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By C OÆKeefe, A Thomas

Boom time in the mining industry has presented mill operators with several unique challenges including the need for increased throughput while being constrained by a shortage of skilled labour and aging capital equipment. New instrumentation technology that provides reduced installation costs; no process down time for installation; and reduced maintenance costs and labour requirements; has been introduced to address the labour situation while maintaining production. This new tech- nology also enabled more accurate and reliable process measurements thus providing the capability for operators to maximise throughput with their existing capital equipment. This passive SONAR based technology can accurately measure the volumetric flow rate of single phase and multiphase fluids as well as the amount of air entrained within slurries. This is accomplished in a non-invasive manner. This paper will describe the principle of operation as well as the application of the technology to critical minerals processing applications. Included will be operational examples comparing the SONAR measurement performance to traditional measurement techniques. These examples will include hydrocylone feed flow, flotation concentrate flow, and slurry streams containing magnetic ores. Actual plant data will be presented as well as a discussion on the operational advantages such a measurement capability.Also described will be the power of the technology platform to provide novel process monitoring and control capabilities such as pipeline sand-out prevention and pipeline acoustic monitoring.

Jan 1, 2009

By N Harries

The management of risks associated with slope instability is an essential process in the safe and economic operation of open cut mines. The æslope stability radarÆ (SSR) has been developed to better manage those risks. The SSR can remotely scan a rock slope to continuously measure any movement of the face. The system can detect and alert users of wall movements with submillimetre precision. The high level of movement precision and broad area coverage of the rock face can allow for a better understanding of the geomechanics of slope deformation, including magnitude of potential failures and additional warning time of impending instability. Additionally, radar waves adequately penetrate through rain, dust and smoke to give reliable measurements, 24 hours a day. SSR systems have been deployed in many mines in Australia, Indonesia, Africa, Chile and the United States. Greater than 100 rock falls and waste dump failures (from several tonnes to millions of tonnes) have been monitored, and on every occasion precursor æwarningÆ movements were recorded by the SSR. This technology enables a radical change in the management of risks in open cut mining. This paper presents recent case studies of how the SSR technology has provided safety and productivity benefits to large open cut metalliferous mines.

Jan 1, 2007

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

By N Meyer

This paper presents a research project referring to the stability of submerged walls of open pit mines and the actual state of development. Obviously the slope stability analysis is always a rather complex problem, because it is difficult to reduce the problem to a design scheme and to define the available in situ soil strength. Especially the design of submerged slopes represents a problem. The state-of-the-art slope stability analysis is based on a simplified modelling of slope failure and soil behaviour and with this predicted stable slope inclinations of sand slopes below water-table are less then half the angle of internal friction. Slope angles calculated like that canÆt satisfy the mining companies. One of the problems that have to be solved is the reliable determination of the long-term stability of non-cohesive, submerged slopes, which is not only dependant on geotechnical and hydrogeological parameters of the subsoil, but is also significantly influenced by how the slopes are made. The research project points at the relations between mining and geotechnical engineering with the main aim to find a more suitable stability analysis which takes both soil behaviour and mining influences into account.

Jan 1, 2003

Comalco Limited has recently completed construction of a $50 million kaolin plant at the site of its bauxite mining and industrial minerals operation at Weipa. The plant will produce 100,000 tonnes per annum of coating grade kaolin for the paper industry. Comalco produced the first coating kaolin from the deposit in 1979 on a trial basis. Since then a variety of quality coating grades with specific particle size distributions and brightness values have been prepared. Extensive drilling and bulk sampling of the deposit over eight years has shown that the ore body is large and of a high grade suitable for the production of premium quality coating kaolins. The processing plant technology was developed by Comalco in association with the European kaolin and equipment producer Amberger Kaolinwerke GmbH (AKW). The Weipa kaolin plant is the first of this size to be built in the Pacific Basin region and it will offer the region's paper-coating mills a stable and reliable source of high-quality kaolin, shipped from an established bulk loading port. The paper provides an overview of the development of the kaolin investment the nature of the production process and details the

Jan 1, 1986

By Henderson N, Schaap H

In large companies with mining operations spread over multiple sites, it is essential that consistency between sites is maintained in preparing and classifying resource and reserve estimates. The endorsement by The AusLMM and AMIC of the "Australasian Code for Reporting of Identified Mineral Resources and Ore Reserves" and the subsequent incorporation of reference to the code into the ASX listing rules for mining companies has provided a basis for the consistent classification of resources and reserves. However, compliance with other criteria more or less stringent than the Australasian Code can present some reporting difficulties. Examples include listing requirements for foreign stock exchanges, particular Acts of Parliament that may apply to individual leases, constraints imposed by individual companies on their own leases, and ultimately, reserves for short, medium and long term planning. Confusion can arise when any two or more sets of reserves for the same lease are compared.. To alleviate this confusion, a standardised procedure was developed for the calculation and classification of coal resources and reserves. The procedure which is geostatistically based incorporates a technique called "Irregular Block Kriging" where specific mining blocks are directly kriged. The procedure has enabled those engineers and geologists with only a basic understanding of geostatistics to apply the technique and not feel hampered by some of the complex mathematics which in the past has tended to inhibit and overcomplicate the use of geostatistics. The procedure has resulted in "cleaner" data bases and hence more reliable reserve estimates.

Jan 1, 1990

Mines in the future deliver a paradigm shift in the way mining, material handling and processing are performed, unlocking significant value through production efficiency, flexibility and lower costs and enabling substantial safety and environmental benefits (V Schweikart). Mines in the future are highly productive, with low production costs and are significantly safer. They operate with a skeleton crew and use intelligent systems that fuse information from field instrumentation and other sources to generate the most efficient operating environment. Automated systems are seamlessly integrated across the mine and across the corporate enterprise. Geological models, long-term and short-term plans create optimised production schedules, suitably generated by the mine simulator. Production schedules are shared with the operations management system for deployment mainly by remotely operated and autonomous equipment. As the schedule is implemented, information is collected and shared with various plans, schedules, models and optimisation programs. This production environment is managed in real time from a æCentral Operations CentreÆ and it is visible across the business providing fast and accurate information about productivity, machine condition and environmental conditions. Central Operations Centres also house teams of subject matter experts that monitor and manage the mines and are able to communicate directly with the skeleton crew in the field. Constraints across the production line are displayed and managed appropriately from this location to maximise throughput. Maintenance is interactive and predictive. Reliability specialists in Central Operations Centres monitor the status of machinery and equipment and adjust maintenance plans and strategies to suit. Mining businesses rely heavily on knowledge workers û people with considerable knowledge and learning û and by manual workers. This new knowledge workforce is a team of associates rather than of bosses and subordinates. Field experts become leaders with tremendous autonomy regarding their work. The former line hierarchy becomes a support structure, intervening only in extreme emergencies; instead of giving orders, they are now removing barriers, expediting resources, conducting studies and acting as consultants.

Jan 1, 2009

By M Brewster

Goldfields Abosso Goldfields Limited (AGL) is a Ghanaian registered company that owns and operates the Damang Gold Mine. Gold Fields Ghana Holdings Limited holds a 71.1 per cent interest in AGL. The Damang concession held by Gold Fields Ghana Holdings Limited covers a total area of 271 km2 located 40 km north of the town of Tarkwa in the south-western part of Ghana. Gold Fields as a company registered on the New York Stock Exchange is legally obliged to be SOX (Sarbanes-Oxley). Sarbanes-Oxley Section 404 (SOX404) is on management assessment of internal controls. The Mineral Resource Management (MRM) function of AGL manages three Prospecting Licenses and two mining licences. At least ten pits/prospects are scattered along the two limbs of the Damang Anticline and have two main types of mineralisation notably Paleoplacer and Hydrothermal. Thus SOX404 procedures are put in place to treat each mineralisation type in the best way for reliable resource outputs and estimates. Generating auditable resources for AGL is a prime but most important function of MRM. Thus important checks are built and designed to ensure that all relevant geological and geostatistical inputs conform to procedures outlined under SOX404 requirements. More importantly sign offs are designed to ensure that technical personnel involved in all aspects of resource and reserve generation are satisfied and can be held accountable.

Jan 1, 2007

This paper examines the latest advances in mine drive and motor systems. In the last decade, the drive technology employed for large mine winders has migrated from the traditional dc technology to ac motors with cyclo convertor drives. Recent advances in pulse width modulation (PWM) drives have resulted in these being applied to large winder drives. While having many advantages for the winder system, the PWM drive must be carefully designed to ensure long-term reliable operation. When combined with induction motor technology, the PWM drive presents the ideal solution for winder drives. This paper examines the factors in choosing a suitable PWM drive for a winder installation. Factors under consideration include: winder duty cycle, drive rating restrictions, choice of power semiconductor device, cooling, and low speed operation.The cage induction motor is the motor of choice for large winder drives and has a number of advantages over the synchronous motor. The induction motor is ideally suited to integrated winder applications where the motor is built inside the friction drum, as installed at WMCÆs Olympic Dam site. The challenges of integrating the induction motor into the friction drum will be detailed, including: assembly, ventilation, air gap adjustment, and position sensors.

Jan 1, 2005

By D Newton

The Mt Morgan Minesite in Central Queensland has been subject to both underground and surface gold mining operations since the late-1800s. The site is largely unrehabilitated and poor quality surface run-off and subsurface leachate is contaminating the nearby Dee River. The site is dominated by a large open cut, which now stores contaminated surface and subsurface run-off. Three models were used to simulate the complex hydrologic processes occurring at the Mt Morgan Mine: a rainfall-run-off model, a groundwater model and a storage behavioural model. Study results showed that the open cut is filling with water and will soon spill large volumes of highly polluted water to the Dee River on a regular basis if no remedial action is taken. This will result in a three-fold increase in pollutant load to the Dee River. Based on a consideration of water quality and quantity it was concluded that the first priority for future minesite water management should be the prevention of spills from the open cut. Potential management options to achieve this objective included surface rehabilitation, catchment diversions, modification of the pump-back system and controlled releases to the Dee River during floods. However, assessing the relative effectiveness of these measures required a thorough understanding of the complex surface and subsurface hydrology of the site. The results of a 100 year simulation of hydrologic processes revealed that previously favoured management options would be ineffective in preventing spills to the river. On this basis, a continuous treat and release strategy was proposed as the only reliable method of preventing future spills. The results of this study demonstrate that good environmental management decisions must be based on an understanding of the relevant physical processes and consideration of cumulative effects over an appropriate time scale.

Jan 1, 2003

By Walsh V

The Australian economy has been adversely affected by the hesitation in developing countries to commit to the construction of .new coal-fired power stations. World coal trade which was expected to grow at an appreciable rate has stagnated, world export coal prices have plummetted, and facilities in place in Australia for the production and export of coal are being underutilized. While in some countries this hesitation has been caused by a reduction in electricity load growth, another cause has been the unduly long lead-time imposed on developing countries by the conventional "Banker's Approach" to the planning and initiation of commitments to finance and construct coal-fired power plants. In some countries electricity growth has been met by increased usage of indigenous energy resources, even though this involves costs in excess of imported coal-fired power generation. The avoidance of foreign exchange commitments in these cases can however be desirable. In many other developing countries however, fuel oil continues to be used for power generation at a cost in foreign exchange of up to 50% above the total cost of coal fuel plus capital to construct a new coal-fired power station. The conventional "Bankers Approach" to new power station planning imposes the need for successive feasibility studies to satisfy the normal processes of international development lending agencies. No feasibility study can however, show how keen vendor countries may be to win major power plant contracts; and no feasibility study can determine whether the power station eventually procured will be one of the more reliable, at better than 80% availability, or one of the more unreliable at worse than 60% Availability.

Jan 1, 1987

This paper presents a review of heat illness in mining, including reference to several recent investigations by the author. Heat illness is a collective term, covering the conditions of heat stroke, heat exhaustion, heat cramps and miliaria rubra. Heat stroke is life-threatening and is by far the most serious condition. It is rare in mining, if appropriate control measures are instituted. Heat exhaustion is primarily due to hypohydration, following prolonged sweating in hot conditions. Symptoms include fatigue, headaches, dizziness, anorexia, nausea, vomiting, shortness of breath, or brief syncope. Confusion, ataxia, prolonged unconsciousness or convulsions are strongly suggestive of heat stroke. Heat cramps are painful involuntary contractions of skeletal muscle associated with work in hot conditions. The limbs are usually involved and the spasms typically last a few minutes, during which the affected part of the body is incapacitated. Heat cramps tend to occur in heat exhaustion, when hypohydration becomes marked. Miliaria rubra is a skin rash caused by extravasation of sweat into the skin, as a result of obstruction of the sweat glands. It occurs after prolonged and profuse sweating in hot environments. It can take three to four weeks of sedentary duties, in an air-conditioned surface environment, for the condition to resolve. Heat illness would be unlikely in underground mining, if the thermal environment was sufficiently well controlled by ventilation and refrigeration. This is however, often not practicable. Where engineering controls alone cannot provide sufficient control of risk, the residual risk can be assessed using an appropriate heat stress index. While procedural controls may further reduce the residual risk, it is important to remember that these are less reliable than engineering controls and cases of heat illness may still occur. Procedural controls include the application of heat stress limits, education, hydration, self-pacing, early symptom reporting, medical advice, acclimatisation procedures, air conditioned accommodation, support to achieve a healthy body mass index, and an effective emergency response capacity.

Jan 1, 2005

Caving is the lowest cost underground mining method, provided that drawpoint spacing, drawpoint size and ore handling facilities are designed to suit the caved material and that the drawpoint horizon can be maintained for the draw life. In the near future several open pit mines that produce in excess of 50 000 tons per day will have to examine the feasibility of converting to low cost, large scale underground operations. Several other large scale, low grade underground operations will experience major changes in their mining environments as large dropdowns are implemented. These changes demand a more realistic approach to mine planning than has occurred in the past, where existing operations have been projected to increased depths with little consideration of the change in mining environment that will occur. As economics force the consideration of underground mining of large, competent orebodies by low cost methods, the role of cave mining will have to be defined. In the past caving has generally been considered for rock masses that cave and fragment readily. The ability to define cavability and fragmentation, the availability of large, robust LHDs, a better understanding of draw control requirements, improved drilling equipment for secondary blasting and reliable cost data have shown that competent orebodies with coarse fragmentation can be exploited by cave mining at a much lower cost than with drill and blast Methods.

Jan 1, 1995

By Poplawski R. F

A 32-channel PSS seismic monitoring system was commissioned at Mt Charlotte mine in 1994, and at the time it was the first such system in Australian mines. The system continuously observes the occurrence of seismic events and locates them accurately in space and time. Mt Charlotte has a history of seismicity, with the largest event in recent years of Richter magnitude 4.3. The decision to 'go seismic' was made despite some uncertainty regarding its potential usefulness. However after the first year of operation, benefits have been realised in terms of less production downtime, improved mine safety and mine planning, and better understanding of the nature of Mt Charlotte seismicity. The seismic network has performed well, recording 550 events in its first year of operation to a location accuracy averaging ¦ 12 metres. System reliability is excellent, with very little downtime, and acceptable operation and maintenance times and costs. Observations show major distinct changes in the rate of mining induced seismicity over time periods of weeks and months. Events have tended to cluster in specific mine areas and on particular faults and structures. Case examples of pillar preconditioning, breakout around an orepass, and a major stope rockburst, illustrate the role of seismic data and the benefits it brings to safety, productivity and planning.

Jan 1, 1995

By Bhattacharyya AK

With increasing demand for more efficient production from the underground coal mines in the Southern Coalfields- of New South Wales, their design and operational aspects are constantly being reviewed and improved. One key area in such pursuits is the reliable design of stable and yielding pillars. The current designs of pillars based mostly on experience leads to unnecessary sterilisation of coal or strata control problems. To explore such mine design problems, computer based modelling is increasingly being applied. In the study described in this paper, the object was to determine the particular width of pillars separating three roadways in a panel at which the pillars yielded completely and their loads largely transferred to the unmined coal at the flanks of the panel. This was approached through a computer simulation of the behaviour of the strata around a panel, in which the three roadways were separated by pillars of progressively decreasing width. A computer program called FLAC based on the finite difference method was used to simulate the relevant strata behaviour in vertical sections. The appropriate in situ values of the deformability parameters relating to the coal seam, roof and floor were determined from the back analysis of some displacement measurements in such a panel. The process involved successive modelling of a vertical section through such a panel,starting with realistic values of the parameters and varying them until the measured and the modelled displacements agreed closely. Based on the results of the numerical modelling, the width of a yielding pillar for the given conditions is Suggested.

Jan 1, 1992

By Falconer A. J

Two magnetic parameters are proposed as a basis for the assessment of ironsands beneficiation. The parameters are deter- mined for raw sand prior to dredging and for magnetic separator head feed over a production period of five months. The relationships between these parameters and the performance of the magnetic separators are examined to establish the value of magnetic assessment compared with the traditional soluble iron assay method. The results illustrate that the first parameter, true magnetic fraction (TMF), has a value superior to that of soluble iron when relating raw sand grade calculated by tri- angulation to magnet performance. In terms of the relationship between magnet head feed grade and magnet performance, TMF and soluble iron perform equally as assessment parameters. For the ironsands mined during the five month period, the second magnetic assessment parameter, composite fraction (CR), is shown to merely reflect TMF and offers no additional information for assess- Ment. Conclusions are that true magnetic fraction has many advantages over soluble iron in terms of time and cost of determination and that it is a meaningful and reliable parameter upon which to base all calculations relating to the mining and beneficiation of ironsands.

Jan 1, 1980

The paper first outlines the conceptual basis for evaluating and controlling geological risk. Geological risk, the economic reflection of the uncertainties associated with tonnage, grade, and other pertinent deposit parameters, is evaluated in terms of economic risk criteria. Delineation provides the deposit information required to appraise and control this risk. The improved reliability of geological estimates resulting from additional delineation reduces the economic risk associated with mine development and production decisions. However, the benefits of delineation, subject to diminishing returns, have to be weighed up against the direct and time costs involved. These costs decrease base case economic values and shift the probability distributions of possible outcomes towards, lower values. The optimum amount of delineation normally is achieved short of the point where economic risk is minimised, depending on the mining company's relative preference for a higher base case value or a lower economic risk. Then, two open pit copper mine examples, based on actual situations, are analysed to illustrate the application of the concepts presented. The first case concerns the extension of ore reserves at an operating mine. Finally, a new mine development opportunity is considered.

Jan 1, 1994

By Roach C

Exploration on the Callide Coalfield by Thiess Bros. Pty. Limited had reached the stage in mid 1976 where there was a need for a comprehensive appraisal of the coalfield geology. Exploration strategy in 1977 - 1978 was defined by the selection of the most attractive targets. All available literature, reports and plans were reviewed and borehole records assessed. The geology of the coalfield was placed in its regional setting and the genesis of the Callide Coal Measures described in a structural and sedimentological context. Their general form and extent was then examined by the technique of stratigraphic analysis through the interpolation and extrapolation of the available data. A "localized" reserve classification was drawn up and reasonable estimates of the various geological reserves produced, in terms of their reliability and depth of overburden. Quality trend maps were also produced. The resultant "base map" was virtually a summation of all the information to June, 1977, and the basis for the exploration programme in the 1977 - 1978 financial year. The technique allowed for "base maps" to be produced at almost any stage, each one a refinement of its Predecessor.

Jan 1, 1978

By E Widzyk-Capehart

The conventional ammonium nitrate fuel oil (ANFO) loader utilises a pneumatic system to control the flow of ANFO (via rotary actuator/ball valve) and air (via an auxiliary air valve). This system, though relatively simple and reliable, has several drawbacks with respect to ease of control and level of automation. In this paper, a radio frequency (RF) remote control for explosives charging is discussed. The system design incorporates electric solenoid valves to control the rotary actuator and the auxiliary air valve. All operations associated with explosives charging are selectable at the remote and are completed according to a modifiable time sequence. This allows the following charging sequence to be reduced to a single momentary application of the remote:removal of water from the hole prior to charging with ANFO; charging of the hole for a preset but adjustable period of time; and removal of the remaining ANFO from the ANFO hose. A specially developed remote switch allows the operator to maintain two-handed control of the ANFO hose whilst achieving full control of the charge-up process. Failsafe electronic architecture is incorporated into the systemÆs design to increase safety to the highest level. Should the RF remote control fail, a wired remote is included in the system to allow for the charging process to continue, albeit at a reduced level of control. The application of the RF remote control system in an underground explosives charging operation minimises and/or eliminates many problems associated with the use of the conventional charging system. These include: the wet-hole problem, trip and entanglement hazards, air embolism and the two-man loader control requirement. The developed remote control unit proved to be effective at removing water from wet holes leading to increased face advance per drilling operation. It proved to be economically feasible, allowed for an increase in systemÆs dependability and safety factor and for a truly one-man operation which resulted in reduced manpower.

Jan 1, 1999

The earth is a planet limited in size and limited in total resources. For the forseeable future, it is the only available habitat for mankind. Therefore, it follows that the more we know about our planet the better we can utilize its space and its resources for our well-being now and in the future. But, to accomplish this, we need reliable basic information. Geosciences provide such information. Recently, Dr. M. King Hubbert took note of the important effect of the geosciences on society, on how we think, and how we live. In the first century of modern geology, 1780- 1880, the influence of geology was primarily on how we think, i.e. changing our concept of the earth from one with a short catastrophic history to one that developed gradually over enormous spans of time. In the second century, 1880-1980, the emphasis was on how we live, on expanding the knowledge base so that we could more easily find and utilize the earth's resources. Now, in the third century, i.e. from 1980 towards the year 2000 and beyond, we should concentrate on both how we think and how we live; i.e. how we can better estimate potential global' resources and how we can manage these resources for maximum benefit to mankind. Like other sciences, the geosciences build upon what has already been done. Progress is achieved by using the thoughts, measurements, and observations of past workers, adding to these the insights from new experiments and from new concepts. Geology has its own methodology and approaches; but more than most sciences, it calls also upon the tools of physics, chemistry, mathematics, engineering, and biology to help solve its problems. Today's increasing population, increasing industrialization, and increasing complexity of modern society demand more detailed geoscience information so as to better use the land, reduce geological hazards, provide an inventory of resources, facilitate waste disposal, and prepare for long-term effects such as changes in climate and sea level.

Jan 1, 1986