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By S Jahanshahi

In an earlier LCA study, the authors showed that the electricity consumption of the electric furnaces used in the production of the ferronickel and ferrochrome feedstocks made significant contributions towards the Gross Energy Requirement (GER) of stainless steel production, on a æcradle-to-gateÆ basis. Given the relatively low efficiencies associated with electrical power generation, substantial reductions in the GER for stainless steel production could be anticipated if more direct use of thermal energy was made in the ferronickel and ferrochromium smelting stages.In view of these findings, a follow-up study was undertaken to investigate the likely environmental benefits of using bath smelting processes for the production of ferronickel and ferrochromium compared to the traditional rotary kiln-electric furnace processes, but still utilising the electric furnace process for stainless steel production. The METSIM process simulation software package was used to set up models of the two bath smelting processes and provide process energy requirements that were incorporated into the LCA. The environmental impacts considered in the LCA were greenhouse (Global Warming Potential, GWP) and acid rain gas (Acidification Potential, AP) emissions and solid waste emissions.The results of the study showed that the bath smelting route reduced the GER for ferronickel production by about 37 per cent over the traditional route, which translated to about a 21 per cent reduction in the GER for stainless steel. The corresponding reduction for ferrochromium was about half that for ferronickel, and when combined with the ferronickel result gave a 25 per cent reduction in the GER for stainless steel production. Similar reductions were also observed for the GWP and to a lesser extent the AP for both feedstocks, as all primary energy inputs were essentially fossil fuel based. Substantial reductions in solid waste emissions were also indicated for the direct use of ores in smelting. By utilising bath smelting processes for the production of the ferronickel and ferrochromium feedstocks, stainless steelÆs suitability for meeting many of the goals necessary for sustainable development, already recognised because of its particular properties, would be even further enhanced.

Jan 1, 2004

By N Pranoto, E Lawell, T Dean, M Grant

The Goonyella Riverside Mine is located 30 km north of Moranbah in Central Queensland, Australia. Recent mining activities have exposed the north–south striking Kenya and Zimbabwe thrust Faults. These faults vertically offset coal seams by up to 25 m and locally thicken coal packages through imbrication of coal seams. The presence of back-thrusts add to the geotechnical complexity of maintaining highwall stability. The Kenya and Zimbabwe Faults have provided multiple challenges to the mining operation, with an unplanned additional 240 kt of coal tonnes being mined from imbrication of coals seams or from the refinement to local scale geological models. These additional coal tonnes have been either identified during the mining of the coal seam or just prior to overburden removal above the coal seam. These faults can also negatively impacted highwall stability with highwall failures, lowering the overall slope angle for pit designs and increasing stand-off distances for hazardous highwall conditions. Unmanned Aerial Vehicles are used to scan exposed highwalls and enable geological mapping via high-quality 3D images. Measure while drill data from drill and blast rigs can provide local-scale intersections of the faults and coal seams. Mine Geologists utilise these and other data sets to create localised geological models refined position of the fault planes and coal seams. These models are utilised by relevant mine site teams to ensure the safe and efficient mining of coal around these faults.

Mar 22, 2022

By P Holtham, W Valery, P Baguley, A Jankovic

There is a growing interest in magnetite ores because of the increasing demand for this commodity. With these ores, there is significant cost associated with milling the ore to fine sizes using ball mills in closed circuit with hydrocyclones. Cyclone classification efficiency tends to be poor due to the large difference in density between magnetite and gangue. This decreases the grinding circuit efficiency and results in over-grinding of magnetite. The objective of the work described in this paper was to modify the Bond locked cycle milling test procedure to quantify the loss of grinding circuit efficiency due to the mineral density effect. The locked cycle test procedure described here includes a stage of magnetic separation treating the closing screen undersize, which allows simulation of magnetite classification. The effect of classifier efficiency on low-density particles (non-magnetics) was simulated by altering the proportion of closing screen undersize bypass returning to the mill. Using a magnetic separator and a screen in the magnetics stream, different proportions of the magnetic fraction can be bypassed, thus allowing simulation of the effect of particle density on classification efficiency. This laboratory test work has confirmed that the impact of mineral density on cyclone efficiency subsequently has a crucial negative effect on ball mill circuit capacity. The results are in good agreement with reductions in capacity observed in practice. Multicomponent grinding and classification models were also developed in the LIMN software environment and were able to successfully simulate both the industrial and the laboratory ball mill circuit. The test and modelling procedures established in this project could be used for improved design of new magnetite ball mill grinding circuits as well as the optimisation of existing circuits.CITATION:Jankovic, A, Baguley, P, Valery, W and Holtham, P, 2015. Effect of mineral density for milling magnetite ores, in Proceedings Iron Ore 2015, pp 159–164 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

By O Arafat, K M. Bartholomew

A voracious consumer of energy and grinding media, the modern ball milling circuit has a huge direct cost impact on a mineral processing operation. Through optimisation, grinding also has the potential to unlock great improvements in recovery and throughput, but how can the complex interactions between mills, classifiers, tonnage, ore-type and downstream recovery be measured, understood and managed in a systematic manner?Functional performance analysis provides the tools and insights needed to measure, understand and improve the two key process efficiencies in ball milling circuits: classification system efficiency (CSE) and mill grinding efficiency.CSE measures the composite performance of the classification system as a whole. In short, the purpose of the classification system is to ensure that grinding mill energy is used to grind coarse particles while minimising overgrinding. CSE is simple to measure in the plant and it provides immediate feedback to the plant metallurgist, mill superintendent and management about the performance of the classification system and the amount of wasted energy in the grinding plant.Mill grinding efficiency measures the capacity of the grinding mill to convert feed-sized material into product-sized material on a tonnes per kilowatt hour basis. It is normalised based upon the ore resistance to breakage, so it provides feedback about the ‘health’ of the milling process under varying operating conditions and ore types. Mill grinding efficiency is measured at the same time as CSE through circuit sampling.Functional performance analysis combines CSE and mill grinding efficiency to provide a measureable, manageable optimisation objective. It also provides a link to tonnage, ore type and recovery. As a result, systematic optimisation of a grinding circuit is a measureable and manageable process to meet business objectives.CITATION:Bartholomew, K M, McIvor, R E and Arafat, O, 2014. Functional performance of ball milling circuits – a plant metallurgist’s tool for process characterisation and optimisation, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 227–232 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

In gold ores, the range of value disclosed by ordinary mine sampling is very wide, and the number of 'samples required for a reliable average is correspondingly great. Even where a large number of samples is available the weighted mean value of the samplesalmost invariably exceeds the true gold content. In operating mines this disparity is overcome by arbitrary reduction of high assays until reconciliation is achieved, but it is frequently necessary, especIallyin exploration, to base an estimate or to reach a decision on a relatively small number of samples from underground openings or even on a few drill hole intersections. In these circumstances, a decisive influence may be exercised by the weight allowed to high assays and to low grade intersections, both of which events are, of course, dependent on the metal distribution in the ore. Where sufficient data are available, statistical analysis will measure the risk involved, but as this information is seldom to be had, the final choice becomes largely a matter of personal judgment.With this problem in mind, a study was made some years ago of the distribution of values in four Western Australian gold ores, with the primary purpose of learning from actual ore-bodies of differing types, something of the metal distribution in the smallquantities of ore involved in individual routine mine samples, and of the importance in each case of high assays. Adequate and suitable data were available in .four cases, in three of which high assays were of frequent occurrence due to the presence of free gold. The results give concrete expression to well known differences of metal distribution, and it is proposed, firstly to record the observed distribution; secondly to examine some of the consequences of the differences in the distributions limd thirdly, to comment, in the light of this data, on the vexed question of the treatment of high assays. Standard statistical procedure was employed in the compilation of the data. The assays were classified by value into groups, each group covering a range of value of 1 dwt. per ton. Assays of less than 1.0 dwt. per ton form the first group; assays equal to or greater than 1.0 dwt. and less than 2.0 dwt. comprise the second group; those equal to or greater than 2.0 dwt. and less than 3.0 dwt. appear in the third group; and so on. Where the number of samples is large, it can be assumed that the mid-value of the group is the mean value of all the samples in the group, thus the mean values of the first three groups are 0.5 dwt., 1.5 dwt. and 2.5 dwt. respectively.The number of samples in the group is the frequency of the group, but for convenience of plotting this frequency is converted into percentage of all the samples in the series. Plotting percentage frequency as ordinate against dwt./ton as abscissa results in a frequency curve-a curve showing the frequency...

Jan 1, 1950

By A S. Fogliata, L Bengochea, G Mas, J E. Lazarte

The Culampajß auriferous district is located in the northern sector of the eastern edge of the homonymous hill, Catamarca Province, Argentina. Tajo Largo mine is situated in the southern flank of Las Minas gulch at an approximate height of 3.600 m above sea level. In the studied area main outcrops are orthogneiss rocks of Chango Real Formation. The ore mineral is native gold with a lesser amount of pyrite, chalcopyrite, haematite, limonite, malachite, azurite and covellite. These ore mineral assemblages are disseminated in quartz veins filling tension fractures in the host orthogneiss.Several types of inclusions have been recognised, including three phase H2O-CO2liq-CO2vap inclusions, polyphase inclusions with H2O-CO2 and one or more solid phases, and two phase aqueous inclusions. In the three phase H2O-CO2liq-CO2vap inclusions the Tmclath is about 1¦C and the CO2 liquid-vapour homogenisation occurs at 26 - 28¦C, to liquid phase. The homogenisation temperature of H2O-CO2 occurs at 365 - 380¦C in the aqueous phase. This set of data defined a solution with a salinity of 14, 4 wt per cent NaCl equivalent and a density of 0.84 g/cm3. In the two phase aqueous inclusions the melting temperature (Tm) of -5.4¦C and the eutectic point (Te) in -38¦C indicates a salinity of about 7.5 wt per cent NaCl equivalent, with the probable presence of Ca2+. Density of fluid is about 0.83 g/cm3. Homogenisation temperature ranges between 260¦ and 280¦C. The pressure, temperature and salinity of fluids in the polyphase inclusions suggest an early fluid of high density and high salinity. The three-phase fluid inclusions may be the result of an unmixing-phase separation of post magmatic hydrothermal fluid due to pressure decrease along fractures. It is suggested that the deposit was formed during the late magmatic hydrothermal stage genetically linked to granitic rocks and can be comparable with the intrusion-related gold system of Baker (2003).

Jan 1, 2008

By L Cain, C Every, S Mirlatifi, J Ashley

This paper presents a geographic information system (GIS) based method for the prediction of ground movement and the associated impact on existing buildings and structures due to tunnelling in the North West Rail Link (NWRL) project. The NWRL is a priority rail infrastructure project for the New South Wales (NSW) Government and includes 15 km of twin tunnels between Bella Vista and Epping, which will be Australia’s longest rail tunnels. The NWRL tunnels will be constructed in an urban environment where the prediction of ground movements induced by tunnelling and the associated impacts to existing structures must be assessed in the early design stages of the project. An assessment process was developed using GIS able to respond to design changes.An iterative GIS analysis methodology was developed to generate ground settlement contours and identify impacted buildings and structures in response to multiple changes in tunnel alignment during design development stages. The GIS analysis undertook to rapidly provide detailed and accurate parameter information including tunnel depth from surface, tunnel separation, diameter and sample point proximity to the tunnel and assess ground movement contours along the project alignment. Determination of the ground surface settlements were based on empirical methods proposed by Peck (1969) and Mair (1993). The control parameters and the relationship between damage categories and risk classifications for impact assessment were based on Burland, Broms and de Mello (1977), Rankin (1988) and Boscardin and Cording (1989) methods.The GIS-based ground movement impact assessment approach adopted for the NWRL project demonstrates an efficient, iterative and robust approach and could provide an initial framework for other similar tunnelling projects where rapid design changes and early understanding of tunnelling impacts are required to bring greatest benefit to all stakeholders.CITATION:Mirlatifi, S, Cain, L, Ashley, J and Every, C, 2014. An iterative geographic information system based approach for the assessment of tunnelling impact to existing buildings and structures, in Proceedings 15th Australasian Tunnelling Conference 2014 , pp 647–652 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 17, 2014

By N S. Weerasekara, S Town, E Lessing, J A. De Torres

Philsaga Mining Corporation (Philsaga) had three main aims in converting their lining system from steel to metal cap. They wanted to increase mill availability, minimise localised high wear and optimise particle breakage to deliver increased efficiency within the milling circuit. Combining Discrete Element Method (DEM) modelling and empirical interpretation of liner wear resulted in a rigorous approach to understanding the impact of mill liners on overall mill performance. This new understanding was subsequently used to not only derive a new lining design to optimise performance and thereby improve overall plant economics, but also to guide further lining development.In this work, detailed DEM modelling, developed from actual plant data, together with optimising liner design for wear paved the way towards the installation of a Metal Cap lining system at Philsaga’s Ø6100 mm SAG Mill. The results were a reported increase in SAG mill throughput of 16 – 20 per cent due to improved breakage through more efficient use of installed power, a reduction in localised high liner wear with overall increase in liner life and reduction in liner replacement time. Site also reported an increased gold recovery of 2 per cent which the improved breakage might have contributed to. This paper will present the design challenges and compare the Metal Cap lining systems performance against Steel lining system. CITATION:Weerasekara, N S, Lessing, E, Town, S and De Torres, J A, 2018. Metal cap versus steel lining system at Philsaga Mining Corporation’s Ø6100 mm SAG mill, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 653–664 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

By M Brady, O Salisbury, C Claassen, B Beamish, H Baxter

Monitoring for signs of elevated spontaneous combustion in the active goaf behind the longwall face is crucial for early intervention of any potential heating incidents. Typically, trigger action response plans (TARPs) are established at the start of longwall mining and often are only reviewed when triggers are activated frequently and become ‘nuisance alarms’, or in the worst case scenario after a heating event. Narrabri Mine has adopted a proactive approach of reviewing the longwall active goaf spontaneous combustion monitoring TARP at the commencement of each longwall block and prior to reaching a known ‘mylonite zone’ of crushed coal, which is associated with increased coal oxidation. The review is based on information recorded from the monitoring data of the previous longwall blocks as well as interpretation of relevant spontaneous combustion propensity results for the coal. This has resulted in the mine implementing a zoned TARP approach for each longwall block covering both the longwall retreat through normal undisturbed coal and the zone where the goaf is influenced by the increased coal oxidation associated with the mylonite coal. The consequence of this approach is that it has removed the issue of having nuisance triggers being activated during mining through a known increased oxidation zone, while maintaining a high awareness of indicators of spontaneous combustion.CITATION:Baxter, H, Claassen, C, Salisbury, O, Brady, M and Beamish, B, 2015. Implementation of a zoned trigger action response plan associated with changing mine conditions at Narrabri Mine, in Proceedings The Australian Mine Ventilation Conference, pp 113–120 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 31, 2015

By G S. C Murray

Major mining projects are developed with the assistance of lending institutions who provide hundreds of millions of dollars in funding over several years, and of course expect those funds to be returned with interest. Two Australian banks have adopted the Equator Principles, an emerging financial industry benchmark for assessing and managing environmental and social risk in project financing. Project financiers have encountered environmental and social issues that are both complex and challenging, particularly with respect to projects in the emerging markets of Asia-Pacific and elsewhere. There are many recent and historical examples of failures by resource companies to effectively manage their environmental, social, safety and security risks, some of which have caused the project to fail completely, and some of which have caused the temporary cessation of production. These events put the financial institutionsÆ funds at risk through inadequate management capacity and non-compliance adversely affecting the ability of the borrowers to repay the loans. They can also reflect adversely on the reputation of the lending institutions. In assessing these risks, lenders are increasingly looking at the track record of the borrower in its country of origin and in other countries where it operates. Lenders are wary of companies that have one standard for operations in a developed country, where the regulatory environment may tightly control what they do, and another standard for operations in countries where the regulatory regime is perhaps less stringent. Lenders may require environmental and social reviews or audits to be conducted on their behalf by competent third parties prior to a loan being approved, and annually over the life of the relationship. The mining industryÆs concept of the unwritten æsocial licence to operateÆ is highly relevant in relation to the delivery of community benefits that are sustainable post-mine closure. This paper provides examples of recent practices that support financial viability and sustainable development, as well as examples of some failures that have put lenders at risk.

Jan 1, 2007

By H S. Shin, H Jin, B H. Ryu, J Lee

Prospecting ice on the Moon necessitates drilling systems to obtain subsurface samples and measure the composition of ice deposits. Landers and rovers equipped with drilling equipment are essential for analysing ice and subsurface resources located at the Moon’s poles. These devices must be small, lightweight, low-power, highly efficient, and high-performance units to function properly in the extreme conditions of the lunar environment. Researchers have developed a prototype drilling apparatus capable of operating in atmospheric and cold environments. A newly developed drilling system in Korea, capable of performing not only sampling but also subsurface investigation, is introduced.

Sep 1, 2024

By Y M. Lee, Y Hong, B C. Kim

Since sintered ore is the primary source for producing molten iron in the blast furnace process, maintaining stable quality despite the utilisation of low-grade iron ore is crucial. However, conventional analysis methods, such as chemical composition, ore size distribution and types of iron ore, have limitations in developing the utilisation of new low-grade iron ore and predicting sintered ore properties. Sintered ores are formed through a complex melting process of granule particles consisting of iron ore, flux and fuel. Consequently, it has been investigated that analysis methods which apply the reactive properties of iron ore to predict sintered ore characteristics. In this study, we estimated the properties of iron ore by simulating the assimilation process of coarse ore, which influences the bonding strength of sintered ores and quantifying the degree of assimilation reaction. Pseudo particles were formed by granulating coarse ore (1–3 mm) with adhering fines, which act as primary melts and sintered at 1623 K. The bonding strength of individual sintered ores, formed from 11 different types of iron ore, was measured using a simplified Tumbler Index (TI) test and each value was indexed as the Iron ore Reactivity Index (IRI). By investigating the relationship between the degree of assimilation depending on iron ore properties and the characteristics of sintered ore, we demonstrated that sintered ores formed from more reactive iron ore exhibited stronger bonding strength. Moreover, when blending conditions resulted in a higher Iron Blending ore Reactivity Index (IBRI), the physical properties of sintered ore improved. The development of this analysis method is expected to not only enable careful consideration of iron ore usability but also allow for the advance prediction of sintered ore qualities by deriving the IBRI.

Sep 18, 2023

By K Fiedler, A Newell, P D. Munro

Test work is the foundation upon which the success of projects and subsequent operations is laid, reflected in Professor Arthur Taggart’s pithy observation: ‘Make your mistakes on the small scale and your profits on the larger scale’. Indeed, Professor AllanTrench has succinctly noted that ‘Get the metallurgical characteristics wrong and you don’t have a project’.With deposits becoming lower grade, more structurally and mineralogically complex, final products requiring lower levels of impurities and tailings management demanding more attention, test work now assumes even greater significance in the acceptance and successful execution of a project. This paper is the first in a series aiming to stimulate thought on the metallurgical test work process by getting back to the fundamental basics through exploring and providing some guidelines for the metallurgical testing world, noting preferred practices as well as precautions and mitigations. This covers the key characteristics of metallurgical test work programs, including what needs to be done, sample selection, quality control and associated drivers, and most importantly, selecting, assessing and managing test work facilities. CITATION:Newell, A, Munro, P D and Fiedler, K, 2018. Metallurgical test work – between a rock and a hard place, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 15–32 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

By G Metzner, R Rodriguez, C Savage

OK Tedi Mining Ltd. (OTML) is in the process of optimising the concentrator performance. One aspect that has been recently implemented is an upgrade of the existing expert control philosophy on the grinding circuit and this will be the topic of this paper. Ore grinding in SAG mills is a multi-input multi-output (MIMO) process subject to several disturbances, most typical being quick acting disturbances such as changes in ore characteristics like hardness and particle size and slow acting disturbances such as ball charge variations and liner wear. The OTML SAG mills treat ore from diverse ore bodies and receive fresh feed subject to large changes in particle size. These circumstances make these mills particularly challenging to control. In this paper, a comparative analysis is presented between the performance of the OTML SAG mill #2 before and after the commissioning of a hybrid control strategy. The strategy uses Expert Knowledge combined with advanced disturbance rejection to reduce the variability of the main process variables, especially pressure and power. It further optimises the overall operation by driving the SAG mill #2 against process constraints (e.g. high power, high motor temperature and high scats recycle rate) and maintaining the operation at or near this point. This strategy is implemented by a combination of the manipulated variables (i.e. fresh feed tonnage and % solids) at any given time.The paper will present trends and a statistical analysis of the comparative results of the mill operation over a period of months, showing a 30% reduction in mill power / pressure variability and a 12% improvement in average power drawn. An increase in throughput was also observed, but cannot be conclusively attributed to the change in mill control due to other changes that were made to the SAG mill #2 during the period of comparison. An additional benefit includes better acceptance from the operators with improved consistency of the SAG mill #2 operation across shifts.The paper will also discuss further improvements envisaged in the continued optimisation of the grinding control circuit.CITATION:Savage, C, Rodriguez, R and Metzner, G, 2013. Hybrid process control strategy for the Ok Tedi Mining Ltd semi-autogenous grinding mill #2 - A comparative analysis, in Proceedings MetPlant 2013 , pp 202-214 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 15, 2013

By S Hanrahan, S McLaughlin

A case study is presented that details the safety journey at a North American project involving two major contracts: a 1000 m shaft recovery and rehabilitation, and the development of a drainage gallery in a large open pit operation. In the early stages of the contracts, there were a number of incidents that created tension between the owner and contractor, which resulted in the contractor being placed on a final warning with almost imminent potential termination. As a result of this, it was agreed to initiate a focused safety recovery plan as a ‘last chance’.Over a period of two years, the engagement and consequent performance of the contractor was turned around, steadily working to set it up for success such that in one of the contract work areas, a record of ‘one year LTI (lost time injury) free’ was achieved. The journey involved the owner and the contractor teams working cohesively to educate all parties in the safety requirements and, most importantly, providing the context and understanding for certain requirements being put in place. Early on in the process, it was recognised that the owner team unknowingly was an impediment in that they did not fully understand the safety requirements and so was not able to lead the way for the contractor effectively. The journey to rectify the situation was supported and followed up by focused engagement with the project team, which generated a progressive improvement in a very challenging environment.In particular, the contractor turnaround was significant and of enough value for the contractor to ultimately export some of the safety systems from this site to other contract sites. This demonstrated the ultimate benefit of the contractor understanding and buying into a safety culture and system.CITATION:Hanrahan, S and McLaughlin, S, 2016. Winning the safety battle, in Proceedings International Mine Management Conference, pp 181-186 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jun 22, 2016

By M Andrew, H Reynolds, R Mills

As the global mining industry continues to grapple with ‘black swans’ (high consequence / low frequency events) for health, safety and environmental losses, the focus is shifting from risk assessment of these events to risk management using selected purposeful controls that reduce the risk.Fundamental to critical control management (CCM) is a soundly based rationale for selecting the right controls for each and every risk. The approach should be based on a thorough understanding of the dynamics of the event: What causes it? How frequently will it occur? How likely is the consequence to be realised? This is typically done through a bowtie and methodical numerical risk analysis. Core to this step, then, is the structure and content of the bowtie; specifically, the analytic architecture that is used to construct the bowtie. Different architectures yield different constructions, and bowties are no different.Although bowties for operational health and safety (OHS) hazards appear to have a common architecture, they are not generic. It is important to stress that they contain site specific information, are prepared by site based operational teams, and vary from site to site to reflect each site’s operational conditions. They are often a product of the knowledge and understanding of the operational teams involved, may be prone to human error, and potentially miss latent hazards that may have been embedded early in the planning, design or construction phase of a mine or facility, or within the mining equipment. Overcoming these deficiencies through constant re-evaluation of the risks, and challenging the content on the bowtie will help to minimise the chance that something will be missed.This paper will cover key themes in bowtie architecture, introduce the concept of barrier models for high consequence event (HCE) bowties and present a relevant case study to illustrate the issues that determine quality in bowtie construction and critical control (barrier) selection and management.CITATION:Mills, R, Andrew, M and Reynolds, H, 2016. Can we stop a black swan breeding? Advances in bowties and critical control management, in Proceedings International Mine Management Conference, pp 105-114 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jun 22, 2016

By B J. Beven, A Harris, L Balzan

Fortescue Metals Group flagship operation, Cloudbreak, is located in the Pilbara region of Western Australia. The mine is capable of delivering an annualised production rate of 40 Mt/a. Positioned 50 km to the east of Cloudbreak is Fortescue’s Christmas Creek operation, which has a combined processing capacity in excess of 50 Mt/a. Following on from these successes, Fortescue advanced development of its western Pilbara mines at the 60 Mt/a Solomon Hub. These processing installations place Fortescue in a strong position to deliver on a guidance of between 155–160 Mt/a for financial year 2014/2015.As Fortescue enters a phase of asset consolidation and debt repayment over expansion, the business is commanding stronger performance through enhanced plant operating practices and mine site cost reduction initiatives. To this end, the strategic placement of instrumentation is an area being given greater consideration. Access to real-time information pertaining to conveyed materials is of major interest to operators for making timely process control decisions. Fortescue has recognised the importance of accurate and up-to-date process information about their ores and hence, has adopted the use of Scantech’s Geoscan mineral analysers at two of their mines.There are two Geoscans at Cloudbreak; one on the ROM feed conveyor and another on the final product conveyor. These allow the in-feed material grade characteristics to be assessed. Moreover, the final product stream can be monitored to ensure product quality is maintained within acceptable quality tolerances. A third Geoscan is installed at Christmas Creek mine on a conveyor that transfers final products to Stockyards.This paper discusses the use of the Geoscans in these installations, including benefits to Fortescue’s operations, as well as functional considerations such as the impact of maintenance and calibration. A discussion of recent advances by Scantech is provided including enhancements to the calibration process and minimising plant downtime, along with a summary of results obtained.CITATION:Balzan, L, Beven, B J and Harris, A, 2015. Geoscan online analyser use for process control at Fortescue Metals Group sites in Western Australia, in Proceedings Iron Ore 2015, pp 99–106 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

By H Utama, hi, A Suw

PT. Indo Muro Kencana (PT.IMK) is gold and silver mine located in Central Kalimantan province, Indonesia. Mining activities in PT.IMK is conducted in Bantian pit area by applying surface mining method and using combination of excavator and hauler (articulated dump truck and rigid haul truck) as the transportation for ore to the crushing plant and waste material to the waste dump. Current blasting practice is ore-waste blasting. Ore-waste blasting is the term where the ore and waste rock are blasted in the same blasting process. Blasting is conducted by using nonel initiation system. By multiple pits operation, monthly powder factor is varied from 0.23 kg/t to 0.27 kg/t. Emulsion blend with density 1.15 g/cc is used as bulk explosive. At this stage, the concept of geoblast is proposed as an engineering tool for Drill and Blast engineering practice in PT.IMK. In addition, there is a need to maintain rock fragmentation by blasting, to maintain monthly powder factor, and to maintain excavator’s productivity. Next, the concept of scaled depth of burial (Chiappetta and Treleven, 1997) and the concept of blastability index (Lilly, 1986) are proposed as geoblast’s tools to improve blasting practice in PT.IMK. It is expected that rock fragmentation by blasting, explosive consumption and excavator’s productivity will be maintained by integration of geoblast and drill and blast engineering. Furthermore, the objective of this paper is to integrate geoblast and drill and blast engineering in order to create an engineering guideline in PT.IMK. Additionally, blasting trials with air decking application is proposed in order to support the geoblast’s improvement. It is planned that these blasting trials will be conducted in 2022. In conclusion, it can be seen that integration of geoblast and D&B engineering in PT.IMK is relevant to improve current drill and blast current practice and applicable to maintain rock fragmentation by blasting.

Nov 29, 2022

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

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

May 9, 2017

By A Jewbali, R Perry, R Inglis, L Allen

"The use of conditional simulation to characterise mine plan uncertainty is increasing for the assessment of risk in mining projects. While the development of grade uncertainty profiles is relatively straightforward and can be validated using standard geostatistical techniques, the addition of geological uncertainty to evaluate total risk remains problematic. Some of the problems associated with geological uncertainty methods include the clustering of data in favourable geologic units, difficulty in training image definition and the inability to address change of support issues for categorical variables. Despite these obstacles, the importance of geological uncertainty as a contributor to total uncertainty has prompted Newmont to explore and evaluate the use of various techniques (and combinations of techniques) on different deposit types.Two orogenic deposits of different geological complexity were selected for the study: Subika, a shear zone-hosted deposit, and Merian, a deposit containing gold mineralisation associated with quartz vein zones and stockwork within which are found higher-grade quartz breccia zones. Newmont trialled various categorical simulation approaches to determine the applicability of these methods for each deposit type and the effect of parameter choice on the width of the uncertainty interval. Some of the techniques that were trialled include multiple point statistics methods, sequential indicator simulation using local probabilities as well as variations of these methodologies.The goals of this study included: gaining an understanding of which techniques may work best in which deposit types gaining an understanding of the intricacies of each method gaining an understanding of the effect that each method has on total uncertainty analysis.This paper presents a comparison of the various techniques and makes recommendations for their use in uncertainty analysis.CITATION:Jewbali, A, Perry, R, Allen, L and Inglis, R, 2014. Applicability of categorical simulation methods for assessment of mine plan risk, in Proceedings Orebody Modelling and Strategic Mine Planning Symposium 2014, pp 85–98 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Nov 24, 2014