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Crushing Plant Process Optimisation Design of processes in order to find the most efficient solution to a specific task is a difficult problem. Often the number of solutions are large and the optimal solution is therefore difficult to identify. Crushing plant process design is no exception from this statement. In order to find the best solution issues like equipment selection and process configuration must be mastered. The solution must both be technically feasible and preferably have a low operating cost. Since crushing plant design is a complex task with a large solution space it is basically impossible to master without a specialised tool. For a long time simulation softwares have been used to assist in the design process. These tools only give answers for how a user defined plant will operate. There are no tools with capabilities to consider different design options in order to determine what the most efficient solution looks like. In this paper a method for crushing plant design optimisation is presented. The novel method utilises a combined optimisation routine and expert system in order to find the most cost efficient solution to a given process task. The user will only need to define the feed material properties, the process capacity, and the end product requirements. The developed system will find the solution lowest production cost per ton.

Sep 13, 2010

Valuable Components Recovery from Lead-Zinc Metallurgical Slag

Sep 13, 2010

By A L. Welsh, P S. Newling

Mill operators are entrusted to manage what are normally the largest capital assets on any mine site. Achieving maximum utilisation and lowest costs that drive operating margins are realised by applying well known fundamentals of good housekeeping and proactive (as opposed to reactive) maintenance programmes. Historically, maintenance and operations staff are bought in late during the construction stage and often do not have the time, know how or tools to put in place (let alone train the incumbent staff) a functioning maintenance system before commissioning starts. They then get drawn into a reactive maintenance paradigm as teething problems post commissioning are dealt with and day to day issues envelop the line tradesmen and supervisors. Additionally, even when some semblance of a planned maintenance system is established, it is often the case that over time personnel and cultural issues mask the development of problematic maintenance practices. As has been observed by the authors on many occasions, even when some basic programmed maintenance system is in place, the collection of maintenance data is often inaccurate, incomplete and not subject to analysis. The net result is of course a high incidence of machine failure leading to lower than expected availability, which ultimately translates to lower revenue and higher net maintenance costs. The time taken and the cost to repair a failed machine is always greater than the timely and planned repair of a worn machine.Upon review of a number of processing plants around the world, especially gold and small base metal operations, it is apparent that companies need to implement maintenance systems whereby the operators are not overwhelmed with data and can manage by exception. Inadequate or inaccurate data collection and analysis result in poor decisions being made and misguided actions taken. GR Engineering Services (GRES) has developed a system to enable the custodians of mining plant assets to make more effective and effective use of maintenance data by being able to focus on the indicators of plant deterioration and to programme concurrent maintenance activities to maximise plant availability and utilisation.This paper outlines the structures that can be employed to address the challenges of implementing a proactive asset management system. The best practice strategies described herein have been based on the fundamentals of a sound asset management framework:a phased approach to the development of Asset Management methodology and processeseffective implementation of programmed maintenance routinesmanaging asset condition data collected from various sourcesefficient analysis of asset data and management by exceptioninterfacing asset management data with Computerised Maintenance Management System (CMMS) and Electronic Management Systems (EMS) systemstips to assist with maximising asset performance.CITATION:Welsh, A L and Newling, P S, 2015. Operating strategies for custodians of company assets creating wealth, in Proceedings MetPlant 2015, pp 338–352 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 7, 2015

Inhibition of Bubble Coalescence by Salts and Sugars

Sep 13, 2010

Mr. Murray said: Having recently returned from a visit to America, it may be of interest to members to hear something from me of the mining fields and metallurgical works which I had the opportunity of seeing, and the impressions which I formed concerning general practice and conditions there, as compared with our Australian standards in the mining industry, and in matters generally.The most striking feature of the North American continent is thehuge plan upon which Nature has built, the multiplicity of immense mountains, rivers, and lakes, the snow-covered tops of the former forming reservoirs for the latter during the summer months, being most impressive to the Australian visitor. Starting from Vancouver I travelled east for over 500 miles through the wonderful Canadian...

Jan 1, 1927

The Physical Basis of Non-Random Breakage in an Iron-Oxide Ore Hosted Copper Gold Ore

Sep 13, 2010

By Frazer E. J, Lwin T

Measurements of coulombic efficiency (QE) for zinc electrodeposition were carried out under mass-transfer-controlled conditions using a rotating disc electrode in synthetic acidic zinc sulphate solutions. Various methods of solution preparation and purifi- cation were investigated using reagents vary- ing from analytical grade to high purity; the purest solution was obtained-by dissolving 99.9999% zinc (Koch-Light) in sulphuric acid solution (BDH Aristar). Improvements in sol- ution purity did not necessarily increase QE, especially where apparently beneficial impur- ities (e.g., Pb) were initially present. The maximum QE obtainable through variation of temperature (T), current density-(i) and elec- trode rotation rate was established using a statistical optimization technique. The QE was determined principally by T and i, with significant interaction between these factors in the highest purity solution. QE contours, which gave an overall view of solution per- formance, were constructed and predictions about the response under conditions similar to plant practice were made. Wark's Rule (the dependence of QE on zinc/acid ratio) was obeyed in the purest solution over the range of composition commonly encountered in zinc plants. High concentrations of Na2SO4 and K2SO4, which occur in some plant solutions, were found to increase QE marginally ("1.2%). The intrinsic effects of individual impurities such as Cu and Ni were evaluated by additions (up to 5 ppm) to the purest solution. Decreases in QE were found to be minimal at the impurity levels normally encountered in zinc plants.

Jan 1, 1987

The mining industry in Australia frequently uses the services of specialist engineering and managing contractors and consultants for a majority of the work required for project development, from feasibility studies to project commissioning. The project owner's prime objectives are to achieve predictability and competitive advantage for their project. As the majority of this work will be carried out by contractors, the effective evaluation, selection and management of these contractors in the most appropriate forms of contracts is an essential ingredient to project success. The first stage to project development should be for the owner to examine its own resources to establish the role that it will fill and thereby identify the role and scope of contractors' involvement. Once the owner has developed this work plan, the selection of contractors and consultants should be structured to ensure that the owner acquires the appropriate expertise and experience to achieve its project objectives. The sequence of selection procedures is: 1. Pre-qualification of prospective contractors according to the owner's adopted criteria, through the use of a pre-qualification questionnaire. 2. Evaluation by the owner tender board according to predetermined mandatory criteria. 3. Preparation of tender documents for submission to qualified contractors. 4. Evaluation of tender submissions by the owner tender board using a pre-determined, weighted matrix of technical and commercial criteria. 5. Final selection and contract negotiation.

Jan 1, 1990

A commonplace, sometimes overlooked or taken for granted, article of everyday existence is the tin can. Produced from thin gauge low carbon steel, and commonly coated with a mere 60 millionths of an inch of pure tin, the product is however strong and corrosion resistant. Tin-plate serves a myriad of purposes-the most important being to meet the requirements of the canning industry. Australia's newest steel product, tin-plate, was first produced on a commercial scale during the early part of August, 1957. The commissioning of the Hot Dip Tinning Plant (Fig. 1) of The Broken Hill Proprietary Co. Ltd. at Port Kembla, marked the culmination of a proposal dating back to 1939, the advent of World War II having caused its deferment to the present time.Cornish tin is known to have been exported as early as 300 B.C. to Syria and tinned vessels existed even in the year A.D. 23. The tin coating of plate could be described as an ancient art, believed to have had its origin in Bohemia in the thirteenth century. During the next 450 years, the process spread through Saxony to Pontypool in Monmouthshire, but it was a further half century before any measure of success was obtained.Perhaps the two greatest milestones in tin-plate manufacture were the rolling of iron plates first carried out in 1728, thereby outmoding the hammer formed sheet, and more recently, the development of the electro-deposition process. By the nineteenth century, several important changes had arisen; namely, the substitution of steam for water power, coke for charcoal in the production of the base metal, and...

Jan 1, 1958

Economic mathematical methods have been developed and applied in the design, planning, development and managing stages in the mining industry. Economic and technological efficiency is achieved with the aid of a large range of probability models, which are used to enable decisions to be made progressively during the different stages. The entire operation is considered as a total system made up of sub- systems and the models representing these are consecutively interrelated with each other. Algorithms and programmes representing the economic mathematical models for all the stages involved were tested and were found to be applicable to the various important mines in the Donetsk basin. Currently, these models are accepted and widely used.

Jan 1, 1977

The movements of the major continental cratons and the distribution of the principal tectonostratigraphic terranes are reviewed in the Circum-Pacific region during Phanerozoic time. It is concluded that major periods of orogeny and consolidation of accreted terranes in the Circum-Pacific region is best correlated with periods of advance of cratonic blocks over the Pacific Ocean basin combined with relative convergent to transpressive motions between the cratons and the Pacific Ocean plates. Continental collisions and collision of terranes with continental margins has not been a significant geodynamic process in Circum-Pacific tectonic evolution. The permanency of the Pacific Ocean basin throughout 500 MA is remarkable. It appears no continental block or large continental fragment has ever entered or crossed the Pacific Ocean basin since early Paleozoic time. This area where no continent has entered for 500 MA is almost coincident with the present Pacific Ocean basin and seems associated with the 25 to 100 meter geoid high which dominates the present-day figure of the Earth.

Jan 1, 1990

By Edwards A. B

This paper presents the results of an examination of four samples representative of the low-lead matte, high-lead matte, lead speiss and antimony speiss, respectively, produced during smelting operations at Port Pirie Smelters. The investigation was undertaken at the request of the Broken Hill Associated Smelters Pty. Ltd., as part of the research programme of the Mineragraphic Section of the Council for Scientific and Industrial Research.Analyses of the specimens are as follows:-

Jan 1, 1949

This paper gives an overview of the difficulties associated with determining the strength of hard rock pillars. Although a number of pillar design tools are available, pillar collapses still occur. Recent examples of large scale pillar collapses in South Africa were caused by weak partings which traversed the pillars. Currently two different methods to determine the strength of pillars are used namely, empirical equations derived from the back analyses of failed and stable cases and numerical modelling tools with an appropriate failure criteria. Both techniques have their limitations and additional work is required to obtain a better understanding of pillar strength. Empirical methods are popular and easy to use, but care should be exercise that the results are not extrapolated beyond the range of the data which were used to derive them. An example is the Hedley and Grant formula (derived for the Canadian uranium mines) that has been used for many years in the South African platinum and chrome mines (albeit with some adaptation of the K-value) to design the pillar layouts. Very few collapses have nevertheless been reported and it might even be too conservative an assumption of pillar strength in these mines. As an alternative, some engineers strongly advocate the use of numerical techniques to determine pillar strength. A close examination unfortunately reveals that these techniques also rely on many flawed assumptions. An area where numerical modelling is invaluable, however, is to study specific pillar failure mechanisms, such as the influence of weak partings on pillar strength. In conclusion, it appears that neither empirical techniques nor numerical modelling currently provide a solid basis to conduct pillar design. It is therefore recommended that both these techniques be utilised when confronted with a pillar design to obtain the best possible insight into the problem.

Nov 25, 2010

Roadheader tunnelling machines have been used in Australia by both mining companies and contractors involved in the mining and con- struction industries since the early 1970's. They have both advantages and limitations, and this paper discusses machine excavation from the point of view of a contractor who has both reaped the benefits and suffered the conse- quences of using roadheaders. The paper also includes brief descriptions of three projects tackled by roadheader, all the projects being Declines.

Jan 1, 1987

New Zealand contract mining has been well established for close to 50 years. The opencast industry has grown from mining quantities of less than 1 million bcm per year in the 1950s to around 20 million bcm in the late 1990s. Trends here are following those in other countries with mining companies looking to contract out more of the so called traditional mining work. The key driver behind this trend is not unique to the mining industry, but is simply a matter of concentrating on doing a few things well. In the case of the mining company this has come to mean owning and developing orebodies and where appropriate, marketing mining products, and leaving owning and operating of mining fleets to the contractor. This has the effect of reducing risk to the mining company as well as lowering costs. Both can be achieved without losing control of the key elements of the operation. Optimising performance is simply a matter of identifying the key drivers behind performance, having the right plant and the right people at the right place and providing these people with the information they need to manage the operation.

Jan 1, 1997

CONTENTSSummary.Introduction.Location and Geology.Historical and Exploitation.Part 1. Washability Characteristics of the Liddell.Seam.Foybrook Open Cut, Top Bench.Sampling.Size and Ash Distribution.Washability Data.Washery Separations.Part 2. Washability Characteristics of the LiddellSeam.Foybrook Open Cut, Bottom Bench.Sampling.Size and Ash Distribution.Washability Data.Washery Separations.Acknowledgments.References.INTRODUCTIONThe washability characteristics, size-range and chemical analyses of the screening from the Liddell Seam are matters of growing interest in view of the increased exploitation of this seam over the last few years, and also since the Newdell Coal preparation plant of the New South Wales Mining Company Proprietary Limited, utilizing magnetite heavy media separation, commenced...

Jan 1, 1954

By M P. Cipold, J F. Bachmann, C C. Bachmann, J Ha, H B. Wurst

In washability, the objective is to establish the set of maximum possible separation performance criteria for a given mineral feed. The method of choice for this has been the conventional sink–?float analysis. Using traditional sink–float method it is not possible to sample and automatically measure. This fact, as well as time, cost and safety aspects, as well as required and manageable sample size of the sink–float method have prompted the search for a new approach for establishing separation performance criteria. This is especially important as performance levels of separator plants can be maximised if reliable information based on an analysis of washability in conjunction with particle size distribution, elemental constituency becomes available in time. The new method to establish washability and associated performance information utilises at least two measurement technologies concurrently: single energy X-ray transmission and image processing. For porous or very inhomogeneous materials the results can be refined further by using dual energy X-ray transmission and image processing.If used as a standard laboratory device the continuous build-up of the washability curve allows to evaluate the statistical significance of the sample size during measurement.The measuring method can even be improved if it is combined with an automatic sampling system that feeds a continuous and representative particle stream to the analyser. Then the value of the collected data increases considerably since the washability data are additionally available in time to be considered in the control of the process plant. The washability curve can be derived and is continuously updated based on the particles measured during the past time interval. Older curves and results are stored in a database and can be retrieved for later reference. This technology now enables automated sampling and integrated automated measurement, which was previously not possible.This incorporation of an automated washability monitor at a representative sample gives near real-time data that would impinge positively on the profitability of the plant operation. The method was extensively tested using a range of samples with different densities, varying from 1 g/cm3 (coal) to 5 g/cm3 (iron ore).CITATION:Bachmann, C C, Bachmann, J F, Cipold, M P, Wurst, H B and Ha, J, 2017. Inline analysis of washability parameters for process control, in Proceedings Eighth World Conference on Sampling and Blending , pp 213–218 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2017

By D Garcés, M Meléndez, R Castro, E Viera

Enhancing the understanding of gravity flow in caving operations is a key factor in the design, operation and success of caving methods. Consequently, much research has been performed to increase knowledge about gravity flow. Many valuable theories have been gained from different research approaches, which include physical modelling, numerical modelling and a limited number of full-scale tests. Recent advances in technology have allowed Codelco Chile to carry out trials using Smart Markers technology. This technology was used in Esmeralda mine’s Block-2 at El Teniente mine from August 2012 to January 2015. This paper aims to determine the characteristics of the extraction zone and obtain the data that will allow greater understanding of gravity flow for design and draw control purposes.The collected data from recovered markers were analysed using a linear interpolation of both the initial position of the markers and drawbell accumulated drawn tonnage. For each drawpoint in the trial, the regularity or irregularity of flow was analysed based on the recovered markers and the drawn tonnage. Correspondingly, the relationship between flow characteristics and observed fragmentation in drawpoints was analysed. The gravity flow of the Smart Markers revealed that current drawpoint spacing provides the interaction conditions of adjacent flow zones. However, it is possible to increase the drawpoint spacing while allowing caved rock to be extracted from the major and minor apexes.The results of this research also verified that full-scale test data are the predominant factor in the production level design and production control at El Teniente mine.CITATION:Garcés, D, Viera, E, Castro, R and Meléndez, M, 2016. Gravity flow full-scale tests at Esmeralda Mine’s Block-2, El Teniente, in Proceedings Seventh International Conference and Exhibition on Mass Mining (MassMin 2016), pp 349–358 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2016

By K F. Tang, J-W Li

"An EXTENDED ABSTRACT is available for download. A full-length paper was not prepared for this presentation. The Xiong’ershan district in the southern margin of the North China Craton (NCC) contains more than 20 gold deposits hosted in the late Neoarchean to early Palaeoproterozoic amphibolite facies metamorphic rocks or late Palaeoproterozoic unmetamorphosed volcanic rocks. Gold mineralisation consists mainly of auriferous quartz veins and disseminated ores in hydrothermally altered zones, with additional gold mineralised breccia pipes. Gold orebodies are strictly controlled by secondary- or higher-order brittle/ductile-brittle faults. Isotopic dating reveals two separate episodes of gold mineralisation: the Shanggong and Dianfang deposits formed in the range of 236 ± 1.4 to 202 ± 18 Ma, whereas the Gongyu, Qianhe and Qiyugou deposits formed between 135.0 ± 0.5 Ma and 124.0 ± 1.0 Ma. Stable isotope and noble gas geochemistry studies indicate that the Triassic gold deposits were precipitated from deeply-sourced, low-salinity fluids at 250–350°C, but whether the fluids were mainly derived from metamorphic devolatilisation or magmatic degassing remains unresolved. In contrast, the Early Cretaceous deposits most likely precipitated from a dominantly magmatic fluid, although metamorphic and meteoric components cannot be ruled out. Results from this study, when combined with regional geological and geochemical data, suggest that the Triassic gold mineralisation was generated by the deformation associated with the collision between the North China and Yangtze cratons, forming the Qinling-Dabie orogen. In contrast, the Early Cretaceous gold veining was a result of lithospheric destruction of the NCC, a process initiated by plate subduction from both the south and north since late Palaeozoic but ultimately triggered by the westward subduction of the palaeo-Pacific plate in the late Mesozoic. This study helps to reconcile the long-term debate on the timing, genesis and geodynamic setting of gold mineralisation in the Xiong’ershan and other districts along the southern margin of the NCC.CITATION:Li, J-W and Tang, K F, 2015. Gold deposits in the Xiong’ershan District, Southern North China Craton – products of Triassic deformation and Cretaceous craton destruction, in Proceedings PACRIM 2015 Congress, pp 341–344 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Mar 18, 2015

By Peverett N. F

The purpose of filtration in a gold reco- very plant is to separate the gold bearing liquid from the solids in the slurry. Some of the gold is inevitably lost due to incomplete separation. An investigation recently completed by the authors has brought to light a method of reducing such losses. In this investigation, the filtration pro- cess was represented by a steady-state mathema- tical model which took account of 14 indepen- dent variables and three parameters. One of the filters in the plant at West Driefontein Gold Mine in South Africa was isolated from the rest and fully instrumented. A computerized data acquisition system was installed close to the filter, and the data obtained from it served to test the model. Using the model together with an optimizing program, the optimum operating point for the filter as a function of throughput was found, and a control strategy developed to minimize the total gold losses in the filter plant.

Jan 1, 1977