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By S Reid, W Chen, T J. Donohue, A Katterfeld

The use of discrete element modelling (DEM) is widespread in the materials handling field, and is used for many applications. One of the important limitations in using DEM is the number of particles that can be modelled, with this limitation often resulting in increasing the minimum particle size in the simulation. This restriction on minimum particle size is usually accommodated in the calibration process where the parameters in the simulation are chosen in such a way as to reflect the presence of smaller sized particles, and in typical applications such as transfer chutes this is standard practice. However, in the application of vibrating screens the inclusion of the ‘fines’ is critically important due to their influence on the screening efficiency. In reality, the presence of fines reduces the screening efficiency for a number of reasons; however, the main mechanism that will be addressed in this study is the effect of adhering fines. This is where the fines adhere to the larger particles and are carried over into the lump stream. The approach for this study will be to firstly consider the relatively simple mechanical sieving process used in the determination of particle size distribution, and then this will be expanded to consider the application of vibrating screens.CITATION:Donohue, T J, Chen, W, Katterfeld, A and Reid, S, 2017. Addressing the challenges associated with the modelling of iron ore in vibrating screens, in Proceedings Iron Ore 2017, pp 155–160 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 24, 2017

By W Assibey-Bonsu

The paper provides a brief review of the multivariate uniform conditioning and the localised multivariate uniform conditioning techniques and presents a case study based on a porphyry copper gold deposit in Peru. Two other important scenarios have been investigated and will be particularly emphasised: The recovered selective mining unit (SMU)s depend on a combination of copper and gold content, which can be expressed by means of ænet smelter returnsÆ (NSR). Two approaches are compared. Firstly, the application of a composite cut-off on NSR on the joint distribution of each grade and the application of uniform conditioning to three variables is investigated, ie for the first approach NSR is used as the main variable. The second approach considers copper as the main variable. In the case of multiple domains the procedure used to apply the technique to process mixed panels is clarified and recommendations are made.

Sep 26, 2011

By K Blay, C McCamley, P Petrucci

The Newmont Boddington Gold (NBG) processing plant was designed for 35Mt/y with ball mills expected to deliver a combined new mill feed rate of 4837 tonnes/hr. Since beginning commercial production in late 2009, the plant has steadily increased throughput to meet design capacity in 2014 and reached 37 Mt/y in 2015. Through improved efficiencies, changes to the milling circuit have taken place since commissioning to take the plant beyond its design to an actual throughput of 39.0 Mt in 2017 and a budgeted throughput of 39.4 Mt/y this year.The NBG milling circuit has four parallel ball mills, each consisting of a 7.9 x 13.4 m ball mill with twin 7.5 MW fixed speed motors in closed circuit with twelve 650 mm cyclones. Each mill is fed by two wet screens with the undersize gravitating to a mill discharge hopper where it is combined with the ball mill discharge and pumped to hydrocyclones for classification. The cyclone underflow is re-ground to a target P80 of 150 µm.This paper will focus on process improvements made to the NBG milling circuit which include cyclone reconfiguration, fine screen panel redesign, implementation of an expert control system, mill power draw increase and grinding media changes to take NBG beyond its design throughput.CITATION:McCamley, C, Petrucci, P and Blay, K, 2018. Going beyond design at Newmont Boddington Gold, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 497–508 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

By M F. Lee

Although the Mt Charlotte gold resource was discovered in 1893, it was only in 1954 that geologists correctly interpreted drill data and defined a large low-grade orebody. The mine has been a large, low-cost and profitable producer since 1962 when bulk mining commenced using cut and fill. From 1968 a combination of long hole open stoping with delayed mass blasting was used. This proved to be an excellent mining method for the large, separate subvertical orebodies. The structured but otherwise good quality rock allowed very large stopes to stand unsupported. Exceptionally large equipment, for its time, was used to efficiently mine, muck and move the ore at low-cost. The mine only just survived severe cost pressures in 1974-76, due to very low gold prices. Better gold prices in 1979 and a need to access deeper ore meant a bold commitment to sink the Cassidy Shaft and refurbish the mine to sustain future profitability. In 1997 the Sam Pearce Decline connected to the underground workings, making it profitable to mine upper level remnant ore. Mining-induced seismicity has been a feature of mining at Mt Charlotte. The main cause has been shearing on structures. A mine-wide seismic system was installed in 1994. Large seismic events have occasionally made management question whether a safe working environment can be maintained. Thorough investigations led to an understanding of the problem and development of procedures to minimise seismicity.

Jan 1, 2000

By G McLeay, T Moran

Long Shaft has traditionally been seen as one of the most challenging mines in the Kambalda area with operations having been suspended by the previous owners in 1999. When mining recommenced in October 2002, the current owners (Lightning Nickel) decided that a different approach was required for mining operations in such an aggressive geotechnical environment. This paper describes how Lightning Nickel has successfully and safely operated the Long Shaft complex on a traditional mining approach, which encompasses the key learnings of the previous owners.

Jan 1, 2005

By Kennewell G. J

This paper aims to present the evolution of the mining method in the Prince Lyell orebody. Initial strategy and practical experience are detailed as are the reasons for and benefits of changes to the method since 1972 when underground mining began. This section of the paper starts with ten series and concludes with 40 series which was completed in 1989/90.In addition, to update the series of papers written by various authors over the past ten years on Mount Lyell, a review of the experience in the current 50 series lift of mining will be given. As well, the basic planning guidelines are discussed for 60 series - the final lift of the Prince Lyell orebody.

Jan 1, 1992

By Z Li, D Chalmers, J M. Tenney

This paper presents the findings and analysis of the investigation of effectiveness of thin spray-on liners (TSLs) as a gas management tool in underground coalmines. The project involves spraying TSL on the area surrounding gas drainage holes whereby the TSL acts as a thin membrane decreasing the permeability of the coal. This restricts air migrating through the coal seam and diluting gas from the drainage holes. There are a number of potential benefits from this technique but key points are that gas drainage holes produce gas with higher concentrations of methane. The design and execution of a field trial to investigate the effectiveness of a TSL on purity of in situ methane from gas drainage holes is presented in this report. For eight drainage holes, the results show an average increase in methane purity by 9.14 per cent and a reduction in air contamination by an average 7.93 per cent. Overall methane flow rate decreased by 27.6 L/s; however, flow rates were unreliable due to poor measuring equipment. For most holes, methane purity was not changed significantly; however, certain boreholes were responsible for most of the variation in methane purity. The boreholes showing a dramatic improvement in methane purity were likely those with intersecting cleats covered by the TSL. If the TSL was sprayed over more area, specifically in areas where the cleats are intersecting with holes, it is likely that purity of methane in the drainage holes will increase.CITATION:Tenney, J M, Chalmers, D and Li, Z, 2015. Thin spray-on liners potential in reducing dilution of in situ gas in underground coalmines, in Proceedings The Australian Mine Ventilation Conference, pp 323–328 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 31, 2015

By Bure R

Approximately 2.4 million ounces of gold and 11.3 million ounces of silver have been produced from the Umuna Lode by Misima Mines Pty Limited between June 1989 and the end of Decemeber 1996. Reserves remaining at the end of December were 32.1 million tonnes at 1.0 gram per tonne gold and 9.7 grams per tonne silver. To attain precious metal production of this volume, an estimated K60,000,000 (1996 Kina) was spent on exploration alone. from the 1940s to the present day. Exploration expenditure for the 1996 calendar year was approximately K4,400,000. With such a large investment in exploration, large quantities of data were generated and stored in various forms. To make best use of this data, it was necessary to organise and systematically store this data in a form compatible with a modern Geographical Information System (GIS). The Umuna Lode on Misima Island is a low sulphidation gold- silver deposit dated at 3.5 ¦ 0.2 Ma. The deposit is controlled by the 50 to 100 metre wide Umuna Fault- a moderate dipping, brecciated clay- chlorite- carbonate altered, normal fault zone. There is approximately 230 metres of mostly dip slip offset on this fault, which is measurable by the offset of the Cretaceous schist, marble and greenstone host sequence. Late Miocene microdiorite spatially related to the Umuna Lode does not appear to be genetically related to the gold- silver mineralisation. GIS was introduced to Misima at the end of 1995 and until recently has been mostly used for data storage and retrieval, the over- laying of various data sets to assist in targeting prospective areas, and as a drafting tool. The use of data-driven, predictive data analysis is the most recent effort in maximising the use of the extensive Misima database. By characterising the key controls and properties of the Umuna- type mineralisation, a Weights of Evidence, data-driven analysis produced a prospectivity map of Misima Island. The purpose of this map was to identify prospective areas yet to be explored and to assess the effectiveness of exploration to date.

Jan 1, 1997

DESCRIPTION OF OREThe ore consists, in general, of a very finely grained mixture of sphalerite, galena, and pyrite, with a gangue of quartz and schistose material, and contains about one ounce of silver to the unit of lead.Minor minerals are chalcopyrite, tetrahedrite, and ruby silver. The amount of gangue within the ore-bodies themselves is usually less than 20% of the weight of the whole. The ore is banded in a way that corresponds to the structure of the original schists, and is by no means uniform in composition-at one point, for example, blende may predominate, and a few feet farther on the body may become highly pyritic.Owing to the intimate association of the mineral constituents of the ore, it is very difficult to separate them from one another.Although this remark applies to ore from all parts of the field, the difficulty is particularly noticeable with Rosebery ore, the minerals of which are more intimately mixed, and are of smaller grain size than are the minerals of the Hercules ore.To effect a reasonably clean separation, it is necessary to grind the ore so that 90% passes a 200-mesh I.M.M. screen. Microscopic examination of the crushed product shows that 85% of the minus 200-mesh material is less than 30 microns in diameter, or, in terms of screen sizing, is minus 400 mesh. Particles under 30 microns are found to consist, of one mineral only, but in particles over this size separation has not always been effected. For instance, it is known that part of the galena and of the pyrite in the zinc concentrate is associated with sphalerite, and that part of the galena in the mill residue is associated with pyrite. There is only slight association between the minerals in the lead concentrate.

Jan 1, 1927

OneSteel and BlueScope Steel have been working with the CSIRO to develop sustainable carbon fuels and reductants which are suitable for use in the iron and steel industry. One of the initial focuses of this work has been a process called steel recarburisation which is the addition of carbon to liquid steel to produce particular steel grades. This paper reports on the preliminary work and the recent full scale recarburisation plant trials conducted at the OneSteel Sydney Steel Mill.   Preliminary experimental work involved kilogram scale recarburisation of liquid steel with a range of commercial and prepared charcoal products. This work showed that charcoal dissolves into liquid steel very quickly and that carbon recovery to steel was inversely related to the charcoal volatile content. Initial larger scale work focused on the collection of wood, and preparation of low volatile charcoal which is required for steel recarburisation. Approximately three tonnes of charcoal was prepared at the Corrimal coke ovens of the Illawarra Coke Company. This charcoal was dried, crushed, sized and packaged in a form suitable for addition to 80 tonne liquid steel ladles.   The recarburisation trial was conducted over 30 ladle heats during June 2009. The charcoal was manually added to the liquid steel in 5 kg bags using normal plant practice. Conventional commercial recarburiser was also added to the liquid steel in alternate ladle heats. The performance of the charcoal was compared with the conventional recarburiser based on the carbon recovery to steel, hydrogen pick-up by steel and the rate of carbon dissolution into steel.   An analysis of the trial results showed that the charcoal performed at least as well as commercial recarburiser in carbon recovery and rate of dissolution but may have resulted in a slightly higher hydrogen content of steel. This is probably due to the higher moisture content of charcoal. The main challenges in the future include: increasing the charcoal density to improve transport and handling economics, securing a sustainable supply of biomass for the steel industry and developing a charcoal production industry so materials of suitable quality for both production and trials on other applications can be conducted.

Jun 1, 2010

By A McKay

The Great Artesian Basin (the Basin) is a large aquifer system underlying more than 20 per cent of continental Australia and most of Queensland. The aquifers of the Basin are an important water source for many industries, including the mining sector. The Queensland Great Artesian Basin Water Resource Plan (the Plan) was released in March 2006. The Plan provides a framework for the long- term holistic management of the aquifers in the Queensland Section of the Basin, in a manner that is consistent with the strategic management plan for the Basin as a whole. The paper describes the Basin and summarises trends in the demand for water in the Queensland section of the Basin. It describes the broad framework for management of the Basin by the individual Australian states, as well as the planning entitlement framework for water resource management in Queensland. The paper discusses the content of the Plan. This includes: the division of the aquifers into management areas and management units for management purposes, provision for protection of the flow of water to springs, limits on further allocating water, provision for a competitive process for access to new water and provision for water trading. Under the Queensland planning and entitlement system a resource operations plan is prepared to specify operational arrangements to implement a water resource plan. A resource operation plan for the basin is expected to be finalised before the end of 2006. The paper summarises the likely content of the plan.

Jan 1, 2006

By McKenzie P

The techniques of geological control developed by the Coal Geology Sections of the Broken Hill Proprietary Company Limited and Australian Iron and Steel Proprietary Limited in providing geological service in the coilieries operated by these associated companies cover the provision of geological control for both planning and production in each of which the significance of geology has in the past been only poorly appreciated by the coal mining industry.While the adoption of similar techniques is well within the capacity of major companies there is considerable scope for the development of government geological services providing specialized assistance of this nature for smaller scale producers.INTRODUCTIONThe coal mining industry in Australia can instance many notable mistakes caused by failure to obtain sufficient geological information or by incorrect interpretation of available geological evidence both before the commencement of mining and during the progress of operations. Substantial development undertaken in, areas with insufficient or inferior coal reserves, difficult mining conditions caused by failure to adjust operations to geological circumstances, and the irregular development of mine workings caused by unexpected geological features, all bear witness to the lack of geological foresight by the industry.Along with the more widespread general use of applied geology, an increasing acceptance has developed during the past ten years of the valuable contribution which can be made by this science to the exploitation of coalfields. In spite of the advances which have been made, there is still a wide scope for further detailed application of geology throughout the coal mining industry in Australia.

Jan 1, 1963

By A Bennett, A Peck

BHP has recently constructed a Hot Briquetted Iron Plant at Port Hedland in the Pilbara region of Western Australia. Supply of iron ore fines to the plant is by conveyor from the companyÆs existing Nelson Point stockyards. The conveyor passes under Port Hedland harbour in a concrete segmentally lined tunnel, approximately 1030 m long and with a 5.1 m external diameter. The tunnel was constructed by a Tunnel Boring Machine (TBM) which both excavated the ground and erected the tunnel lining. The tunnel was bored between cut and cover in situ concrete portal structures, the TBM being launched from the Finucane Island side towards Port Hedland town. The alignment required lengthy gradients of 1:6 on either side of the harbourÆs dredged channel, under which the tunnel is bored with a minimum clearance of 8 m.The tunnel is fitted-out with:1800 mm belt conveyor capable of 10 000 tph;walkway along which a specially designed inspection/ maintenance vehicle can run; andtunnel services including power, light, fire detection and suppression communications, water mains for wash down and sumps and pumps for drainage.This paper gives a general overview of the design and construct contract, important aspects of the design and the construction process itself.

Jan 1, 1999

Mining is both a high risk and a long term business. This is dramatically illustrated by the fact that, on average, the explorer will expend over $30 million in a ten year period for each significant economic discovery. The time required to complete the exploration process is one of the most substantial commitments made by any mining company. For example the time lag between the implementation of an exploration programme and an economic discovery is variously estimated to take two to ten years. The ore definition phase following discovery currently takes between two and five years while subsequent mine development may take one to two years in easy situations and up to 8 in difficult environments. In most countries the critical path through the early stages is determined largely by technical considerations but in almost all countries the path through the later phases is dictated by the plethora of permits, licences and community involvement steps.

Jan 1, 1982

By Davies S. G, Jayaweera A

The oxidation of nickel sulphide and copper sulphide concentrates, and coal, has been studied under non-ignition and ignition conditions using Differential Thermal Analysis (DTA) and Thermogravimetry (TG). The non-ignition reaction was favoured by slow heating rates < 10°C min-1), low masses < 10 mg) and an air atmosphere. Under these conditions, the typical stepwise oxidations of the various sulphide minerals present in the concentrate were observed as resolved exothermic peaks in the DTA curves and weight losses in the TG curves. Above a heating rate of 10°C min-1 , sample masses in excess of 10 mg and an oxygen atmosphere, an ignition reaction was induced, as indicated by a major high energy exotherm in the DTA curve and a major rapid weight loss in the TG curve. The ignition temperatures of the minerals under ignition conditions, found for 15 mg samples heated at 20°C min-1, were 434°C for the nickel sulphide concentrate, 372°C for the copper sulphide concentrate, and 230°C for the coal. By plotting a curve for mass against ignition temperature at constant heating rate and extrapolationto zero mass, a value of 470°C was obtained for the mass independent ignition temperature of the nickel sulphide concentrate. Ignition temperatures and extents of reaction at various temperatures were obtained using the TG technique in a novel manner which produced heating rates of 4500°C min-1. Under ignition conditions, the oxidations approximate to flash smelting conditions.

Jan 1, 1985

By V Louchnikov

Ever increasing depth of mineral extraction presents a challenging environment for hard rock underground mines. High in situ stresses and associated seismicity with potential rock burst hazards are the major decisive factors contributing to the choice of a ground support regime. Conventional ground support systems, designed primarily for static loads, are not always capable of providing safe working conditions for underground personnel in seismically active mines. Systems specifically developed to resist dynamic loading and allowing for larger deformations are therefore preferred alternatives. High-tensile chain-link mesh has a proven record of successful use in open cut operations in various rockfall barrier installations due to its high energy absorption capacity. It has also been used in underground operations in various parts of the world. Its application in Australian underground mining, however, is limited due to the high labour intensity. This paper describes a method of mechanised installation of a chain-link mesh as trialled at Golden Grove, a base metals underground mine in Western Australia. A purpose-built mechanised roll mesh handler, developed in Australia, was used in this trial. The handler is compatible with all standard multi-boom underground drill rigs and is operated utilising the hydraulic circuit normally used for the feed arrangement.A number of operational benefits have been identified during the trial, the main two being:•improved safety of underground personnel due to the reduced amount of manual handling, and•increased productivity due to the decreased cycle time (the trial suggests a 40 - 50 per cent reduction in time over the weld mesh installation method).Although the energy-absorbing mesh combined with yielding rock bolts is a ground support system of choice for rock burst prone conditions, the operational upsides recognised during the trial imply that this product can also be competitively used in less demanding ground conditions where customarily weld mesh or shotcrete are used as a primary surface support.

Mar 21, 2011

By D R. Seaman, R P. Tooher, B A. Seaman

"Several mine scheduling tools exist for use in optimising and scheduling the reserve according to in situ value. These tools generally value the ore on a per block basis according to regressed recovery models based on ore grade and type. It is then the task of the plant metallurgist to ensure that these ore blocks are fed to the plant in a manner that satisfies the prevailing plant constraints. This task is often completed in complex Excel® spreadsheets that are modified over time with factors applied to account for plant modifications or limitations.It is the authors’ experience that this approach is difficult to audit and replicate in a consistent manner. Furthermore, operational decisions, such as primary grind size or autoclave oxidation are made on the metallurgist or managements’ perceived optimum value and does not necessarily represent a cash flow based optimum.Many processing plants contain multiple internal constraints. As ore feed grades and properties change over the life-of-mine (LOM), processing-bottlenecks shift from one unit process to another and different operating strategies need to be adopted to maximise cash generation from the process.This paper presents a unified optimisation approach to scheduling ore based on a circuit mass balance to describe the process plant with individual models for each significant unit operation. The approach allows for optimisation over multiple input variables and the inclusion of linear and non-linear constraints.This optimisation process has been applied to different complex gold operations. The end result is an automated scheduler that selects the optimum blend of ores as well as plant operating conditions that satisfy all internal plant and shutdown constraints while maximising the objective of choice (metal production or cash flow). The models are also valuable for evaluating expansion or debottlenecking opportunities of individual processing units. These models are coded in Matlab® R2016a provided by MathWorks®, and can be deployed to end users in a compiled version with significant savings in time to run different scenarios over the Excel®-based systems.Citation:Seaman, D R, Tooher, R P and Seaman, B A, 2016. Optimisation of Complex Gold Processing Plants with Multiple Unit Operation Constraints - the Newcrest Planning Scheduler, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 191–198 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

For the past 40 years, underground trucking using diesel powered or electric wheel driven vehicles, either conversions of surface trucks, or purpose built, has been the preferred means of ore and waste transport in underground mining. The relatively low capital cost, flexibility and requirement for minimal infrastructure means that trucking systems are selected in the early stages of a mining operation. An increase in the carrying capacity of trucking systems with dimensions to operate within existing development excavations is the solution to long term ore and waste underground haulage systems using trucks. The next generation of underground trucks will be low profile articulated trucks with carrying capacities up to 60 t.

Jan 1, 1998

By A Millar, B Wraith

Process plants are characterised by variability of performance over a wide range of time-scales; reflected in fluctuations in metal recovery, concentrate grade, plant throughput and reagent costs. In turn, these fluctuations impact financial metrics such as operating costs and revenue. The primary cause of plant variability is variation in the physical, lithological and mineralogical characteristics of the ore fed to the plant. The variability of the ore is driven by the intrinsic heterogeneity of the geology and mineralogy of the orebody, the mining method and mine production plan, the capacity to stockpile and blend, as well as the plant flow sheet and the level of plant automation. Whilst the impact of ore variability on process plants is universally recognised, it is rarely quantified in financial terms. Consequently, opportunities to reduce its impact are often overlooked due to the lack of a basis for a quantifiable cost-benefit analysis to justify improvement initiatives. This paper will present case studies using production data from the Renison tin concentrator and a zinc concentrator. These case studies demonstrate that as the standard deviation of plant head grade increases (as a proxy for ore variability), plant metal recovery subsequently reduces. The metal recovery is then converted into plant revenue losses, to quantify the economic impact of ore variability. The Renison case study demonstrated that whilst a very rare occurrence, revenue losses were as high as 34 per cent (relative to the baseline) when standard deviation was at its highest. The zinc concentrator case study demonstrated that revenue losses were as high as 6 per cent (relative to the baseline) when standard deviation was at its highest. Options are available for reducing and managing ore variability in the process plant. These options include changing mining practices so that the ore is fed to the plant with less variability, more advanced process plant control systems and the use of predictive geometallurgical models.

Aug 24, 2022

By Jury C. G

A decade of expansion and high production targets have led to changes in the number and structure of the Mount Isa Mines Limited work- force. Falls in labour turnover and absenteeism are correlated with two demographic variables, improved selection and placement procedures and home purchase facilities. Some results of recent population surveys are presented and discussed in terms of future housing needs and potential employment problems encountered by school leavers.

Jan 1, 1974