole stope design perspective. However, changes to the blasting design, specifically modifications to the blast delay initiation sequencing, primer positioning and blasthole dump combined with timely stope surveying and back analysis, were implemented with the aim of preventing bridging in this narrow vein operation.

Jan 1, 2008

A series of numerical experiments were performed in order to define the fracture strength of schistose rock during crushing. Fracture strength was shown to decrease as the fabric aligned with the principal axis of loading. One of three types of characteristic stress-strain behaviour are defined by the orientation of the fabric with respect to the applied stress.

Jan 1, 1993

The Illawarra District, from 50 to 100 miles south of Sydney, is one of the State's important coalfields. It extends from Clifton on the north, to the Shoalhaven river on the south, and from the coast westward beyond the coastal scarp.For descriptive purposes, this area falls naturally into two zones:(a) the coastal belt backed-by the eastern edge of the plateau;(b) the plateau, westerly from the coastal scarp.(a) The Coastal Belt.A triangular shaped area extending from Clifton to the Shoalhaven river, composed for the most part of soft coal measures strata of Permian age, which, on weathering, undermines the massive overlying Mesozoic sandstones and causes the gradual recession of thecliffs.South of Wollongong, upper marine sediments and contemporaneous igneous rocks make their appearance beneath the coal measure beds and occupy the greater portion of the coastal belt.(b) Plateau Area.Extending westerly from the coastal escarpment is a plateau known as the Robertson Tableland, composed of Triassic sandstone and shales dipping gently in a northerly direction, and capped in places by Wianamatta. shales and r.rertiary basalts. This tableland is approximately 2400 feet above sea level in the vicinity of Robertson, and gradually falls to about 750 feet at Waterfall.The plateau area for the most part is highly dissected, rough, steep gorges alternate with sharp ridges.A large part of the northern watershed of the Robertson tableland is a reserve for Sydney water supply, and large dams have been constructed at Cataract, Avon, Burke, and Cordeaux.

Jan 1, 1938

By C Claassen, R Balusu

Computational fluid dynamics (CFD) models have been developed based upon field data collected from a longwall mine in New South Wales, Australia to study the behaviour of goaf gas flow in both active and sealed goaf areas. A base CFD model was built to represent the goaf situations when the active longwall retreats near the finish-off line. Results from the base model were calibrated and compared against field goaf gas monitoring data. The base model was then used to carry out parametric studies to investigate a number of operational scenarios and their impact on goaf gas behaviour. CFD modelling results indicate that the overall goaf gas flow pattern changes as the operating longwall retreats towards finish-off line. In all cases, oxygen penetration into the active goaf remains high, reaching 15 per cent or higher, even at some 800 m behind the longwall face.The modelling results also indicated that it would be difficult for early detection of an active goaf heating (on the maingate side) based upon CO readings in the return airflow, as the main stream of the gaseous product will be flowing into the sealed deep goafs in adjacent longwall (LW) panels. Monitoring points (such as tube bundles and bag sampling points) should be selected at deep seated seals along the active goaf so that abnormal CO or C2H6 readings can be picked up for early detection and location of potential heating spots; goaf inertisation can be better achieved by injecting inert gas such as nitrogen at deeper points (>200 m) behind the operating longwall; the injection of in-seam drainage methane into the goaf areas will only have a limited impact on goaf inertisation as much of the injected methane will migrate towards deep and higher parts of the goaf due to its buoyancy effect.

Sep 26, 2011