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By Kendall W. T C

This paper provides a brief overview of the history of the Chaffers Dewatering Project which was successfully commissioned in August 1993. Until the end of 1992 the `Superpit' and the deep mines of the Golden Mile had all been dewatered by a staged pumping system from the 28 level in the Lake View Shaft, which was removed at that time when the Lake View Mine was absorbed into the Superpit. Feasibility analysis had indicated that adaptation of oil industry technology offered the greatest potential for a low cost solution to the problem of dewatering the open pit and deep mines. A KCGM engineer and one of the authors visited the Jackson oilfields to look at the deep well pumping technology in use there in early-1991. In the final analysis a new dewatering station was established in the 23 level crushing station of the Chaffers Shaft using conventional plunger pumps, but the rising main was screwed 178 mm OD (7 inch) casing the suspended from the surface to a depth of 686 metres, and was installed using oilfield personnel and methods. Only the second installation of its kind in Australia, the project achieved the dewatering objective at about half of the capital cost of the more conventional approach and at lower operating costs as well.

Jan 1, 1995

By M N. Mian

The Cayeli volcanogenic massive sulphide deposit is located in Black Sea region of Turkey. Cayeli Bakir Isletmeleri (CBI) was formed as a joint venture between Inmet (Canada) and Eti Holding (Turkey). CBI is processing complex copper/zinc sulphide ores. The Cayeli concentrator was commissioned in 1994, with a design capacity of 600 000 tonnes/year. The grinding circuit was a classical rod mill/ball mill combination. The rod mill was converted to a primary ball mill in May 1997. The reasons for conversion were to use mill power more efficiently and eliminate feed interruptions during rod charging. The grinding circuit now has a primary ball mill in open circuit, and a secondary ball mill in closed circuit with hydrocyclones. Classification was originally done in two stages with hydrocyclones. Both mill discharges were combined and pumped to a primary cyclopack having two, 500 mm diameter cyclones. Primary cyclone overflow was pumped to a secondary cyclopack for further classification. The secondary cyclopack had ten, 200 mm cyclones. Both unit underflows were fed to a secondary ball mill by gravity. The secondary cyclone overflow, typically 62-64 per cent passing 36 ¦m, at around 42 per cent solids (w/w) was fed to flotation circuit. In order to increase circuit capacity to 1 000 000 tonnes/year and to improve control over the grinding circuit, it was decided to convert the classification circuit from two stage to one stage. For this purpose, six Warman Cavex cyclones having 400 mm diameter were installed. Now, the combined primary and secondary ball mill discharge was classified in single stage with the Warman cyclones in closed circuit with the secondary ball mill. The cyclone overflow goes directly to the copper rougher circuit as flotation feed. The grinding circuit is producing a flotation feed of 70 per cent passing 36 ¦m. The change over to single stage classification at Cayeli was successful. A mill throughput of 1 000 000 tonne/year is being achieved with better control over classification, and improved grind size. Results and comparison between the two classification circuits are presented in the paper.

Jan 1, 2003

By Houghton BF

Ruapehu is an extremely active andesitic composite volcano, built in at least four cone- building episodes over the last 250 ka. The volcano was constructed by a variety of extrusive and subplinian, strombolian, phreatomagmatic and dome-related explosive eruptions from summit, flank, and satellite vents. The volcano may be subdivided into the cone itself, of volume 110 km3, and a surround- ing epiclastic ring plain of similar size. Four facies associations can be recognised at Ruapehu,-two each on the cone and on the ring plain. Neither cone nor ring plain provides a complete record of the history of the volcano. The cone is dominated by the products of extrusive eruption, as primary pyroclastic deposits are seldom preserved, being rapidly removed by erosion from the steep water- saturated and/or snow-covered flanks of the cone. The ring plain consists of the products of mostly explosive activity forming an alter- nation of primary pyroclastic fall deposits and material transported from the cone by lahars, floods and debris avalanches and then rapidly reworked in sediment-choked hyperconcentrated Streams.

Jan 1, 1987

By A Suokas

Boliden Tara Mines Ltd, located in County Meath Ireland, produce in excess of 2.5 million tonnes per annum of ore from the underground resource located 40 miles north west of Dublin. The zinc-lead ore is mined using long hole open stoping techniques, with ore treated on site. The operation is continually searching for new ways to improve productivities at the mine, and have employed a detailed data acquisition and reporting system on site to provide feedback around performance. One area where both Boliden Tara Mines Ltd and Orica Mining Services believed improvements could be made was in the application of bulk emulsion technology through an Orica supplied but Tara operated Maxipump Delivery System for all production and development blasting at the mine. Both parties committed to the evaluation of this technology at the mine, however the capital cost and technical and economic changes meant the project needed to be diligently investigated and any improvements documented. The first stage of this project was for Orica Mining Services personnel to visit the operation, and conduct a detailed analysis of the operationÆs performance over the past 12 months. The next step in moving forward was then to commission and utilise the customer operated emulsion system at the mine. This was then followed with the collation and analysis of data from the demonstration period to examine and document the benefits of the system. This paper is a summary of the observations made during the site inspection and the data analysed to date, and has been used in determining operational and financial improvements in the comparison between a Maxipump Emulsion Service and the current ANFO loading systems.

Jan 1, 2005

This paper will address this question from the point of view of a drill and blast engineer or researcher working in open cut and underground mining operations. The paper will establish a common set of reference standards for high-speed imaging and data capture, which engineers and researchers can apply when deciding which type of imaging technology is appropriate. It will present an overview of current image analysis technologies and practices in use across a range of appropriate scientific fields and draw lines of commonality of approach between these fields and the field of mining and blasting applications analysis and research. In addition, the paper will examine the different technologies from an image quality and data stream reference point, ease of operation, cost, and reliability parameters. Finally, this paper will present an argument for the hybridisation of established and new technologies which could provide a more beneficial approach to the use of imaging as a tool of quality control, research and analysis in the mining based industries. This will include a novel approach to digital high-speed imaging and data analysis in the field, which should deliver high-quality images and data analysis in a time frame that is more appropriate to the need for immediate action, analysis and problem solving.

Jan 1, 2007

HISTORY OF PROCESS DEVELOPMENT The manufacture of coke from coal commenced at the beginning of the 17th century by heaping coal into circular mounds in the open, covering with earth, clay or ash and slowly burning the coal in the mounds to produce a heap of coke. Naturally the process was slow in production rate with low coke recovery due to the loss of that part of the coal which was completely burnt to ash. As a natural consequence of this initial carbonisation method, a coke oven design was developed so that the coking chamber, which was constructed of brick, was circular in plan, cylindrical in section with a dome shaped roof - similar in shape to the original coal mounds. As the shape of the chamber was similar to the old dome shaped beehive, the ovens were called beehive ovens. The ovens were built in long single or double rows with retaining walls between each oven and as such were known as a battery of beehive coke ovens. In these early beehive ovens, coal was charged from hand wheeled tubs into a hole into the top of each oven, hand- levelled with a rake and the oven side opening sealed with bricks and clay except for some small holes in the opening to admit limited quantity of air for combustion. Coking commenced by the heat retained in the brickwork from the previous charge. The gases evolved from the coal, together with the admitted air, were partially burnt inside the oven to supply the heat for carbonisation and the surplus gases were burnt to waste at the top charging hole. The heat from this gaseous combustion inside the oven together with the reflected heat from the brickwork of the arched roof of the oven allowed carbonisation of the coal charge to proceed from its surface slowly downwards to the floor of the oven. At the end of the coking cycle (usually 4 or 5 days) when there was no more evolution of gases, as indicated by diminishing gas flame and a drop in oven temperature, the brickwork of the oven opening was removed. The coke was then quenched by inserting a pipe with spray holes to spray water over the coke charge in the oven after which the coke was raked from the oven. The work of charging and levelling the coal, bricking and removal of oven opening, quenching and raking out the coke all required manual labour. As these ovens only carbonised a 5 to 7 ton charge of coal per cycle of 4 to 5 days, to produce 3 to 41/2 ton of marketable coke, the labour required per ton of coke was high.

Jan 1, 1975

By M I. Pownceby, M A. Rhamdhani, D M. Fellicia, S Palanisamy, R Z. Mukhlis

The trend of global copper production has prospectively increased over time. Based on typical mined ore grades, 1 t of copper ore generates approximately 6–10 kg of copper, which requires much energy, usually in the form of metallurgical coke. Copper production using carbon as a fuel and reductant contributes up to 0.3 per cent to global greenhouse gas (GHG) emissions. As a result, research into decarbonisation processes applicable to reducing low-grade copper sulfide ores, copper oxides, electronic wastes and other alternative complex Cu-rich materials has increased. Alternative fuels for reducing carbon-rich emissions in pyrometallurgical copper processing include methane, ammonia, biomass, solar and wind power, but in recent times increased focus has been on hydrogen as a potential fuel and reducing agent for materials such as oxidised copper scrap, Cu2O/CuO and Cu-rich slags/e-wastes. From a thermodynamic perspective, hydrogen exhibits a significantly more negative standard Gibbs free energy (ΔG°) than copper oxide making it a suitable reductant and the exothermic thermal effect from reaction between hydrogen and Cu2O/CuO may be used to control process parameters. These characteristics renders hydrogen an ideal gas for reducing copper oxides and copper-containing slags/e-wastes. This review article assesses previous research on utilising hydrogen for producing and refining copper from primary and secondary feed materials.

Jun 19, 2024

By J Watson

Electronic detonator technology has been under development for the last two decades. Currently, there are a number of systems commercially available with several others still under development, each with its own unique features. This technology can offer a significant advantage to the drill and blast engineer through their ability to initiate an explosive charge at the æplannedÆ time. This new technology has created huge interest within the drill and blast community and also raised their expectations to produce better blasting outcomes. In many cases, specifications (or even expectations) of desired blast results are not properly defined. Interaction between the input variables (rock mass characteristics and blast design) and results (fragmentation, throw, damage, ground vibrations, etc) and their mechanisms, or relationship to one another, are not very well defined or understood. That is why rock blasting is still considered by many as an art rather than science. With one of the few remaining variables (cap scatter) now controllable, todayÆs blaster finally has the ability to apply science to his trade. Even though electronic detonators are available and becoming more commonly used, current field practices are not always conducive to extracting or deriving the maximum benefit from this new technology. In the authorÆs opinion, the following need to be understood to derive and sustain the maximum value: clear definition or specification(s) of desired outcomes from a given blast; impact of different features in an electronic detonator system (precision, accuracy, flexibility, reliability, etc) and their impact on the desired blasting outcomes; interaction of blast design variables (energy, energy distribution, timing, blast geometry) and their impact on desired outcomes; impact of rock mass variability and quality of blast implementation on the desired blasting outcomes; and critical need to utlilise appropriate tools and systems in order to measure and quantify benefits.In the authorÆs opinion a scientific implementation process is the key to derive the benefits. This paper analyses the industryÆs preparedness to derive the benefits from this technology and proposes a scientific methodology to understand, evaluate and sustain the value from this technology.

Jan 1, 2004

By Richardson G. W, Yap L. C

Friction rock stabilisers (FRS) are steel-based, thin-walled tubular ground reinforcement widely used in underground mines in Western Australia. Following installation these stabilisers are subject to corrosion which may reduce the load carrying capacity and lead to unexpected ground falls. Although corrosion has been recognised as a common occurrence, particularly under aggressive mine water and mineral conditions present in underground mines, the knowledge of the effects of corrosion on the mechanical behaviour of FRS is limited. The Department of Minerals and Energy of Western Australia has conducted a laboratory based program of studies to investigate the effect of corrosion on the mechanical properties of FRS. The studies have focused on the effect of corrosion on tensile strength of FRS and frictional resistance along the interface between FRS and the drillhole wall. The results indicate that under certain conditions corrosion damage can significantly reduce the effectiveness of FRS.

Jan 1, 1996

By S Grimsey, E Janetzki, J Emery

Floor failure on the longwall face is a complex problem due to the dynamic interaction between the surrounding strata and powered roof supports involving multiple variables. It can also be highly problematic and costly when not well understood as there are significantly less remedies available post event. This was the early experience at the case study mine where significant lost time was incurred due to unplanned delays in the first two panels. To detect and prevent such occurrences is clearly the best approach, hence a tool to predict both floor failure occurrence and magnitude prior to mining was developed. Several parameters were determined as the key drivers for the failure events that had been experienced at this site. These parameters were, in list of influence from highest to lowest, material strength, retreat rate and the presence of water. The parameters were evaluated using a semi quantitative risk rating system ‘Heave Risk’ and given a weighting per their apparent influence. This ‘expert system’ methodology was selected as the use of risk rating systems in underground coal mining is well established. The heave risk model was first applied to previously mined panels. It accurately identified all areas of known major floor heave, with clearly defined areas of low and high risk apparent. The heave risk model was then used prior to mining and evaluated post mining based on observed conditions. It was found to also be highly accurate for prediction. The variability of each parameter and its influence on the overall risk rating is illustrated and discussed.

Nov 29, 2022

By H Mansouri, M A. Ebrahimi Farsangi, F Faramarzi

A blast fragmentation model is developed based on the gamma function to describe the run-of-mine fragmentation distribution. The model presented is aimed to benefit from simplicity in application and also to be efficient in description of the fine to coarse part of the blast rock fragments. In fact, the gamma based model (KC-KUM), gives a unit distribution curve, which is made up of two separate equations, covering different fragment sizes in the muck pile. The generated values of the fines to central part of the equation and the central to coarse part of the equation are connected at the 40 per cent grafting point. For validation, eight production blasts, which were specially designed for this purpose, were carried out at an iron ore mine (Jalal-Abad iron ore mine/Iran). Results achieved by KC-KUM and two of the most well-known models. Kuz-Ram and Swebrec, are compared with measured data. Moreover, to assess the models’ efficiency in presenting the best distribution curve, a Logarithmic error method is chosen. Based on the achievements. KC-KUM has the least deviations by the least absolute log error of 0.52, whereas the values obtained for the Swebrec and Kuz-Ram models were 0.79 and 1.34 respectively. Furthermore, the models were applied to predict X80 for 12 production blasts carried out at Gol-e-Gohar iron ore mine/Iran. These predictions were compared with the results from these trials. The coefficient of determination (R2) and root mean square error (RMSE) are calculated. Consequently, the highest R2 was obtained for KC-KUM at 0.837 with the least RMSE of 11.31. On the other hand, R2 and RMSE are equal to 0.832 and 20.19 for Swebrec; and 0.813 and 19.75 for Kuz-Ram respectively. The results obtained suggest the superiority of the KC-KUM model over the other two models in assessment and prediction of blast fragmentation in a reliable way.CITATION:Faramarzi, F, Ebrahimi Farsangi, M A and Mansouri, H, 2015. Prediction of rock fragmentation using a gamma-based blast fragmentation distribution model, in Proceedings 11th International Symposium on Rock Fragmentation by Blasting, pp 685–692 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 24, 2015

By R Verreet

In April 2000 Mount Isa Mines installed hoist ropes of a new design on the double-drum winder at their P49 shaft. The ropes, CASAR Duroplast, were about three times as expensive as the previously used triangular strand ropes. The P49 shaft is situated at Mount Isa MinesÆ George Fisher Mine, located some 30 km north of Mt Isa. This shaft used the tried and proven 6 x 33 triangular strand style ropes. The rope life attained by these ropes at the time was acceptable due to many years of satisfactory performance. The following study indicates the improvement of service life using CASAR Duroplast rope in P 49 shaft, which depends on shaft and winder parameters of that particular shaft and cannot necessarily be generalised to other shafts.

Jan 1, 2005

By P Hayes, B Zhao

A range of materials are treated in zinc fuming processes to recover metal values and produce benign slag waste products. The selection of the optimum process conditions in these various technologies can be greatly assisted by the use of a chemical thermodynamic model of the system. In this paper the effects of slag chemistry on the liquidus temperatures, subliquidus phase equilibria and thermodynamic properties are described by a FACT model of the ZnO-PbO-FeO-Fe2O3-CaO-SiO2 system. In addition new experimental data on the effect of Al2O3 on the liquidus are presented. The implications of these findings for plant practice are discussed.

Jan 1, 2000

This study begins with the semivario- gram modelling of variables rutile grade and clay content from a beach sand rutile deposit. This is followed by two dimensional block kriging. The deposit was divided into blocks of 30 x 30 x 1.5 m dimensions and the kriged estimate together with the associated kriging variances for each variable within each block were determined. Finally, using the results of the krig- ing program and considering the acceptable limit of clay content together with the cutoff grade for rutile, a method for optimization of mineable thickness and hence the tonnage of ore was applied and the results were dis- Cussed.

Jan 1, 1986

By E Forbes, G V. Franks

"This study investigates the dual function of a temperature responsive anionic co-polymer of poly (N-isopropyl acrylamide) (PNIPAM) as a selective flocculant/flotation collector. PNIPAM is used for separating hematite from 50:50 mixtures of hematite and quartz, at a variety of particle sizes. The performance of PNIPAM in this system is compared to that of conventional flotation collectors: sodium oleate and sodium dodecyl sulfate. The results of the study demonstrate that anionic PNIPAM used at 50¦C (above the lower critical solution temperature (LCST)) is the most effective flotation collector for hematite particles in the size range between 10 and 20 ¦m. This is attributed to the increased probability of both particle/bubble collision and particle/bubble attachment through the formation of hydrophobic hematite aggregates. Anionic PNIPAM used at 50¦C also produced the highest hematite recoveries for very fine hematite particles (circa 1 ¦m). However this recovery was completely unselective. This lack of selectivity is partially attributed to the activation of quartz particles by PNIPAM, but is thought to mainly occur as a result of entrapment of quartz particles within the matrix of hematite aggregates.CITATION:Forbes, E and Franks, G V, 2013. Selective separation of hematite from quartz by flotation using a temperature responsive polymer, in Proceedings Iron Ore 2013, pp 381-390 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Aug 12, 2013

By X Sun, L B. Zhou, H Yi, X Tang, P Ning

The rapid industrialisation in China has consumed large amounts of various industrial raw materials, which has left behind large quantities of industrial solid wastes produced from the processes of mining, mineral processing and smelting. The storage of huge quantities of industrial solid wastes is an obvious risk to the environment and human well-being. As the first step to fully appreciate the scale of this risk, it is necessary to carry out research for developing a pollution source environmental risk assessment system (PSERAS), especially for the typical staple industrial solid waste (TSISW). This paper aims to discuss the frame of the PSERAS for TSISW for large scale production. This system consists of two aspects: predicted factors and accidental ones, which involve physical, chemical and biological risk assessments, on-site and during transportation process. Two analysis methods, the analytic hierarchy process (AHP) and fuzzy logic assessment (FLA) were used to handle the complexity of environment and non-quantitative data. The risk assessment system for such a complex objective is difficult and the assessment of relative factors is problematic through the usual quantitative analysis. With the proposed PSERAS, it is possible to define the risk class of pollution sources. Furthermore, the risk assessment results will be helpful to the decision-maker, especially when facing unknown risks in the environmental management of industrial solid wastes. In addition, by means of the PSERAS, risk factors can be ranked against their contributions to environmental risk, in order to calculate their relative priorities in decision-making.CITATION:Sun, X, Ning, P, Tang, X, Yi, H and Zhou, L B, 2012. Environmental risk assessment system for typical staple industrial solid wastes, in Proceedings Life-of-Mine 2012 , pp 301-304 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 10, 2012

By Flierman GA, Van Toor CH

Investigations were carried out of burden distribution using a full scale model of the furnace top. Various charging sequences were used and large differences were found between ore charged as sinter-pellets and as pellets-sinter. These were attributed to the differences in the angle of repose between the two materials. Permeability index was defined which was independent of the driving rate from which a furnace resistance index was obtained for use in weekly reports. Results are summarised as a single expression between blast rates and pressures and the values of Qbl and Qmax are continuously measured to aid the operators in controlling the wind rate in the safe AP region. Results also indicate a reserve in capacity of No. 7 BF.

Jan 1, 1975

One does not need to travel too far back in time to find that the manpower requirements for new projects were focused mainly on: ò plentifulness of supply; ò cheapness of use; and ò fitness for use. These were primarily quantitative considerations and corresponded with the dominant view of labour as a commodity. Qualitative considerations were not very evident with the exception of judgements of industrial militancy. It was not unusual for areas of known militancy to be excluded from the recruitment net (eg Captain's Flat, Broken Hill, Pilbara).

Jan 1, 1991

Two continuous computer controlled, remote air analysis (RAA) systems operate at The Zinc Corporation, Limited (ZC) to give early warning in case of an underground fire at ZC or New Broken Hill Consolidated Limited (NBHC) mines. Air drawn from underground sampling points via a tube bundle system is analysed for carbon monoxide and carbon dioxide. An alarm is sounded if the concentrations of these gases exceed bench mark figures.

Jan 1, 1983

By Saint-Smith J. C

The anode, tank house and wire bar plant and operations are described with particular reference to those features of design and methods which are characteristic of this refinery at its inception.Reference is also made to auxiliary equipment, transport and materials handling facilities.The work of commissioning the plant late in 1959 is discussed and comment is made on the organisation of construction and origin of the equipment.LOCATION OF PLANTThe site chosen for the copper refinery is on level ground adjacent to the junction of the Mount Isa and the main north-south railway lines at Stuart near Townsville, Queensland. Blister for refining is received by rail from Mount Isa. Refined products are taken 10 miles by road to Townsville Harbour for shipment to other Australian ports or overseas, or despatched by rail direct from the plant.Adequate room for expansion was provided to cover copper refining and any associated industry. The layout of future extensions was planned and space reserved for them before detailing the original units of the main refinery.The initial plant also provides convenient storage facilities and is laid out to derive the greatest benefit from prevailing northerly breezes during the humid tropical summer.As far as possible, the working areas are located so that the prevailing winds cool them as they traverse the buildings.These factors are of very great importance since this is believed to be the only copper refinery in the tropics operating with all white labour and in any case the Company set out to provide the best possible conditions for its operating personnel.

Jan 1, 1961