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By N Strong

Cracow is a high-grade; low-tonnage underground gold mine located approximately 500 km north-west of Brisbane in Central Queensland. It is a steeply dipping, narrow vein, epithermal gold and silver deposit that is accessed via a decline from surface. Cracow is owned by joint venture between Newcrest Mining (70 per cent) and Sedimentary Holdings (30 per cent). The orebodies are 5 m wide on average and the ore is extracted via sublevel open bench stoping. Stopes are extracted to a strike of approximately 25 m before being backfilled with waste. Prior to the introduction of electronics, the mine would remove a small amount of the previous backfill out to create a void, and then begin blasting two to three rings at a time, with the ore being extracted between each blast. This method caused the ore to be blasted onto the waste backfill resulting in dilution of the high-grade ore. It also meant that the extraction of each stope took a number of weeks and numerous blasting events. In the fourth quarter of 2005, the mine struck a geotechnically sensitive stope, where all 20 rings had to be extracted in a single shot or risk possible geotechnical problems that could sterilise the ore. Due to the limitations of NONEL« delay detonators the mine could not fire all the rings in a single shot and needed to use an electronic detonator system to extract the stope. Some unexpected benefits to the mine were increased fragmentation, reduced vibrations, reduced dilution, improved efficiency and improved hanging wall and footwall conditions. After the success of this first electronic shot, the mine has since moved to firing all their stopes with electronic detonators. With electronics the mine has been able to fire much larger blasts, and has in fact moved to firing their blasts in the opposite direction, firing towards the draw point instead of into the waste backfill, thus reducing ore dilution.

Jan 1, 2008

By R Williams, P Godwin

In a time of changing rainfall patterns and in the light of recent tailings dam failures, there is closer environmental scrutiny for proposed tailings dam construction or expansion. Therefore the elimination of the traditional tailings dam could provide both environmental and cost benefits to an operation. One method to dewater tails is using pressure filtration to achieve lower moistures than what is currently available using other dewatering technologies. Further benefits include a higher rate of filtrate recovery, reuse of waste material and the potential for dry stacking of the filtered tailings cake, thereby minimising both risk and cost. This paper chronicles the replacement of two existing belt filter presses with a single McLanahan recessed plate filter press to dewater a tailings stream at a Bacchus Marsh site. It covers the slurry testing, equipment selection, installation, commissioning and operation of the filter press to achieve the following objectives:• removing the current tailings dam and slimes cells from the existing process to minimise failure risk and reduce the cost of a dam upgrade, as well as operational and maintenance costs• free up the surface area which was previously occupied by tailings dams and slimes cells• recover additional water to be returned to the process• reduce flocculent usage• reduce truck movements and handling.The project’s owner also expects to reduce carbon emissions by over 3000 t over the lifetime of operation as well as substantially reducing operating expenditure. By recognising the carbon reduction benefits, the project owner was able to successfully achieve partial funding through the Voluntary Waste Industry Protocol.An unanticipated, but as yet unquantifiable, bonus for the project was to seek an offtake agreement for the tailings thereby allowing the tailings to be considered a valuable source of beneficiated clay suitable for the construction industry.CITATION:Godwin, P and Williams, R, 2017. Pressure filtered tailings – environmental and cost benefits, in Proceedings MetPlant 2017, pp 324–334 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 11, 2017

In mineral asset valuation the use of any valuation method requires the input of competent and independent technical professionals. A resource valuation must be as transparent as possible to allow others to assess the validity of their underlying assumptions. Materiality is a dominant factor in all valuations and a valuer should set out the basis for the subjective decisions made in this regard. Any valuation methodology must comply with the requirements of the law, practice notes and guidelines issued by the various relevant authorities and professional bodies. The valuation methodology chosen to value a mineral asset depends upon the amount of data available on that asset and the reliance that can be placed upon those data. Mineral assets generally fall into one of three broad categories, depending upon their state of development, ie whether they are at the exploration, development or operating stage. Naturally there are transition phases. Hence, there are ""Grass Roots"" Exploration Areas and Advanced Exploration Prospects; Pre-Development Projects and Developing Mines; and Operating Mines. The features of each of these mineral asset status categories are described, mainly in terms of the confidence in the contained identified Resources/ Reserves. The various subjective methodologies available for the valuation of ""Grass Roots"" Exploration Areas and Advanced Exploration Prospects -are specifically reviewed. The pitfalls in adopting a ""recipe"" approach are noted. It is the author's view that the Expected Value Method (based on the probability adjustment of the output of a Discounted Cash Flow/ Net Present Value model) has little application in the valuation of exploration mineral assets, so it is only briefly addressed. The methodologies reviewed are listed below. ò Multiple of Exploration Expenditure Method (expenditure based). ò Joint Venture Terms Method (expenditure based). ò Geoscience Rating Methods (eg Kilburn - area based). ò Comparable Market Value Method (real estate based). ò Rules of Thumb (eg $/Resource or production unit; % of in situ value). Some recent Prospectuses are used to provide examples of their misinterpretation and misapplication.

Jan 1, 1994

By J Araya, O Leiva

The mine evaluation process, composed of the designing, planning and valuation of a mine project, is, among other variables, based on an estimated orebody model. However, as the information from the drill holes is limited, it is impossible to know with certainty the mineral content in each block within the estimated block model. Consequently, uncertainty about the value of metal grades, or other geological attributes, arises because of the lack of information at unsampled locations. This is one of the reasons why, in any mine operation, there will always exist a divergence between estimated and real values. Cut-off grade optimisation is the process used to determine the operating mining strategy (long-term production scheduling) that will maximise the total profit value (normally referred as the net present value (NPV)) of a mine operation. This is done by defining a dynamic cut-off grade policy which is constrained by the production capacity of the mining, mill and refining.Real options is a type of contract, written on real assets such as mining, oil and other natural resource industries, that gives you the right but not the obligation to exercise the contract. It is based on operational and managerial flexibility, which allow mine decision makers to react to either good or bad operational and economic events in the future. But, what do geostatistics and cut-off grade optimisation have to do with the application of real options in a mine project evaluation process? The objective of this paper is to answer the previous question by showing how geostatistics combined with cut-off grade optimisation are key tools for corporate/managerial decision makers, which allow them not only to analyse the resource/reserves of their projects, but also to generate operational strategies that can maximise project value by minimising the downside risk due to ore tonnes and grade uncertainties, while achieving operational and physical constraints such as mining and processing capacities. A real copper grade open pit mine project is used as a case study.

Sep 26, 2011

By Munro DL

The Mary Kathleen uranium deposit is in north-west Queensland, approximately halfway between the townships of Mount Isa and Cloncurry, at long. 1400 009 E and lat. 200 44' S. The deposit Iwas discovered by prospectors of the Walton McConachy Syndicate early in July, 1954, and climaxed a very intensive ground search by hundreds of part-time prospectors. during the uranium boom from March to July 1954ò Numerous small deposits, mostly in the vicinity of Mount Isa, were discovered in various rock environments, but Mary Kathleen is the only large deposit and, apart from a few tons of hand sorted material from the Milo lease, is the only deposit that has been worked. Exploration of the surrounding area, and proving of the economic worth of the deposit, were conducted from the time of discovery until February 1956 by a geological team camped near the deposit. Proving was carried out by drilling a pattern of vertical and inclined diamond drillholes at fifty-foot centres over the outcrop. An adit was driven eastwards through the deposit. Metallurgical research and design work in the South Australian Department of Mines Adelaide Laboratories were based on core samples and bulk samples from the deposit. The signing of a contract in March 1956 with the British Atomic Energy Authority to supply 4500 short tons of uranium oxide allowed mining to commence, and enabled the planned construction of water supply, township and treatment plant to proceed. The open out mine and plant are now serviced by a modern township, four miles away, which is connected to Cloncurry and Mount Isa by road. Although little field work has been done since the exploration phase, this paper differs in interpretation from a previous paper (Matheson and Searl, 1956) in that it is based on a revised structural inter- pretation (Compana, 1958), detailed mapping of progressive exposures in the open out, and a re-examination of diamond drill cores.\

Jan 1, 1968

Block caving is the lowest cost underground mining method but it has relatively high risks and a high up-front capital and development cost. It has application to large, often lower-grade orebodies where high production rates can provide good returns on the investment. However, it has a range of technical risks that are peculiar to block caving and the usual financial, political and environmental risks that may be exacerbated by the long lead-in times associated with the development of a block cave operation. With initial development costs that may be $100 M to $1000 M when the building of a treatment plant is also required, it is obviously important to minimise and manage the risks. In a greenfield project, commitment to a substantial proportion of the capital expenditure may be required to gain access to the deposit, and the decision to proceed at this stage would be based very largely on interpretations of drill hole data. In established mines the data may be supplemented by geological mapping and past experience, etc. The quality of this data is critical and yet it is frequently degraded through poor techniques and avoidable omissions. The final decision to proceed would be assessed on projected commodity prices, mining capital and operating costs, dilution and run of mine ore grades. The latter will vary over the life of the project and these can be estimated with drawdown or draw control modelling techniques. In this modelling, there are further risks in the assumed modelling parameters or that the modelling technique may not be applicable or appropriate. The paper addresses the most critical technical and operational risk areas and provides some practical precautions that can be taken to reduce these and improve the reliability of the geological and geotechnical models.

Jan 1, 2000

By C Katonga

Mindola mine is currently the deepest mine in the Zambian copper belt. Stoping is currently active to 1330 m below surface with long range plans indicating future production from 1590 m level. The orebody is tabular and dips between 55o to vertical. The thickness varies from 8 to 14 m. The vertical crater retreat method of mining was first introduced at Mindola mine in the late-1980s following several trials that helped define the design criteria for its application. Over the last ten years the method has been continually modified to improve safety and maximise ore production. For example, due to the weakness of some rock units within the orebody formation and the instability of the hanging wall, the last VCR slices are usually between 8 - 10 m thick, and efforts are being made to strictly apply shrinkage method in order to reduce dilution. Recent advances in mining technology in the areas of equipment, blasting techniques, rock mechanics and materials handling have been employed to increase the overall productivity of the mine. Large down-the-hole machines capable of drilling 165 mm diameter blast holes, up to 80 m long are used in stoping. Each stope produces up to 20 000 tonnes of ore per month and can last for three months. Heavy systematic ground support of VCR development has significantly enhanced safety for mining crews and equipment. Crater mining has not only improved productivity and enhanced safety, but also overcome various problems associated with conventional sublevel open stoping previously employed at the mine. This paper discusses the technical and operational aspects of vertical crater retreat mining at Mindola mine during the last ten years. The changes in mining method are often accompanied by changes in mine design, blast design, mining equipment, ground support and operating practices.

Jan 1, 2000

By R Domotor

Brisbane’s Airport Link is Australia’s largest road infrastructure project, worth a total value of A$4.8 billion. The project is using surface and underground blasting to excavate hard volcanic rock, Brisbane Tuff. This paper tells the story of the most challenging and difficult blast of the whole project: the removal of a remnant pillar of rock (approximately 2250 m3) next to a major arterial road and within 100 m of existing infrastructure including a number of heritage listed buildings, residences and privately owned sensitive receivers. The pillar consisted of a hard rock wall (Brisbane Tuff) between 2 m and 6 m thick, 15 m high and 35 m wide; with in situ precast concrete piles embedded within 1 m of the boundary of the pillar. Orica Australia Pty Limited was contracted by Thiess John Holland, to perform the work in this area, including design, modelling, drilling and loading of the explosives, as well as blast clearance and shotfiring. Access to the area was limited so all explosives and equipment, including the 20 t drill rig, had to be lifted in and out by crane. Due to the nature of the blast, with infrastructure 5 m directly in front of the 15 m high face, there was only ever going to be one chance to get this blast right. This was an extremely complex blast which required the use of a number of different types of packaged explosives, as well as special timing techniques only made possible by using electronic initiating systems. This type of blast is high risk, and is more typical of a building demolition in the urban environment. The blast was fired on the 25 September 2010, and was highly successful. The environmental results for vibration and overpressure were well under the imposed limits, and the embedded concrete piles remained undamaged.

Nov 8, 2011

By K Williams, M Pender, T Honeyands, T Krull, D McCallum, R Holmes, R Orense

Bulk cargoes, including iron ore fines, must be shipped according to the rules agreed by the member states of the International Maritime Organization (IMO). One critical safety measure is the transportable moisture limit (T?ML) required for Group A cargoes (cargoes that may liquefy). A number of shipping incidents involving iron ore fines from India, where liquefaction of the cargo was suspected to be the cause, have brought the issue of iron ore fines T?ML into the spotlight. Extensive research has been undertaken by the major iron ore producers from Australia and Brazil to support the IMO in developing regulations for the shipment of iron ore fines. To this end, iron ore companies sponsored the AMIRA P1097 project to establish a modified T?ML test approach specific to iron ore fines. The project was undertaken by TUNRA Bulk Solids, CSIRO’s Centre for Bulk Solids and Particulate Technology and the University of Auckland, with project leadership provided by Creative Process Innovation. This program of work supported test work findings from the IMO Iron Ore Technical Working Group, which reported its findings in September 2013.The purpose of this paper is to present the major research findings from the AMIRA P1097 project, which includes a review of the original T?ML methods, highlights of the research that supported the new iron ore fines T?ML method and an outline of current iron ore T?ML requirements.CITATION:Williams, K, Honeyands, T, Holmes, R, Orense, R, Roberts, A, Pender, M, McCallum, D and Krull, T, 2015. Maritime bulk cargo transportable moisture limit requirements for iron ore shipments, in Proceedings Iron Ore 2015, pp 399–410 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

By Iley J. D, Siviour N. g, Moffatt R. J

The process of desilverising by fractional crystallisation with reflux was investigated through laboratory batch tests and continuous laboratory bench scale tests at CSIRO Clayton, to a 300 kg/hr pilot plant at Port Pine. The pilot plant built at BHAS comprised a vertical cylindrical refining column with internal diameter 250 mm and height 3.2 m, attached at the top to an off-set cylindrical stirred crystalliser tank. Crystals were made in the crystalliser by intermittent immersion of steel cold fingers, which were water cooled between immersions. Gas heat was used for melting the crystals at the base of the column and for side compensation heating. A computerised in strumentation system was employed for data logging and for controlling some critical plant operations. A mechanical device was first employed to promote counter-current plug flow of crystals down the column against the rising stream of reflux liquid, but this was found to be unsatisfactory owing to excess noise, frequent mechanical failure, and excessive accumulation of dross. Plug flow was finally promoted by pulsing the column. Low silver levels, less than 1 gitonne, were achieved with both methods of crystal transport under total reflux conditions. The pulsed column gave results for silver and bismuth which agreed with the theoretical predictions of a computer model, but there was some selective drossing of antimony. In the mechanically agitated column, excessive drossing promoted selective removal of most of the antimony and some of the bismuth, and the results after extended operation were well removed from the theoretical predictions. Plant failures and operating problems prevented the achievement of satisfactory product quality with the necessary reliability under production conditions. Other priorities necessitated the termination of the project before the process could be optimised.

Jan 1, 1989

By H Askari-Nasab, E Torkamani, M M. Badiozamani, S P. Upadhyay, M Tabesh

"Decision-making in mining is a challenging task. Optimal decisions regarding shovel and truck allocations, aligned with the optimal short-term production schedules, are crucial in keeping the operations in line with the company’s long-term objectives. In this paper, we present two main modelling components as the means to achieve near-optimal operational plans: a mixed integer linear goal programming model to allocate trucks and shovels to mining faces over a shift-by-shift basis so that operating costs are minimised and resource utilisations are maximised through the planning horizon a discrete-event simulation model to investigate the behaviour of a truck-and-shovel haulage system in the presence of uncertainty within mining operations. The goals integrated into the mathematical model are to: maximise production minimise deviations from the target head grade minimise deviations in tonnage feed to the processing plants from the desired feed minimise operating cost.The mathematical model provides shovel assignments and the target productions as an input to the discrete event simulation model while meeting the desired goals and constraints of the mining operation. We illustrate the applications of the discrete event simulation model by presenting a large-scale oil sands case study. The main contribution of this work thus far is the development, implementation and verification of a simulation model with a link to optimal short-term mine schedule and extraction sequence of mining faces, which assists in achieving a high level of mine plan compliance across short-term planning and operational planning time horizons.CITATION:Askari-Nasab, H, Upadhyay, S P, Torkamani, E, Tabesh, M and Badiozamani, M M, 2014. Simulation optimisation of mine operational plans, in Proceedings Orebody Modelling and Strategic Mine Planning Symposium 2014, pp 299–312 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Nov 24, 2014

By C Artica

Two quantitative methods for Mineral Resource classification have been applied to a copper skarn deposit beneath a large open pit that is mining a world-class porphyry complex. A drill hole spacing study (DHSS) using the single block kriging method (SBK) and a conditional simulation method (CS) were applied to the skarn deposit and the results compared. Inputs to both processes included the proposed mining rate and stope designs to estimate the likelihood of achieving grade and metal production targets. Mineral Resource classification of the deposit considers the relative precision of tons, grade and metal predictions over quarterly and annual production periods. These relative precision estimates are calculated at 90 per cent confidence interval (CI). The SBK method represented the production period as a single large block. Kriging estimates were performed in the large block for various synthetic drill hole grids, and the estimation errors derived. The error was assumed to be normally distributed due to the large block size and quantity of samples, allowing CIs to be deduced. The CS method followed a conventional sequential Gaussian simulation workflow where grades were simulated with a 5 ft × 5 ft × 5 ft grid node spacing inside mineralisation domains. Each realisation was then averaged up to monthly production volumes represented by a combination of designed stopes, and the coefficient of variation (CV) for the averaged grade was calculated. CI on the relative precision of grade predictions were then deduced from the CVs. The two methods produced similar results; despite being calculated independently. CS results were used to report uncertainty in the proposed life-of-mine plan and highlight areas for additional drilling. SBK results were used as the basis for Mineral Resource classification as this method has been previously applied to the skarn deposit.

May 24, 2023

By T Alexieva

Since the early 1900s the geotechnical community has investigated every significant failure of a tailings dam, improved our knowledge of the behaviour of the tailings storage facilities, developed analysis methods, compiled lessons learned, and committed to zero failures. The rate of occurrence of tailings dam failures has reduced since the 1980s, however, failures continue to occur and continue to surprise us. At BHP, we have decided to take an approach to the tailings management that is similar to the approach to safety. We are looking at ways to eliminate, substitute, separate or engineer around the hazard (tailings dam failure). As such, our ultimate long term goal would be to eliminate the need for new tailings facilities. Unfortunately, we have not developed yet technologies for extracting many of the common metals and minerals without producing tailings. Our shorter term goal is to substitute the current conventional slurry tailings facilities with less risky dryer facilities. We are working with vendors and research organizations to develop technologies that can be efficiently applied on a large scale. At the same time, we are committed to using the best available engineering to reduce the risks associated with our existing and new conventional tailings facilities. The best engineering can be achieved by people with the appropriate education, experience, attention to detail, discipline and authority. We have implemented a system of governance to make sure, we have the best engineering applied to all our facilities, considering the specific conditions at each site.This paper presents the current tailings governance process at BHP, and the initiatives that were undertook towards achieving a zero failure goal. CITATION:Alexieva, T, 2018. Tailings governance, in Proceedings Mine Waste and Tailings Stewardship Conference 2018, pp 2–7 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 23, 2018

By A J. Gunson

The Norman B Keevil Institute of Mining Engineering, or the Department of Mining Engineering (the Department), at CanadaÆs University of British Columbia (UBC) is addressing the integration of sustainable development concepts into mining education and research on behalf of industry and society. Over the past decade, the DepartmentÆs education and research model has been evolving to incorporate collaborative and multidisciplinary strategies, where sustainability initiatives are taught in classes, supported in research and discussed in a voluntary collective of mostly graduate students û the Sustainability Working Group (SWG). The SWG has brought together a diverse array of disciplines from academia, industry, government, non-governmental organisations (NGOs) and mining communities. The operational mechanisms and structure of the SWG have enabled momentum to be gained through several multidisciplinary educational and research networking initiatives. It acts to attract new students with diverse backgrounds, foster innovative research, develop relationships and networks, and create the space to discuss progressive ideas and projects. The original cohort of SWG graduate students laid the foundation for sustainable research initiatives within the Department at UBC. Novel research has incorporated topics such as: community resilience, artisanal small-scale mining, sustainability indicators and corporate social responsibility, environmental assessment and impact benefit agreements and the recycling of waste. Propelled by the support of the Department and inspired by the works completed, a host of new graduate students have embarked on their research quests to integrate sustainability principles into their projects. Such projects include: social impacts and benefits of mining, artisanal small-scale mining, community health, the production and transport of mine pollutants, mine waste management, mineral process plant design and the evolution of community education and mine policy. This paper reports on the departmentÆs continuing research and development towards an understanding and evaluations of the ongoing contributions of mining to sustainable development.

Jan 1, 2009

By A Horeth, E Duggan, B Versiani, A Gooch

Iron ore screening plant productivity is strongly affected by the performance of the shuttle operation, with the control system robustness and associated strategies having a direct impact on utilisation and throughput rates. A number of aspects intrinsic to the methods and technologies traditionally applied on the motion control of shuttles are often observed to decrease the efficiency of the ore distribution process across multiple screening modules, which ultimately impacts the plant’s production. Those include the number of operational scenarios that are unmanaged by conventional discrete control logics which may intermittently lead to undesired events, such as ‘high level alarms’ and ‘low level interlocks’ in the screening bins. This outcome usually demands excessive manual intervention by Control Room Operators. A Reinforcement Learning (RL) Artificial Intelligence (AI) solution was deployed to control the motion operation of the scalping and products screening shuttles in an iron ore handling plant. The RL algorithm was trained in advance to handle multiple operational scenarios and generate optimised outputs. In nominal operation, the shuttles are moved in a modulating and highly predictive fashion over the whole range of safely reachable bins. When the need occurs, the AI control agent deviates from that modulation behaviour, limiting its travel range or moving to other groups or clusters of available bins by employing ‘bin jumping’ or ‘ore break’ strategies. The RL platform capabilities include the ability to learn in real time to account for and auto-adapt to new operational patterns and process changes whilst applying improved strategies for shuttle dwelling times, target setting and speed control. The deployed Reinforcement Learning AI solution has better managed the existing challenges associated with the shuttle operation and control, and resulted in a more efficient ore delivery process, superior operations stability and increased production rates.

Nov 8, 2021

By C Claassen, R Balusu

Computational fluid dynamics (CFD) models have been developed based upon field data collected from a longwall mine in New South Wales, Australia to study the behaviour of goaf gas flow in both active and sealed goaf areas. A base CFD model was built to represent the goaf situations when the active longwall retreats near the finish-off line. Results from the base model were calibrated and compared against field goaf gas monitoring data. The base model was then used to carry out parametric studies to investigate a number of operational scenarios and their impact on goaf gas behaviour. CFD modelling results indicate that the overall goaf gas flow pattern changes as the operating longwall retreats towards finish-off line. In all cases, oxygen penetration into the active goaf remains high, reaching 15 per cent or higher, even at some 800 m behind the longwall face.The modelling results also indicated that it would be difficult for early detection of an active goaf heating (on the maingate side) based upon CO readings in the return airflow, as the main stream of the gaseous product will be flowing into the sealed deep goafs in adjacent longwall (LW) panels. Monitoring points (such as tube bundles and bag sampling points) should be selected at deep seated seals along the active goaf so that abnormal CO or C2H6 readings can be picked up for early detection and location of potential heating spots; goaf inertisation can be better achieved by injecting inert gas such as nitrogen at deeper points (>200 m) behind the operating longwall; the injection of in-seam drainage methane into the goaf areas will only have a limited impact on goaf inertisation as much of the injected methane will migrate towards deep and higher parts of the goaf due to its buoyancy effect.

Sep 26, 2011

By S Kost, R Nievergelt, F Cortes

In recent years, the use of steel fibre-reinforced concrete (SFRC) for segmental tunnel linings has become increasingly popular due to numerous advantages including durability, resistance to spalling, reduced cracking at corners and edges and significant cost-saving potential. One of the key parameters for measuring the performance of SFRC is the residual (post crack) flexural strength. A problem often faced in design and quality control of SFRC is the high variability of results obtained by standard beam test methods, with reported coefficients of variability (CoV) in the order of 25 per cent. The high test variability results in a relatively low permissible design strength relative to the average flexural strength of the material and commonly leads to non-conformances with respect to residual flexural strength during production testing.This paper presents the implementation of an alternative testing method using large round determinate panels (RDPs) for quality control testing of the SFRC used in the segmental lining of the City East Cable Tunnel (CECT) in Sydney. The alternative RDP test method was found to correlate well with standard beam tests and significantly reduce the variability of test results, minimising the risk of outlying residual flexural strength results, with zero non-compliant test results reported during the production period.This successful implementation of an alternative test for post-crack flexural strength with lower variability in results constitutes a relevant precedent to demonstrate the feasibility of this approach which contributes to the development of more cost-effective concrete mixes and minimises the risk for non-compliant results and the contractual disputes that commonly arise from these.CITATION:Cortes, F, Nievergelt, R and Kost, S, 2014. Development of a segmental lining specification for steel fibre reinforced concrete flexural strength testing using round panel tests, in Proceedings 15th Australasian Tunnelling Conference 2014 , pp 461–468 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 17, 2014

By N A. S Webster

The reaction sequences involved in the formation of iron ore sinter phases were determined using in situ synchrotron-based X-ray diffraction. Experiments were carried out using a synthetic sinter mixture containing 77.36 per cent Fe2O314.08 per cent CaO, 3.56 per cent Si.O2 and 5.00 per cent Al2O3 corresponding to a basicity of ~4. The alumina content represents the upper level of alumina concentrations measured in phases formed in industrially produced plant sinter. Data were collected during heating of the sample to 1350°C under an atmosphere of 0.5 per cent O2 in N2, equivalent to an oxygen partial pressure of 5 × 10-3 atm. This temperature was sufficientto ensure melting. Data were also collected on cooling of the sample back to room temperature to examine recrystallisation of phases from the melt.Results showed the sequence of reactions initially involved the formation of calcium ferrite phases C2F and CF. These subsequently reacted with the silica and haematite leading to the solid state formation of SFCA and SFCA-1. SFCA and SFCA-1 were the last phases to form in the system and were both stable up to ~1260°C. Above ~1260°C, melting of the SFCA phases and reduction of the remaining haematite occurred producing the assemblage magnetite + melt.During cooling, both SFCA phase types recrystallised from the melt initially coexisting with magnetite until secondary haematite formed. This is the fi rst study to demonstrate that both SFCA and SFCA-1 are precipitated from the melt during cooling of iron ore sinter. Future work will extend the range of compositions studied to examine the effect of basicity and alumina concentration on the phase assemblages as a function of temperature and oxygen partial pressure.

Jul 11, 2011

By M Hilden, G Forbes, Z Ye, M Yahyaei, F Reyes, V Jokovic

Soft sensors offer several practical advantages for the process control of comminution circuits by combining multiple conventional sensors and other data sources with real-time analysis using mechanistic, phenomenological or machine learning models. While there has been a growth in the use of machine learning techniques for developing soft sensors in minerals processing applications, this paper describes advantages and challenges of using soft sensor models developed on the basis of process knowledge. Recent experience with three new soft sensor technologies developed by the authors are discussed. The Mill Filling Inference Tool which has been implemented at several mine sites, compares SAG mill load cell and power draw measurements with outputs of a semi-mechanistic power model to estimate the mill ball and total filling in real time. The progressive wear of the mill liners is modelled, allowing the model to correct the load mass due to the mass loss automatically and to estimate the charge trajectory. This information enables the mill to be operated more confidently near its limits. A coarse-ore stockpile soft sensor as been recently developed using a 3D cellular automata-based model to track ore size throughout the pile, and estimating the live capacity and size at each stockpile feeder to the primary mills. Finally, a hydrocyclone soft sensor is being developed to monitor performance using available hydrocyclone models to estimate the size and flow balance around the cyclone in real time. The model-based soft-sensor approach aims to synthesise and analyse existing data and provide operators and engineers with process- and model-relevant information that can facilitate making better process decisions. Maintenance data has proven useful for model development as it allows soft sensors to automatically adjust and compensate for the effect of progressive wear, for example for mill liners, thus helping the models to maintain calibration throughout the equipment life.

Aug 24, 2022

By S Zummar, A Van den Bulck, T De Staercke, T Van Rompaey

An increase of 22 per cent in lead usage is expected in the European Union by 2050. During lead refining, the Harris process is a critical step in which a salt melt is used to remove arsenic, tin and antimony. During this process, the caustic salt melt absorbs these impurities, requiring regular evacuation before saturation. Current metallurgical practices for: 1) determining the end point of the lead alloy involve time-consuming sampling and offline analysis, and 2) determining the end point of the caustic salt melt are based on subjective visual observations by the operator. In the context of Industry 4.0 concept, automating these processes becomes desirable, as smart sensors systematically collect real-time data in an unbiased manner. This research focuses on monitoring the Harris refining process using objective methodologies. Two different methodologies are investigated. The first methodology focuses on electrical conductivity changes of the caustic salt melt as function of Sb content. For this study, synthetic and industrial samples are used. A lab-scale electrical conductivity set-up was built to accommodate the aggressiveness of the salt melt. Initial findings suggest a promising relationship between electrical conductivity and Sb content in the caustic salt melt. Although the results are preliminary, the study provides valuable insights by enabling real-time measurements. The second methodology focuses on measuring the electromotive force (EMF) in lead doped with Sb at pilot-scale. Multiple probes are reevaluated for their effectiveness in Sb measurement. Ultimately, a partially stabilised MgO probe with Ni as a reference, without cardboard and copper protection caps, yields promising results. A correlation between EMF and Sb content is observed. However, repeatability issues arise due to possible wire interference at low temperatures. The results underscore the potential of advanced measurement techniques in optimising lead alloy production within the context of Industry 4.0.

Aug 21, 2024