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By J M. Galvin

History attests to the catastrophic consequences that fire, explosion and contaminated, noxious andirrespirable atmospheres can have for workplace health and safety in underground coal mining. It also confirms that fires and explosions present the greatest risk of partial or total loss of underground mines and equipment and that this risk continues to materialise. The design, implementation, operation and maintenance of the mine ventilation system are core controls for managing the hazards associated with these risks, both for preventing them from materialising and for mitigating their consequences if they do materialise. These are most effective when embedded in a risk management approach.

Oct 12, 2022

By J Kwak

Driving sustainability concepts and practices into the heart of the design process is the key to achieving a successful, sustainable plant design. Engineering design practices, tools, systems and methodologies should be prepared around true eco-efficiency parameters, adopt wholesystems-thinking and consider life-cycle impacts for the design task. Experience dictates that the application of sustainable plant design practices is most likely to succeed if: The principles are well documented and explained. All stakeholders agree on what sustainability means. Sustainable plant design is treated as a core process. The principals of sustainable plant design are equally applicable in brownfield and Greenfield environments. Although brownfield situations provide the designer with less latitude for change, these types of projects do allow easier measurement and demonstration of relative impacts. This paper further develops the above points by drawing on case studies from HatchÆs repertoire.

Jan 1, 2004

By D Kent, J Bullock, M Wilkinson

Over the last few years at Glencore’s Mount Isa Copper Operations (MICO) mining conditions have become increasingly challenging through lower head grades and higher work indices. MICO has had great success improving operating efficiencies and increasing productivity through focusing on technology, innovation and operational discipline. The recent implementation of the Mine Site Technologies (MST) ImPact System has supported the continued transformation of the MICO operations through improved personnel safety and direct measurement of productivity. The ImPact System has implemented new safety systems such as the heavy vehicle proximity detection system, underground personnel tracking system and emergency evacuation dashboards improving the overall safety of the workforce. The ImPact System has facilitated productivity improvements via real-time equipment and personnel monitoring, and the implementation of exception reporting (personnel productivity), KPI reports and production dashboards, and transparent reports highlighting developing maintenance issues.This paper discusses the components of the ImPact System, the current installation at MICO, and critically analyses the implementation processes and right sizing of the system to meet the needs of the business today and into the future.CITATION:Bullock, J, Kent, D and Wilkinson, M, 2017. Productivity and safety improvements supported by MST’s ImPact System at Glencore’s Mount Isa Copper Operations, in Proceedings 13th AusIMM Underground Operators’ Conference 2017, pp 279–286 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Oct 16, 2017

By Stephenson D. B, Burgess J, Burgess F. L, Marshall S. H

A new high intensity flotation process 'FASTFLOT' is explained and its theoretical advantages compared with other flotation systems are discussed. The results of initial FASTFLOT testing on the zinc roughing circuit at Pasminco Mining, Broken Hill South concentrator are presented and compared to recent plant data. The comparison suggests that on roughing duties, the FASTFLOT process yields superior concentrate grade while requiring less than one third the residence time of a conventional mechanical cell plant. Strategies for FASTFLOT deployment are also presented.

Jan 1, 1994

THE following paragraphs represent an endeavour to describe, briefly the equipment used for the manufacture of sulphuric acid and superphosphates by the Corporation.SULPHURIC ACID PLANTS.Two separate units are in operation, No. I Plant working on sulphur dioxide generated from pyritic ore, No. 2 Plant working on sulphurous gases obtained from the Huntingdon-Heberlein desulphurizing process. The latter plant is unique in being the first installation for the successful use of these gases.

Jan 1, 1918

By G B. Smith

Barrick (Australia Pacific) Limited initiated a trial of Caterpillar’s Minegem autonomous loader technology in 2009 at the Kanowna Belle mine in Kalgoorlie. Autonomous loader technology offers the potential to improve loader productivity, reduce operating costs and improve safety through removing personnel from the mine operating environment. This paper discusses the implementation of the technology at the mine site, the data collected during the trial and quantifies the benefits of using automated loader technology in comparison with teleremote loader operation. The lessons learned from the trial and work planned for the future in respect of this technology is also discussed.

Mar 21, 2011

By M Recabarren, A Echeverria, J Ronda, J I. Guzman, R Dodds, G Juarez, E Vila-Echague

A strategic mine plan is a fundamental part of any mining operation. It must provide a realistic and operative extraction and processing schedule, and yield the highest value for the business. For open pit mines, the problem can be modelled as a set of blocks representing the deposit, for each of which we need to decide if it is going to be mined, if so, when and where it will be sent (process, stock or dump).This problem can be proven to be of NP-Hard complexity. The traditional approach used by mining engineers to tackle this complexity is to separate the problem into more tractable components, solving each separately. The first step is to use the Lerchs-Grossman (LG) algorithm to obtain the final pit limit, as well as a set of optimised pit shells (nested pits), using different input prices. Then, using this input, operational phases are designed. Third, the set of phases can be used as an input for a phase-bench style optimisation, usually using a mathematical programming-based algorithm.There are, however, several problems with this approach. First, dividing the problem into simpler parts has the consequence that any compromises made at early stages limit the potential value left for the following steps. Second, LG is a static algorithm, with no concept of the time-value of money, capacity limits, opportunity costs, etc. Phase design is essentially a manual step, for which nested pits provide insufficient information in practice, and therefore the quality of the result in terms of potential net present value (NPV) depends strongly on the experience and expertise of the designer. This means that key input data such as commodity prices, different processes capacities and mine movement limits, are considered only at scheduling, when there is little room for optimisation. This sequential approach limits the potential value in each step, where a simplified problem is addressed, instead of addressing the real, and more complex problem, which is dynamic and should be solved as a whole.We present in this paper an algorithm, and its commercial software implementation, that addresses the dynamic problem as a whole, simultaneously and automatically creating a high-value strategic mine plan that adheres to basic operational constraints, determining dynamic cut-off grades and delivering a set of phases which can serve as a much stronger guide than nested pits for the final design. We discuss some of the key elements of the algorithm and propose a new methodology for strategic mine planning, where phase design dynamically responds to mining strategy definition. Results using different mining and operational parameters on a fictitious copper deposit are used as a demonstrative example.CITATION:Juarez, G, Dodds, R, Echeverria, A, Guzman, J I, Recabarren, M, Ronda, J and Vila-Echague, E, 2014. Open pit strategic mine planning with automatic phase generation, in Proceedings Orebody Modelling and Strategic Mine Planning Symposium 2014 , pp 147–154 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 24, 2014

By D Lucato, B Haase, R Saha, S Limberger-Forte, J Lishman

Cadia East Mining operations have employed geometallurgical techniques to advance the understanding of the in situ rock hardness variability across existing Panel Caves (PC). Geometallurgy advances the understanding of variability across an orebody through the integration of geology, mineralogy and processing response and therefore enhances spatial mapping of comminution or separation properties. Spatially extensive geometallurgical measurements are necessary so that continuous rock properties can be generated and used for the development of comminution and processing domains using geostatistical modelling. Standard testing protocol across geological and mineralogical domains is vital to understand the variability in deposit wide comminution and separation properties. The high cost and large sample requirements associated with metallurgical test work typically results in insufficient data density and distribution, making it difficult to model and map deposit scale variability. Quantitative hardness proxy tools are useful to measure in situ rock hardness, however this data is typically either sparse or missing within advanced mining operations. In recent years, mineralogy and multi-element assay data has often been collected as part of the standard geological data set and is generally coincident with metallurgical test work. In this paper relationships between mineralogy and comminution parameters have been applied to multi-element assay data with coincident measured Bond Work Index (BWi) data to generate a predicted BWi using linear regression. The predicted BWi is intended to supplement existing measured BWi data to enable better extrapolation across the deposit. Geostatistical Conditional Simulation methods have then used the predicted and measured BWi data to produce a BWi variable as a new input to the resource model. The simulated BWi can be used as an input for specific energy models to predict required grinding energy consumption across a deposit.

Mar 22, 2022

By R A. Pax

Operational grinding mills emit significant acoustic emissions which are a consequence of the dynamic environment prevailing inside them. From a technical perspective, the noise presents an opportunity to determine some details of the processes occurring inside the mills. The noise generated is not random and can be attributed to a range of events that occur inside these mills, consequently non-contact acoustic determinations of in-mill behaviour provide powerful insights into the operation of primary comminution tumbling mills. To enable a logically coherent picture to be formed of the processes inside a mill, arrays of microphones have been used. This approach allows a clearer picture of the in-mill behaviour of the charge to be accessed. In contrast to single microphone approaches, usually located near the expected charge toe position, an array of microphones allows much more useful information to be obtained from grinding mill noise.This paper will discuss and present data obtained from microphone arrays positioned at the toe and shoulder locations of a mill, and how this information can then be used for the optimisation of grinding mills in real-time.CITATION:Pax, R A, 2012. Determining mill operational efficiencies using non-contact acoustic emissions from microphone arrays, in Proceedings 11th AusIMM Mill OperatorsÆ Conference, pp 119-126 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Oct 29, 2012

By J Player, R de Vries, E Villaescusa, R Hassell

Concerns regarding the uncertainty of stope dilution at MMG Dugald River Underground Mine led to a trial stoping program to acquire full-scale comprehensive geotechnical information and to test the validity of the geotechnical and mining parameters. Given that stope production drilling and blasting is a key parameter that influences dilution a detailed stope blast vibration project was implemented. The stoping trial consisted of 19 stopes, a combination of both sublevel open stoping and longitudinal and transverse stopes, of which five were monitored for blast vibrations.The blast vibration project utilised 20 triaxial geophones and five triaxial accelerometers installed in the hanging wall of five monitored stopes. For each stope fired, full blast waveforms were recorded along with detailed information of the blast design. Analysis of the blast vibrations used the Holmberg-Persson approach, with potential damage determined by the relative (Holmberg-Persson) K values.The project identified the benefit of parallel, breakthrough slot holes in reducing blast vibration damage. The results show that radial rings toeing or stabbing into the stope wall lead to higher vibrational energy yield which contributed to increased overbreak. Hanging wall overbreak, by comparison, with parallel, breakthrough blastholes with 1 m standoff, combined with lower density explosive charging (0.8 EP) and increased delays limited blast vibration damage. A number of ring burdens from 1.4 m to 2.5 m were monitored with no difference in terms of energy yield being identified. Changes to the stope drill and blast design are suggested to better control the large blast vibrations and recommendations from this project have been implemented into future mine design and planning.CITATION:Hassell, R, Villaescusa, E, de Vries, R and Player, J, 2015. Stope blast vibration analysis at Dugald River Underground Mine, in Proceedings 11th International Symposium on Rock Fragmentation by Blasting, pp 221–232 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 24, 2015

By H Kundapen, B R. Bolton, H Davies

The Ok Tedi porphyry copper-gold mine is located in the Star Mountains of Western Province, Papua New Guinea. Open-cut mine commenced in 1984 and is due to cease around 2010. The mine produces a total of 88 Mt of waste annually including 58 Mt overburden and 30 Mt tailings, which are discharged directly in to the Ok Tedi River. Mine derived wastes are transported downstream and deposited within the river channel in a variety of bar forms. The prevailing hydrogeological conditions including, velocity, competency, capacity, gradient, grain size and specific gravity, control the deposition and segregation of these sediments. Periodic exposure of the reactive sulfides to oxygen during fluctuations in the river discharge may result in oxidation, localised acid generation and liberation of metals into solution. To evaluate the significance of this issue, Ok Tedi Mining Limited initiated an investigation of the sediments deposited in the upper Ok Tedi River as part of its overall ARD Management Program. The specific objectives were to: evaluate the acid-forming characteristics of identified high sulfide river deposited sediments; characterise geochemically the waters in contact with sulfide-bearing river deposited sediments; map and monitor exposure areas and oxidation depth of deposited potentially acid forming (PAF) sediments; determine the depositional processes controlling sulfide distribution; and assess lag period, oxidation and metal release rates for the sediments. This work included the analysis of sediment and water samples collected on a 50 + 50 metre grid at six gravel/sand bars. The sediment samples were analysed for total sulfur, ANC, NAG, total sulfur and total copper. Water samples were tested for general water quality parameters, sulfate and a suite of dissolved metals including; Al, Ca, Cd, Cu, Fe-sol, K, Mg, Mn, Na, S and Zn. This paper presents the results of these investigations with particular emphasis on the geochemistry of the river sediments and associated contact waters.

Jan 1, 2003

This paper reviews recent advances in geophysical tools for mineral exploration. It does not restrict comments to methods which are usually applied in the tectonically active belt surrounding the Pacific Ocean, where geophysics has often been secondary to geological prospecting (eg visual recognition of surface alteration) and drainage geochemistry; but considers geophysical tools applied to a broader range of both deposits and terrains. For example, the subdued topography of much of Australia and Canada has lent itself to the development and extensive application of airborne methods. In Australia, deep weathering and transported cover have necessitated the use of geophysical methods to not only detect anomalies but also to map and understand basement geology. This same weathering has caused specific problems, particularly for electrical methods, but recent improvements in instrumentation, processing and visualisation have largely overcome them. A great deal of geophysical data is now being collected by government agencies, often from the air, and made readily available to explorers. In several Australian states it is free, often on line, and in almost all cases it is relatively cheap. These regional data sets are often augmented by more detailed local surveys in areas of interest. Although æanomaliesÆ are still important much more is being done with the high quality data which is now available The results are used for geological mapping, to test geological hypotheses, to construct detailed 3D geological models and, together with fluid flow modeling, to predict optimum locations for mineralisation.

Jan 1, 2004

By S Saydam

Professional engineers need to be able to apply university learning to practice. In particular, they have to take responsibility for interactions between technical systems and the complex social environments in which they operate. The most effective way of building this competency is through active experiential learning. We have been developing an advanced educational integrated simulation system to provide mining engineering students with an interactive and immersive learning experience that is not otherwise possible. This will give students an authentic experience in working with industry software packages, while also contextualising the learning in terms of the broader and longer-term impact of technical decisions. We have been piloting the system, in undergraduate courses in order to establish its effectiveness in building systems thinking competencies for mining engineering. For postgraduate students and professionals, the same tools and methods can support studies of more challenging and complex scenarios where mining engineers have to place their decisions within complex global industry contexts.

Nov 22, 2011

Two key elements in the design of a pastefill or high density hackfill system are the preparation of the backfill material and its distribution underground. This paper examines these two areas. Owing to the essentially impervious nature of total mill tailings, preparation of pastefill and high density fill from current tailings involves a physical dewatering process. There are currently three methods available for this process: I. Vacuum or pressure filters. These represent the 'traditional' approach to the preparation of pastefill. 2. Paste production storage mechanism. This is a thickening/storage mechanism developed with the specific objective of producing paste/high density backfills. 3. Fluidization. This system utilises silos fitted with simple dewatering devices and nozzles. Recently developed by CANMET, it provides the simplest and most economical approach. This paper describes and compares the three preparation methods, from a practical and an economic point of view. Once the pastefill/high density fill has been prepared and binder added, the backfill must be distributed underground into the stopes. A fundamental factor in the design of a distribution system is the rheology of the material- No two materials will exhibit the same properties, and a sequence of rheological and related testing is required prior to the completion of the design of the underground distribution system. This paper covers the testwork normally required and discusses the fundamental design parameters of pastefill distribution systems. The final section of this paper summarises the use of pastefill at three mincsin Canada.

Jan 1, 1998

By L Clarkson, D Williams, P Redcliffe, F van der Wal

This research presents a snapshot and insight into the trends, patterns, and common considerations identified in the current standing of real-time tailings dam monitoring practice. Based primarily on information derived from concurrent research by the author (in form of a Catalogue of Real-time Instrumentation and Monitoring Techniques for Tailings Dams), challenges and opportunities when transitioning to a real-time monitoring system are discussed. Learnings and key considerations between different monitoring approaches are explored, including themes of limitations and advantages that were observed consistently through global supplier feedback.

Jul 1, 2021

By T R. Justice

The Eastern Distributor tunnel is located approximately 24 m beneath the suburbs of Woolloomooloo and Darlinghurst to the east of the central business district of Sydney. The 1.7 km long tunnel will carry three lanes of northbound traffic over three lanes of southbound traffic in a æpiggybackÆ arrangement, with a maximum cross-section 22 m wide by 12 m high.The tunnel is constructed predominantly within horizontally bedded Hawkesbury Sandstone. In the unweathered to slightly weathered state, the rock is typically medium strength (average UCS about 24 MPa), with an average quartz content of 72 per cent.Major geological features that intercept the tunnel route are the Woolloomooloo Fault Zone and two extremely to moderately weathered dolerite dykes. The fault zone intersects the tunnel at about 25¦ to its alignment and comprises a series of discrete faults over a width of approximately 50 m. The overall movement of the fault zone appears to be reverse. The two dykes are the 1 m wide Oxford St Dyke and the 6 m wide Great Sydney Dyke.This paper outlines the site investigations and the interpreted geotechnical model for the tunnel route prior to the commencement of tunnelling. This model is then compared to the encountered conditions. The very good correlation between the expected and the encountered conditions shows the high quality of geotechnical investigation and interpretation.

Jan 1, 1999

By D J. Williams, A K. Kho, A Shokouhi, N Tucker

The disposal of dewatered coalmine tailings and coarse reject within spoil piles is gaining popularity as a means of eliminating separate surface tailings storage facilities or dams. The contrasting characteristics of coalmine spoil, coarse reject and tailings are somewhat complimentary, making the co-disposal of dewatered tailings within spoil piles geotechnically feasible and environmentally attractive. However, the impacts of mixing plant rejects within spoil piles are not well understood; in particular, the effects of water draining from the mixed plant rejects on the moisture content of the surrounding spoil. Changes in moisture content can cause additional collapse and degradation settlements of the spoil pile. A series of laboratory tests has been undertaken on mixtures of dewatered coalmine tailings, coarse reject and spoil. The results of these tests have been incorporated into a spreadsheet-based settlement prediction tool to investigate the effects of incorporating mixed plant rejects on total spoil pile settlements. This paper presents the laboratory tests undertaken, the incorporation of the test data into the settlement prediction tool, and settlement estimates for the various mixtures at different stages of construction.CITATION:Kho, A K, Tucker, N, Williams, D J and Shokouhi, A, 2015. Impact of co-disposing mixed plant rejects on spoil pile settlements, in Proceedings Tailings and Mine Waste Management for the 21st Century , pp 51–62 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 27, 2015

By A Poliakov, E Donskoi, K Vining

The automated optical image analysis software Mineral4/Recognition4 (M4/R4) is capable of performing comprehensive characterisation of different materials throughout the iron ore value chain, including ore fines, lump, sinter, pellets and coke. It has been successfully used by CSIRO for industrial and research projects and has been independently licensed to several world leaders in iron ore production and ironmaking. The M4/R4 software was strongly integrated with a Zeiss microscope to make use of the company’s powerful AxioVision software. This required users to own both Zeiss microscope hardware and AxioVision software in order to be able to use M4/R4 to its full image acquisition and analysis capacity. Therefore, it was not available to the users of equipment produced by other major microscope manufacturers. In recent times however, Zeiss has indicated that the AxioVision software will no longer be supported. To overcome this limitation, CSIRO has proceeded with the next generation of this software, Mineral5/Recognition5 (M5/R5). Importantly, the M5/R5 system has been developed without any dependence on a specific microscope hardware/software platform. Furthermore, the image analysis functionality is now based on openCV open access software and has been fully rewritten using stateof- the-art software development tools to allow reading and processing of all major image formats. Although past applications have been specific to iron ore and ironmaking applications, other improvements, such as an increased number of minerals allowing better gangue segmentation, flexible mineral definitions, improved software modules behaviour and refined analysis routines enables the platform independent M5/R5 image analysis system to be used by researchers in any area of mineralogical or materials research.

Nov 8, 2021

By D Sibthorpe

The employment of a tunnel boring machine (TBM) is the default delivery method for the realisation of traffic, utility and primary resource underground space worldwide, with hundreds of kilometres completed safely each year. This is not yet the case for the mining sector in Australia, specifically underground coal mining. The safety advantages of TBM delivery when compared to New Austrian Tunnelling Method (NATM) delivery, or that of drill and blast, remains unrealised.With coal access drifts ranging between 1000?m and 3000?m in length, the construction of these facilities using TBMs could be done in a fraction of the time when compared to current practice. TBM world records currently stand at 435?m/week or 1600?m/month for the 7.0?m to 10.0?m range. Resource owners and developers should embrace the opportunity to deliver access to their orebodies in only a few months, excluding machine assembly and disassembly time.There are challenges in utilising TBMs for construction of Coal access drifts, such as; TBMs generally being bespoke design, maximising capital efficiency for drift development, and geotechnical variances between projects. This paper explores safer and more cost-effective options. This paper also provides detail of how the configuration within a completed drift could be optimised to ensure all site specific needs are met with regard to future use of the drift. The paper also includes descriptions of the engineering solutions that are available for physical and atmospheric challenges specific to coal drift applications and how the TBM manufactures are adapting to the regulatory requirements are also covered.Due to downward pressure on high cost bases and ever increasing safety requirements the popularity of TBMs in the Australian mining sector can be expected to increase and eventually become the default delivery method for coal drift construction, building them cheaper, faster and?safer.CITATION:Sibthorpe, D, 2014. Coal drift construction by tunnel boring machine, in Proceedings 15th Australasian Tunnelling Conference 2014 , pp 671–682 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 17, 2014

Rope guides, consisting of ropes spanning between anchor points at the top and bottom of shafts, have frequently been considered as a viable alternative to fixed guides, comprising buntons and guides. However, their design has generally been based on empirically derived rules, arising from European hoisting practice of 50 to 100 years ago. This paper describes a recent technology development project aimed at defining and quantifying the important forces acting on rope guided conveyances, calculating the resulting displacement of the conveyances and assessing whether the displacements are acceptable or not. The paper describes the derivation of aerodynamic force coefficients based on CFD analyses and other significant forces acting on the conveyance and rope system. The conveyance displacements may be calculated using computer simulation of the mechanical system, or approximately using simplified equations given in the paper. Measurements taken to confirm the suitability of the proposed formulation are described. The combination of displacements and assessment of the rope guide system design are proposed, based on the ratio of design clearances and the predicted displacements.

Jan 1, 2005