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By G Caddy, M Middleton, S Kerec, R Keil, J Tsalapatis

Arrium’s OneSteel Whyalla Steelworks in South Australia is a fully integrated plant which operates a single blast furnace. The key operational objective has been to maintain high process availability and stability while maximising the process efficiency and the produced hot metal quality. All ferrous raw material input feeds are sourced exclusively from company iron ore deposits in the nearby Middleback Ranges. The Whyalla blast furnace has mostly operated using a combination of a high percentage of pellet feed, produced in Whyalla, together with screened lump ore.The unique ironmaking challenge has always been to extract the maximum value from the ferrous burden feed available locally. In earlier times, high-grade hematite lump ore was available for both screened lump ore and pellet production. Blast furnace trials from acid to fluxed pellet feed commenced in 1977. The furnace pellet feed has been wholly fluxed since 1981. Many pellet/lump ore feed mixes and significant pellet chemistry composition design changes have been made over the years. These changes have been aimed at best balancing the ferrous burden availability/cost and the optimum reducibility/high temperature melting behaviour of the charged ferrous feed within the blast furnace. In more recent times since 2007, the Whyalla blast furnace operation has transitioned from a hematite based pellet feed to a magnetite based pellet feed while there is an ongoing contest dealing with diminishing absolute quality/increased variability raw material feed inputs.The paper will detail key elements of the Whyalla blast furnace operational philosophy with regards to ferrous feed use and process optimisation. The blast furnace ferrous feed design considerations will be discussed, together with the test work performed, the operational and slag design transition strategies employed and the process results achieved.CITATION:Tsalapatis, J, Middleton, M, Keil, R, Kerec, S and Caddy, G, 2015. The use and optimisation of ferrous feed at the Whyalla Blast Furnace, in Proceedings Iron Ore 2015, pp 377–384 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

"Recognising that the mining industry is wedded to the break-even cut-off grade rather than a cut-off grade that optimises value, the author examines some perils and pitfalls in the use of break-even grades that lead to what the author calls ‘negatively geared ore reserves’.Negatively geared ore reserves occur when a portion of the ore reserves actually has a negative value and is effectively being subsidised by the more profitable portion of the ore reserves. This situation is generally difficult to detect with the level of information available to the public investor. The ore reserves can still be quite profitable in total, but now possess a level of risk that may not be appreciated.The risk profile (financial risk) of a negatively geared ore reserve is far greater than for a non-negatively geared ore reserve. Like a negatively geared investment property in a falling property market (for readers familiar with the Australian tax minimisation investment strategy), when the price of a commodity falls, a company that possesses a negatively geared ore reserve loses value at a magnified rate relative to a company that has a neutral or positively geared ore reserve. In the extreme case of a major commodity price reduction, as happened with the gold price in mid-2013, the negatively geared ore reserve can easily become negative value in total, not just in part.The negatively geared ore reserve is sometimes intentional – for instance in order to increase published ore reserve tonnages and meet the CEO’s key performance indicators – but is also often unintentional, resulting from various errors in the break-even calculation. Common errors in calculating a break-even grade include using fixed metallurgical recoveries, not including allowances for ideal laboratory versus real plant results, ignoring available operational data and using modal rather than mean parameter values in cost and performance calculations.This paper examines a common value distribution profile in many ore reserves and the effect of common break-even grade errors on this profile.CITATION:Poniewierski, J, 2016. Negatively geared ore reserves – a major peril of the break-even cut-off grade, in Proceedings Project Evaluation 2016, pp 236–247 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Mar 8, 2016

Responsibility for the administration of mineral resources is divided between federal and provincial governments. The paper traces the evolution of mineral policies at both levels of government, from the end of World War II to the present. In the immediate post-World War II years, the emphasis was on supplying the raw material needs of a rapidly growing world economy. Policies favouring growth and development of the Canadian mining industry were instituted during this period. Two decades of uninterrupted expansion (the 1950s and 1960s) ensued. The decade of the 1970s was a turbulent one for Canadian mineral producers. Governments intervened more substantially than ever before. Moreover, the industry suffered from an intense period of competition for resource revenues by the two levels of government. At the same time, far reaching changes were taking place in the structure of world mineral markets. To date in the 1980s, the mineral industry has, perforce, adapted to existing mineral market structures. Mineral policies, too, have shown signs of adapting to the needs of the mineral industry. Whether the resulting mix of policies will permit the revitalization of the Canadian mining sector remains to be seen.

Jan 1, 1986

By S J. Henderson

Pumped co-disposal of coal processing waste was promoted in the 1990-2000s as a low-cost highperformance alternative to tailings dams. In particular it would avoid high up-front capital for rejects trucks and dam embankments, and would produce a combined waste deposit with better geotechnical properties than either coarse rejects or tailings. Overall, the promise was not delivered; in particular, upon discharge the waste segregated by size, and operators responded by moving the coarser waste to contain the finer waste. In consequence, not only did design analysis lag behind construction, but some of the initial expectations persisted with the result that analyses did not fully represent what was occurring on the ground. After more than twenty years inspecting, designing and tending Co-Disposal Areas (CDAs), it is apparent that they are essentially upstream constructed tailings dams with some more favourable aspects but also a few unique quirks. Although waste management technology has moved on somewhat, the high cost of changing CHPP waste circuits means that most mines with pumped codisposal will continue to discharge mixed waste slurry into CDAs. It is therefore worthwhile to share some lessons in the hope of promoting sounder design, operation and rehabilitation. These include: • Discharged waste does not form a homogeneous wholly competent deposit but instead comprises materials ranging from sandy gravel to silty clay with the distribution determined by movement of the discharge and decant structures; • CDAs circulate and contain a lot of water; • As a result of the first two points, some areas of the CDA comprise saturated fine waste that is no different from tailings and, like tailings, often behaves in an undrained manner; • Seepage is inevitable and desirable because strength improves as water is removed. However, stability is strongly impacted by pore pressures and in design these need to be rationally rather than optimistically considered; • As CDAs are built to about 40m or higher, strength-deformation characteristics of the foundation become more important; • Even if geomechanically stable, CDAs will need covers to prevent salts and acids from reaching the surface; and • Erosional stability of the cover material(s) will probably dictate maximum slopes for rehabilitation.

Jul 1, 2021

By S McKnight, L Koroznikova, J Begelhole

"This paper outlines a simple methodology for iron ore characterisation. Iron ores commonly contain a range of iron oxides with varying iron content along with generally minor quantities of lighter silicate gangue phases, giving rise to density variations. Companies tend to rely on heavy liquid separation (HLS) in the evaluation of samples arising from exploration, mining or metallurgical processes. Heavy suspension separation (HSS), a simple laboratory technique of density fractionation, employing suspensions of fine tungsten carbide (WC) particles in lithium heteropolytungstate (LST) solutions, can be used in the evaluation of iron ore.As part of Arrium Mining’s program to improve its knowledge of ore types being processed in two hematite ore beneficiation plants (OBP), metallurgical evaluation of hematite feed and geometallurgical evaluation for the OBPs has become a major focus.Metallurgical evaluation of the hematite ore ultra-fine size fraction, formally treated as waste but now upgraded by HSS, is a part of Arrium’s program to improve recovery.The HLS method for iron ore characterisation is not generally used as part of routine iron ore feed metallurgical evaluation due to the expense, toxicity and time-consuming nature of the technique. Results show that the HSS method for iron ore characterisation can achieve low-cost, low-toxic separation and can be used on-site to improve turnaround time of results (Begelhole, Jasper and Koroznikova, 2013).Arrium have applied this technique successfully for the past three years to progress process improvement for the two OBP as well as to assist Arrium’s on-site laboratory services, Bureau Veritas in Whyalla.The main objective of this program has been to further develop the HSS procedures using a low-toxicity, high specific gravity (SG) suspension; LST and WC as the dense medium for metallurgical evaluation of ultra-fines.A suspension of a particular density will separate iron ore into two products: a sink fraction (denser iron oxide – hydroxide particles) and float fraction (silicate – iron ore composite particles). A theoretical grade and mass recovery can be calculated, and a grade – mass recovery curve can be constructed for iron.Metallurgical evaluation of the plant feed ultra-fine size fractions are used to improve efficiency of an upgrading plant process. This type of characterisation can be used to prepare feed piles of known processing characteristics, or to benchmark the performance of the process against what can be theoretically achieved.CITATION:Koroznikova, L, Begelhole, J and McKnight, S, 2016. Characterisation of Low-grade Hematite Ore Ultra-fine Size Fraction Particles by Heavy Suspension, in Proceedings The Third AusIMM International Geometallurgy Conference (GeoMet) 2016, pp 327–334 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Jun 15, 2016

In terms of tunnelling the mining industry is generally thought of as the crude cousin of the civil construction industry. Mining has tended to concentrate on speed and flexibility rather than the high standards required in civil tunnelling. Historically this difference has been based on the belief that such high standards were not required by the mining industry, they would slow down the development of the project and as a result increase the costs and extend the time period between start up and a positive cashflow.For civil works the construction of a tunnel is the project, for mining the construction of declines, crosscuts and drives are merely the means of accessing the orebody so that the real work can begin û MINING. Extraction of ore is the core business of most mining companies û it is what pays the bills.Though most mining companies have the equipment, the people, the knowledge and the ability to excavate tunnels, in the past mining companies did not appear to put the same energy into their tunnelling operations as they put into improving their ore extraction operations. In the past decade this appears to have changed, many mining companies now realise how important the correct excavation of a decline is to the success of the overall mining operation. They began to recognise that there were cost benefits to be gained in using the correct development techniques without overly sacrificing the benefits of speed and flexibility.This recognition also coincided with the growth of underground contractors whose predominant work was primary development (declines and ore access crosscuts and drives). The contractors again had the same knowledge, the same people, and similar equipment but their focus was different from that of the mining company û the contractors were focused on the development of the mine, the excavation of declines, crosscuts and drives. These deliverables were the contractorsÆ core business û itÆs what paid the bills.

Jan 1, 1999

By G R. Power

A useful way to assess potential productivity of SLC mines is by quantifying tonnes/drawpoint/day to be extracted from the mine. However limited industry information has been published to help mines benchmark this number. This paper assesses industry data which can be used to support estimates of potential productivity from new mines based on tonnes/drawpoint/day. The information used has been extracted from historical production schedules which indicate what was achieved, rather than what was planned. It has been assessed using an algorithm created for the purpose and is presented with discussion of varying definitions of active drawpoints, analysis of the data and inquiry into some of the underlying contributing factors.

Mar 15, 2021

By S Hapugoda, H Han, L Lu

Sinter quality depends heavily on the mineral phases, textures and physical structure of the sinter, which are formed upon solidification of the sinter melt. The interaction of sinter initial melt with its surrounding materials will impact the properties of the sinter melt and consequently the solidified structure and quality of resultant sinter. Spreading and penetration are two important phenomena dictating the interaction of the initial melt with its surrounding materials, such as nuclei and adhering fines. In the present study, the penetration behaviour of an initial melt into various natural iron ore substrates of different ore types during sintering was studied using a laboratory scale penetration testing procedure. The penetration depth and width were found to increase with temperature and vary with the type of iron ore due to their unique pore structure and mineralogical texture.

Nov 8, 2021

By F K. Altuntov

The study presented in this paper is based on the Kiirunavaara underground mine located in the northern part of Sweden. The deposit is mined using the sublevel caving (SLC) mining method. This paper briefly reviews the alternative SLC layouts, as well as presents challenges for the application. In Kiirunavaara currently, the traditional SLC design is employed, however, continuous improvement of material transportation systems used in mines generates a need for investigation of the current and future production area layouts in sublevel caving mines. When identifying the potential benefits of the alternative production area layouts, the production targets and effects must be further investigated to understand the benefits and potential effects. In this study, several different layouts have been investigated and evaluated. The designs include different development configurations and orepass infrastructure moved further away from the orebody and still require further investigation.

Mar 29, 2023

Large areas of ground are permanently supported on coal pillars, both in extensive old workings and current drivages in active mining operations. Continued growth of civil infrastructure is resulting in more surface development above old bord and pillar mines and an increased need for mine development beneath existing surface structures and features. The result is a greater likelihood of conflict between miners, developers and regulatory bodies. However, over the last 40 years there has also been significant improvement in the general level of understanding of pillar behaviour and stability, both in Australia and overseas. This paper examines some of the issues to be considered when undermining surface structures or undertaking surface development above old workings. The Factor of Safety (FoS) methodology widely employed for the assessment of pillar stability is reviewed, including the key geometrical, geological and statistical concepts associated with the probability of pillar failure; local and international experiences are examined and significant parameters isolated. Common concerns are addressed in the context of actual practical experience, utilising a risk management approach. Recent advances in methods for the assessment of pillar stability are put forward, along with criteria for arriving at rational design outcomes.

Jan 1, 2005

GOOD ventilation is recognized as an essential for the preservation of health, and laws have accordingly been framed in many countries for the provision of adequate ventilation in factories and places of public resort as well as in mines.Apart from the legislative enforcement of hygienic measures as a matter of public 'policy, the ventilation of mines has an important economic aspect, since it affects to a large extent the industrial efficiency of the workmen, and consequently the cost of mineral production. Until recent years the ventilation of metal mines has not generally received much consideration, and the importance of pure air has been sometimes overlooked. To the absence of explosive gases in such mines, and to the cost of the installation and working of mechanical ventilators, may generally be attributed disregard of adequate ventilation. In this paper it is not proposed to furnish statistics on the mortality and morbidity of miners, or a treatise on the medical aspect of the rock-dust problem, to further elaborate which would be superfluous, the deleterious effects of the latter having been...

Jan 1, 1912

By Iwu GO, Almond DP, Joasoo _

The gravimetric integral Knudsen effusion method was used to measure cadmium activity values in binary liquid In-Cd alloys in the range 523 to 573 K. The activity measurements together with other studies from the literature indicate that special bonding conditions exist in the melts near a composition corresponding to InCd3. Sound velocities in In-Cd melts were also measured using a precision pulse-echo over- lap method in the range 404 to 953 K. The frac- tional deviation of experimental and ideal isentropic compressibilities at 623K shows a functional dependence on composition with a pronounced maximum near the composition 75 at.%.

Jan 1, 1980

By A K. B Chigwada

Mining organisations grapple with the same problems year after year, wasting incredible amounts of time and money. According to estimates from the International Labour Organization (ILO), over one million work-related deaths occur annually, and hundreds of millions of workers suffer from workplace accidents and occupational exposure to hazardous substances worldwide. Many accident reports cite human failure as a primary cause (Busse and Johnson, 1998). The workers at the Bhopal chemical plant pumped methyl isocyanate into a leaking tank (Morehouse and Subramaniam, 1986). On 3 December 1984, more than 40 tons of methyl isocyanate gas leaked from a pesticide plant in Bhopal, India, immediately killing at least 3800 people and causing significant morbidity and premature death for many thousands more. The company involved in what became the worst industrial accident in history immediately tried to dissociate itself from legal responsibility (Broughton, 2005). Australia is not spared from safety problems either (Lucas, 2022). The ILO Convention 176 (1995) as a response provides that national law should inter alia provide for the supervision of safety and health in mines; the inspection of mines by designated inspectors of the competent authority; the procedures for reporting and investigating of fatal and serious accidents; the compilation and publication of statistics on accidents, occupational diseases and dangerous occurrences; the competent authority to suspend or restrict mining activities on safety and health grounds until conditions giving rise to the suspension are addressed; and worker consultation on matters related to safety and health in mines. This has assisted in getting enough data to define the magnitude of the problem to the mining sector.

Apr 16, 2024

By M Aros, L Reilly

Iron ore is normally sold in bulk at certain specifications. These include iron grade and specific contaminant grades, typically silica, alumina, phosphorous and sulfur. These target grades are normally agreed between the mining company (producer) and the steelmaking company (customer).This study presents an alternative to traditional cut-off grade calculation, using linear programming that maximises the total ore inventories within a predefined mining envelope while meeting the specified targets. Providing a feasible mining sequence that maintains the target grade is not covered in this study.The method was applied to Fortescue’s operations. The complexity arising from differing ore quality within each mining horizon, variable yields and upgrades and the need to control iron and contaminant grades provided a good opportunity to test an alternative method of ore selection. The new method significantly reduced the time spent in cut-off selection and sensitivity analysis, and provided an optimised solution.CITATION:Aros, M and Reilly, L, 2014. Ore selection optimisation for an iron ore deposit using linear programming, in Proceedings Orebody Modelling and Strategic Mine Planning Symposium 2014, pp 345–350 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 24, 2014

In the past few years the Rietveld method emerged as a routine tool for quantitative phase analysis (QPA) from X-ray diffraction data. Fast and reliable results became possible by combining modern computer technology and optimised mathematical algorithms with the fundamental parameters approach in the Bruker AXS TOPAS software. Here the routine analysis of bauxite raw material and of aluminium bath electrolyte is presented. The accuracy of bauxite quantification was tested by analysing the IUCr round robin sample. An agreement of better than one per cent was obtained for minor constituents and a maximum deviation of 2.5 per cent for the major phases. This is excellent agreement with expected results from weighting. Ten different phases were quantified in natural samples from Turkey with a precision better 0.5 per cent for the major phases and one per cent for the minor phases. Additionally, crystallite sizes were obtained from the peak profiles that give valuable information for the processability of the material. XRD data from solidified aluminium electrolytes were rapidly measured using silicon strip detector technology. With the LynxEyeTM detector full patterns were collected in 90 seconds and analysed with TOPAS. It is shown how to derive well-established measures such as bath ratio and excess AlF3 from the Rietveld results. These measures are widely used in aluminium production and readily available with very high precision. The excellent agreement with ALCAN reference data demonstrates the outstanding accuracy of the method. The mean deviation between here presented results and reference data is below 0.5 per cent for total CaF2, below 0.25 per cent for excess AlF3 and 0.02 for the bath ratio. The precision of the method was evaluated by repeated measurements.

Jan 1, 2008

The arbitration process, and its drawbacks: Any time you have taken part in a major arbitration, and the decision, when it comes out, is not what you thought it would be (which is bound to happen occasionally), the normal reaction is something like æthe arbitrator got it wrongÆ. Again normally, when you have cooled down a bit, and you look in more detail at the decision, you can see, probably, æwhere he got it wrongÆ (it is only male arbitrators who get it wrong). Ultimately, when reason prevails, and you reflect on it, you can see that what really happened was that you failed to get the arbitrator to see what you were getting at in the point or points concerned. This is doubly frustrating, when you consider what has been involved in getting to this point, having been through it all at least twice. An alternative to this process may be the dispute review board.

Jan 1, 1999

By D McKeon

In July 2006, ten Mining Engineering students and Associate Professor David Laurence from the University of New South Wales (UNSW) participated in the universityÆs inaugural overseas mining field trip. The ten-day trip to western Canada involved visits to two mines in British Columbia, the Diavik Diamond Mine in the Northwest Territories and the Syncrude oil sands operation in Alberta. Importantly, the groupÆs main objective was to gain a global understanding of todayÆs mining industry by observing the different cultural, legal, social and environmental setting found in Canada. It should be noted that the entire trip was planned, organised and directed by the students and benefited from extensive industry support both in Australia and Canada. This report intends to provide an overview of the field trip and describe to a limited extent the Canadian approach to mining.

Jan 1, 2007

By M Zlatev, S Silge

Producers of primary resources such as iron ore face the challenge of processing crude materials with increasing levels of impurities, which may result in the requirement for wet processing. This results in a significant increase in water usage, power consumption and operating costs. Given the remote locations of most operations in Australia (Stewart et al, 2013; Prosser, Wolf and Littleboy, 2011), the required volumes of power and fresh water for wet processing can be very difficult to achieve.HAVER&TYLER is renowned across the world for their screening technology in wet and dry processes. Its innovative Hydro-Clean® system represents a cost-effective and eco-sensitive way to clean any crude materials and material blends with a grain size distribution of 0–150 mm that are contaminated with adhesive clay, slit and other impurities.CITATION:Silge, S and Zlatev, M, 2015. Iron ore washing – achieve more with fewer resources, in Proceedings Iron Ore 2015, pp 519–528 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

By B Banerjee, H Masoumi, X Shen, S Raval, D Tannant

Structural mapping of pit walls can be performed using digital images and photogrammetry software, but the performance is limited by weather and environmental conditions including dust, rain and light. On the other hand, active sensors such as terrestrial laser scanners (TLS) and total stations (TS) suffer from vertical orientation bias and occlusions when persistent discontinuities dip at the same angle as the scanner line-ofsight. The recent development of the compact light detection and ranging (LiDAR) systems has made it possible to mount these sensors on unmanned aerial vehicles (UAVs) or drones which offer the potential to overcome limitations that are inherent in existing mapping systems. This study details the research involving integration and application of an advanced UAV-LiDAR system for structural mapping of a highwall. A state-of-the art laser scanner with an inertial measurement unit (IMU) and real-time kinematic global positioning system (GPS) was integrated on to a UAV. The system was first tested in a laboratory condition. Then the UAV-LiDAR system was employed to map a highwall of a coal mine. The planned flight trajectories tested the system at variable distances from the highwall face and at various speeds. The raw data collected from individual sensors were fused, filtered to remove noise, and segmented to produce a surface scan model. Finally, the point density and surface coverage were measured using the surface scan model of the highwall. The parameters were compared with equivalent measurements computed from a reference TLS data. The study demonstrates the capabilities of a UAV-LiDAR system to generate accurate and occlusion free data for mapping highwall geological structure with very quick and efficient flights in the field. CITATION:Raval, S, Banerjee, B, Shen, X, Masoumi, H and Tannant, D, 2018. Evaluation of a UAV-LiDAR system for mapping geological structures in an open pit highwall, in Proceedings The Fourth Australasian Ground Control in Mining Conference (AusRock), pp 496–503 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 30, 2018

Prefeasibility planning and cost estimation of conveyor systems has historically been undertaken by comparing fi xed plant transport requirements to that of similar systems in service. This paper describes the development of a prefeasibility conveyor technical design and cost estimation application using Microsoft Excel Visual Basic for Applications (VBA) platform. The application tool known as D-Convey (Dachshund Convey) was developed with the goal enabling the end user: to develop a technical model for conceptualised conveyor systems, to perform economic analysis on the developed technical model, and to conduct a comparative and risk analysis. An Excel VBA based platform was utilised to draw upon both the analytical and graphical capabilities of a spreadsheet. Some of the features of D-Convey system include a revolutionary dynamic graphical help system, known as the 'information pane' in lieu of traditional help fi les as well as the use of familiar graphical user interface elements such as the MS Offi ce 2007 task ribbon. The D-Convey system incorporates material database allowing for mass handling prefeasibility estimation in other industries; it has been validated at a local quarry.

Dec 6, 2010