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By D Beck

Open access to forecasts of mine geotechnical performance in the form of open databases of model results has been considered risky in the past, with a concern that the results will not be understood or will be misused. However, some modelling techniques allow very high similitude modelling of mine deformation and the results can be presented as deformation, damage and other parameters which are unambiguous and which all engineers can be more easily trained to understand. With some effort, sufficient reliability and quantifications of error are possible to overcome many of the issues.Allowing more members of the planning team to have direct access to forecasts of mine deformation will promote awareness of geotechnical issues and will act as a mechanism for improving mine designs. The models will also be more easily integrated into quality assurance programs, by providing a framework for understanding measurement results.The sufficiency requirements for undertaking simulation aided mining engineering will be presented, included some conclusions about requirements for training, quality standards and software development.

Mar 21, 2011

By V Lishchuk, C Lund

"Geometallurgy aims to improve resource efficiency by creating a spatial model of an orebody in order to forecast ore processing behaviour. This enables calculation of the economic value of each ore block and the use of this information for production optimisation and hence an improved economic return. Modelling uses different approaches to link geological information with mineral processing: traditional approach uses chemical elements; proxy approach – small-scale geometallurgical tests; and mineralogical approach – minerals.A geometallurgical model is obtained during execution of a geometallurgical program encompassing the entire value chain of ore processing. Available methods for establishing a geometallurgical model are in many cases limited and not yet comprehensively validated. Some of the limitations include: sampling density, assaying methods and quality, forecast accuracy block model content, geostatistical solutions for non-additive components, blending and assessment of positive impact of geometallurgy on the project. Synthetic ore models combined with process simulations and production scheduling, based on strong case studies, present a viable way to address these shortcomings. Such synthetic ore models will have realistic elemental and mineral distribution, textural attributes and 3D variability for input into the design of an appropriate geometallurgical program.A synthetic orebody was created for an apatite-bearing iron deposit. Variability in modal mineralogy was described by geostatistical parameters combined by a set of linear and trigonometric functions. The generated synthetic deposit model was used to develop a mine production plan to generate a simulated process feed. The process feed had detailed information required for beneficiation process simulation: modal mineralogy, chemical composition of minerals, grain size and specific gravity. The synthetic system was used to measure benefits that a geometallurgical program developed for real cases could provide, compared to production where only head grade is optimised. These include a reliable sampling strategy and confidence in the feed-quality forecast for economic evaluation.CITATION:Lishchuk, V, Lund, C and Lamberg, P, 2016. Development of a Synthetic Ore Deposit Model for Geometallurgy, in Proceedings The Third AusIMM International Geometallurgy Conference (GeoMet) 2016, pp 275–286 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Jun 15, 2016

By S Flanagan, M M. Mete, A R. Tiryaki, M Guresci

First Quantum Minerals (FQM) operates the Cayeli underground copper mine in Turkey. In response to a lost time incident (LTI) that occurred at the mine in 2022, the mine management decided to introduce a new safety approach on-site. The initiative began with a comprehensive safety culture analysis conducted by Arti Consulting, involving focus group studies. Employees actively participated in candid discussions, sharing their insights on safety issues and offering solutions. These conversations were meticulously audio recorded, resulting in over 150 000 words collected from more than 100 employees. These transcribed narratives then underwent rigorous semantic analysis, with the assistance of a sociologist, to identify and dissect patterns of unsafe behaviour. This analysis found areas for improvement, particularly in near-miss and incident reporting, quality of safety toolbox talks and effectiveness of pre-work risk assessments. Subsequently, mine management deliberated on these insights and devised corrective actions. An emphasis was placed on involving all employees in the corrective actions through communication training, empowering them to own the decisions and changes made. These impactful measures were seamlessly integrated into FQM’s Think! Safety Program, which embodies FQM’s sensible health and safety strategy. FQM partnered with Strika Entertainment (Strika) to develop innovative visual-first safety communication tools that use illustration, animation and graphic design to simplify complex messaging into easy-to-understand edutainment. As part of this approach to safety communications, Cayeli and Strika revamped the safety toolbox talks to encourage employees to voice their concerns and receive feedback when their suggestions were implemented. The response from employees has been positive, with over 200 unsafe behaviours and conditions reported within the initial two months of launching the Think! Safety Program. Remarkably, the Cayeli Mine has not experienced any LTIs for the past 500 days as of 9 December 2023. This paper encapsulates the dedicated efforts to transform Cayeli into a safer mining operation.

Apr 16, 2024

By Gupta R. C

Direct reduction of iron ore by solid reducing agents have been studied extensively and summarised by several authors (Otsuka and Kunii, 1969; Abraham and Ghosh, 1979; Frauhan, 1977; Rao, 1971; Kawasaki, Sanscainte and Walsh, 1962; Ghosh, 1970; Rao, 1979). While studying the reduction behaviour, it is generally agreed that the reduction occurs via gaseous intermediate, generated by carbon gasification reaction which involves mass transfer, heat transfer nucleation and growth, etc through a) reduction reaction occurring at solid reductant, and b) reduction reaction occurring at solid iron oxides, thus making the overall reduction process very complex in terms of clearly defining the reduction kinetics of the system. In addition to this, practical difficulties like correctness of reaction temperature, (Seaton, Foster and Velasco, 1983) difficulties in isothermal temperature studies of reduction, difficulties in monitoring the reduction process while using gaseous reductants and separation of reduction by volatile matter from overall reduction process make the reduction kinetics more complex (Misra).

Jan 1, 1999

By E E. Hall, S, E D. Thimons, R J. Timko

The heart of mine ventilation science and technology is the protection of the life and health of the miner. Lung diseases that result from overexposure to various mine aerosols can largely be prevented by maintaining concentrations below prescribed limits. Maintaining safe aerosol concentrations depends, in part, on our ability to know what mine aerosol concentrations are in a timely and accurate way. The Centers for Disease Control and Prevention (CDC), National Institute for Occupational Safety and Health (NIOSH) has been developing several new tools to help miners monitor respirable coal dust, silica and diesel particulate matter. This paper will discuss three main topics. First, the latest results of the person wearable dust monitor (PDM), developed by Rupprecht and Patashnick under CDC contract. The PDM was tested side-by-side with conventional samplers at a number of US coal mines and results indicated that the PDM was comparable to conventional samplers. Second, improvements to the dust dosimeter monitoring technique that includes a new pump with built-in pressure transducer and algorithm to convert differential pressure to dust concentration have shown good precision. Third, advances in the use of the detector tube technique to monitor tailpipe diesel emissions and ambient diesel particulate matter show that strong correlations exist between differential pressure measurement and elemental carbon in the samples.

Jan 1, 2005

By I R. F MacCulloch, K Jones

Pintail Systems, Inc, a Colorado USA based company has developed and commercially applied bioremediation processes for biological detoxification of cyanide compounds in mine waste. Site-specific microorganisms are isolated from spent ore, tailings or process solutions and augmented in the laboratory for cyanide oxidation, denitrification and metal biomineralisation. Biological processes typically treat complex contaminants (cyanide compounds, soluble metals and nitrates) in a fraction of the time of conventional remediation processes. Cyanide is used in microbial metabolic processes as a carbon or a nitrogen source. Biological detoxification processes applied at the end of mine life can end long-term liability and perpetual monitoring and containment. Case studies from commercial application and demonstration programs for the US Environmental Protection Agency will be presented in this paper.

Jan 1, 2004

By Pfeifer H. C, Nicacio P. A D

Sinter has been used as part of the metallic charge in large-scale blast furnaces for many years with the well-known benefits in terms of productivity and fuel consumption. However, because of the high investment in a conventional sinter plant, small blast furnaces and the associated integrated mini steel plants have not taken the advantages of using sinter. Recently KTS Korf Tecnologia Siderurgica, a division of Mannesmann Demag Ltda in Brazil, has developed a mini sinter plant for which the investment is compatible with small blast furnaces. Consequently, it is of great interest to evaluate the economical impact of using sinter in such small-scale integrated steel plants. In order to compare two alternatives, ie 100 per cent ore and 70 per cent sinter in the blast furnace burden, mass and heat balances for the entire operation from sinter plant through the blast furnace and EOF-based melting shop, were performed to evaluate the final production cost of the liquid steel. It was found that, depending on the sinter feed price, substantial savings can be obtained with the use of sinter.

Jan 1, 1999

By S Barrow, D Kent

Controlling the access of equipment, and people, has become more critical over the last few years for improving productivity and to meet safety responsibilities imposed by legislated obligations to have safety management systems. Hence Mine Site Technologies (MST) has spent the last three years completing the development of the tagging system to meet the mining industryÆs requirements, particularly streamlining access control. The basic tagging system tracks active Tags carried by personnel, or attached to vehicles and equipment, within underground zones. These Tags are detected (read) by Beacons placed strategically throughout the mine. As a Tag, or Tags, go past a Beacon they are read and the information transmitted back to the main database PC. This allows the current whereabouts of personnel and equipment to be known, as well as the history of their movements. The objectives of implementing the TRACKER Tagging System at Oaky No 1 Coal Mine were to: maintain a count of personnel inbye a particular point, and can alarm when a pre-set number is reached (eg the limit imposed by availability of SCSRÆs, etc); maintain a count of vehicles (and vehicle type) inbye a point, and can alarm if when a pre-set number is reached (eg when rated diesel units exceeds the limit for the ventilation present in that zone); manage the vehicle fleet, by keeping track of various vehicles underground better control and dispatch management of the equipment is achieved; keep track of equipment, knowing the location of equipment (such as forks, baskets, pumps, fans, etc) where last used or stored will minimise the risk of losing gear and assist in keeping inventory to a minimum; and locate personnel in emergency situations, by placing read Beacons throughout the mine the location of all personnel can be known in real time so that in the event of an emergency, their withdrawal can be monitored.

Jan 1, 2005

By J Allen, B Oats, S Palaniandy, M Lollback

The Julius Kruttschnitt Mineral Research Centre has conducted an intensive VertiMill® (VTM) survey program at the Cannington mine concentrator as part of the ‘collaborative research in stirred milling technology’ program funded by Metso Minerals. Since 2003, Cannington has progressively added grinding capacity into the circuit through VTMs operating in secondary and regrinding duties. Cannington was one of the first mines to adopt this technology in secondary duty by installing two VTM-1500-WBs as part of a capacity expansion to produce sub-100 µm rougher feed. Subsequently, an additional VTM-800-WB was installed in the lead regrind circuit to prepare sub-20 µm cleaner stage feed.Several surveys were carried out to evaluate the VTM performance over a range of changed conditions. Among the key changes in operating variables were circuit power draw, feed rate and water addition to the bottom of the mill. The average specific energy for secondary duty was 3.7?kWh/t. The lead and zinc regrind mills consume 8.1 and 15.3 kWh/t respectively. Generally, the VTM installations have successfully prepared feed for rougher and cleaner circuits by reducing the top size into the floatable regime with steeper particle size distribution, which has led to enhanced recovery. The survey results show the success of VTM installations in secondary (receiving feed from autogenous circuit) and regrind duties.CITATION:Palaniandy, S, Powell, M S, Hilden, M, Allen, J, Kermanshahi, K, Oats, B and Lollback, M, 2014. VertiMill® performance updates in secondary and regrind duties at Cannington mine, BHP Billiton, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 263–272 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

By B Nielsen, H Lehto, B Musuku

"The demand for fine and ultra-fine grinding associated with the processing of more challenging, finer grained orebodies and the global driver of minimising energy consumption has been an increased focus in our industry. Outotec’s stirred milling technology, the high intensity grinding mill (HIGmill™), was launched in 2012 in response to this industry need. First Quantum Minerals Ltd selected HIGmill™ technology for its Kevitsa mine in Northern Finland. The 700 kW mill is grinding copper rougher concentrate to improve copper/nickel separation and copper recovery. Selection of the HIGmill™ followed mineralogy analysis and laboratory and pilot testing for HIG milling in parallel with flotation tests to determine optimum grind size and energy input.The paper discusses the challenges and successes of the test work, manufacture, installation, commissioning and subsequent operation of the mill. Grinding performance is presented and a comparison between predicted and operating energy efficiency is made. In addition, the various steps to optimise wear rate and minimise maintenance and downtime are made, with particular reference to internal geometry of the mill.Citation:Nielsen, B, Lehto, H and Musuku, B, 2016. Design, Installation, Commissioning and Operation of Fine Grinding Technology at the Kevitsa Mine, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 59–66 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

The paper covers the history and develop- ment of electrical and diesel-powered hydrau- lic percussion rock drills. It examines main design aspects and problems encountered in pro- ducing an efficient and reliable machine to fully cover the nominal hole sizes required for underground development, production drill- ing and for general quarry work. The main design features and advantages of a hydraulic rock drill are relatively low input power requirement to energy per blow (this being achieved by the use of an electric or diesel- powered hydraulic system) and a specially con- structed piston using a powered damper cylinder to absorb the recoil forces from the drill steel and reduce stresses on the drill, feed and hydraulic boom. A further important design feature is the anti-jamming device which controls the drill both during manual and automatic operation. This anti-jam device works on feed and rotation press and prevents the drill bit becoming jammed in broken or soft ground. These features and many other mechanical and environmental benefits are highlighted when comparing hydraulic percussion rock drills with current pneumatic machines. The hydraulic rock drill gives an overall high penetration and production rate, with an added bonus for ergonomy and environmental conditions such as lower noise level, no fogging from air and oil exhaust (which naturally gives better air for breathing),plus improved vision when in under- ground situations. Hydraulic rock drills and systems have been fully tested in many mines, quarries and contract sites during the past years. They h6! been improved and modified and are now provi~ to be very reliable and economical piece drilling equipment whò in mines and quarries.

Jan 1, 1978

By H Thanasekaran, M J. Mankosa, J N. Kohmuench, G H. Luttrell

"Fluidised-bed flotation has been demonstrated over the last 16 years as an effective method for improving the flotation recovery of coarse particles. This technology has been successfully deployed into the industrial mineral sector with multiple installations within phosphate beneficiation plants and potash mills. Due to the minimal mineral surface expression required when utilising this technology, more recent studies have centred on the applicability of using this HydroFloat™ technology for the recovery of coarse sulfides and base metals. Multiple approaches have been investigated to determine the best means for implementing this novel coarse particle flotation system into both existing and new plant circuitry. These include the treatment of tailings to recover values that have been lost using conventional technologies and also the direct treatment of a coarse feed, either within the grinding circuit or by use of a separate split-feed flotation approach. Recent applications of the technology will be presented along with data generated from several test campaigns and ongoing research investigations. The benefits of properly applying this technology, such as reduced power consumption and increased mill capacity will be discussed.Citation:Kohmuench, J N, Thanasekaran, H, Mankosa, M J and Luttrell, G H, 2016. The Impact of Fluidised-bed Flotation for Treating Coarse Sulfides, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 105–112 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By B Kilgariff

Flotation has been in use at Broken Hill for nearly 100 years, and the process has gone through many different optimisation studies over that time. This paper reviews the current flotation practice at the Perilya Broken Hill Mine, and details one of the recent optimisation studies conducted using mathematical modelling and simulation tools. The optimisation study consisted of surveys of the lead and zinc circuits, mapping of the floatability components of the ore and developing models of the lead and zinc circuits. The models were then used to conduct simulations to simplify the circuit. The study allowed plant personnel to identify optimum operating conditions for their current flotation cells, as well as possible improvements in circuit configuration and cell capacity.

Jan 1, 2005

By A Winchester, D Grant

The massive 1100 Orebody in Mount IsaÆs X41 Copper Mine has been extracted over the last 40 years form north to south utilising sublevel open stoping methods.De velopment has continually stepped ahead of production to provide access to new primary stoping blocks. The remaining secondary pillars contain stopes with one, two or three fill mass exposures and were constrained by access requirements and stope extraction turnaround time.The remaining southern mining areas consist of large 40 m wide by 300 to 400 m long east-west transverse pillars that have been left to provide access for ventilation and service requirements. Three large transverse cross-cuts or transverse pillars û 4180 x/c, 4010 x/c and the Panel pillar now remain. The 4180 x/c was the last major transverse pillar to be successfully broken.This transverse pillar is being extracted in a retreating sequence, creating 3SLOS stopes due to the surrounding backfilled stopes.In recent years the extraction of the first, and most critical, stopes in the transverse pillars have resulted in large changes to the induced stress field. This paper describes the extraction of the 1.1 million tonne stope P418 in the 4180 x/c pillar.T echnical challenges that were faced and how they were overcome to allow for the successful extraction of the stope are described.Critical to the success of the P418 stope extraction were the rehabilitation methodology used; extraction strategy modifications to address deteriorating ground; mass firings with multiple directional changes; managing the exposure of backfill of variable strengths; and geotechnical monitoring prior to, during and after extraction.

Jan 1, 2005

The Kiirunavaara apatite-magnetite orebody is about 4 km long and approximately 100 m thick sheet-like body, which lies roughly in a north-south direction and dips from the horizontal plane along its entire length, in towards the town of Kiruna. The origin of this orebody has been a matter of controversy, with both magmatic and hydrothermal origins proposed. Traditionally and for practical purposes this rich apatite-magnetite ore has been divided into two main types: low phosphorous ore (B-ore) and high phosphorous ore (D-ore). Further the low phosphorous ore is divided into the low alkali (B1) and the high alkali (B2) ore.

Jan 1, 2006

A Good Product Range - So What! While in terms of water, waste management and environment protectrion, the Gippsland Basin may appear to have a good product range, what does this really mean? What it means is that, like any product range, the virtues of the product range must be sold and accepted by a majority of the public. The social, economic and environmental benefits of any enterprise using these products must be sold and accepted by the regional population. Many a budding entrepreneur has failed because he assumed that the public would accept his product, so good did it appear to be! However, we know that such an assumption must be avoided and that a great deal of time and effort needs to be invested in promoting and gaining acceptance of a product to ensure a long term and viable market.

Jan 1, 1992

By L Kormos, V Lawson, G Hill, G Marrs

"In sulfide nickel deposits throughout the world, pentlandite and pyrrhotite are commonly found together along with varying amounts of chalcopyrite and platinum group minerals (PGMs). The mafic or ultramafic host silicates associated with the sulfide mineralisation commonly exhibit a complex assemblage of magnesium bearing silicates, many of which themselves contain significant nickel. Four types of ore are proposed, each presenting their own processing challenges. These are: economic grades of Ni, Cu and PGE (platinum group element) in a pyrrhotite-bearing sulfide deposit, with low pyrrhotite to pentlandite ratios  economic grades of Ni, Cu and PGE in a pyrrhotite-bearing sulfide deposit, with moderate to high pyrrhotite to pentlandite ratios uneconomic high pyrrhotite: low tenor deposits low-grade low sulfide, high MgO ± PGE deposits that can sometimes be economically mined and processed.The grades and recoveries of nickel concentrates produced from sulfide ores can be significantly impacted by the ore mineral texture, the nickel tenor of the sulfides, and the polytype of pyrrhotite which may be either hexagonal (non-magnetic) or monoclinic (magnetic). The mineralogy of the silicates is also of great importance, especially the magnesium silicates and those which tend to produce particles which are asbestiform or which affect slurry viscosity. Other magnesium silicates such as serpentine carry nickel in solid solution, limiting the recovery entitlement of nickel by flotation because serpentine is not amenable to sulfide flotation mechanisms. Differences in plant flow sheets and reagent assemblages are required to effectively separate these minerals.Experience from a variety of plant operations and from extensive flow sheet development programs are discussed. Examples are given of where significant improvements in nickel circuit performance can be made by adjusting plant physical processing conditions or process chemistry to compensate for measurable ore properties and characteristics.CITATION:Lawson, V, Hill, G, Kormos, L and Marrs, G, 2014. The separation of pentlandite from chalcopyrite, pyrrhotite and gangue in nickel projects throughout the world, in Proceedings 12th AusIMM Mill Operators’ Conference 2014, pp 153–162 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Sep 1, 2014

By Beech-Jones J. M

At Port Latta in Tasmania, Savage River Mines operates vertical shaft furnaces for the firing of pelletised magnetite concentrates. At times the temperature profile of the furnace has changed markedly, necessitating the- burning of greater quantities of fuel to maintain good pellet quality. A study of the oxidati=of magnetite concentrates was under- taken because this exothermic process supplies much of the heat required to indurate the pellets. Using the thermal analyses methods, different magnetite concentrates from Australian and overseas were heated in air under identical conditions, to compare rates of oxygen uptake and of heat release. In addition, a compari- son was made of the oxidation behaviour of different particle size fractions of a selected concentrate. Particle size analyses, x-ray diffraction and dilatometer tests were used to aid inter pretation of the thermal analysis traces. The investigation emphasized the importance of particle size and ferrous iron content in determining' oxidation rates from the commencement of heating.

Jan 1, 1974

By Urie R. W

Fluidized bed roasting of copper concentrates from Mt. Morgan, Mt. Lyell, Mt. Isa, and Peko was performed in a 3 ft 6 in diameter, slurry fed, pilot plant roaster operated under autogenous conditions to produce calcines with desirable leaching properties. A 12 in. diameter, externally heated roaster, provided with a dry feed system, was also used.An account is given of important factors which influence roaster behaviour and performance, and the effects of operating variables on calcine composition and leaching properties are described. Due to copper ferrite formation, a maximum of approximately 50 per cent of the copper in the calcines may be in the form of CuO before the copper leach efficiency falls significantly below lOO' per cent. Recovery of gold by cyanidation of leach residues was consistently high and independent of roasting conditions.INTRODUCTIONIn traditional practice copper is produced by pyrometallurgical techniques when the ,copper minerals in the ore or concentrate are predominantly sulphides, and by hydrometallurgy when the minerals are oxidized. Copper smelting is most suited to large scale operations, and for many years small to medium size mines with sulphide orebodies have been interested ill; alternative processes.Since hydrometallurgical plants (ie. leaching and electrowinning plants) are essentially unitized, they may be scaled down in output without much loss in efficiency or increase in processing cost, and many proposals have been made for the application of this type of process following roasting of the sulphides to render the copper soluble. However, until the advent of fluidized roasting, it was not possible to control the roasting operations sufficiently precisely to produce calcines consistently of the required leaching characteristics.

Jan 1, 1961

By C McGuire, W Harris, S Arsenault, D Witow, B Rogers

Mining deep orebodies is increasingly becoming the norm as the ‘easy’ orebodies are depleted. Deep ore mining requires significant ventilation and cooling infrastructure to not only meet regulatory requirements for air quality but also to achieve acceptable workplace temperatures with the higher strata rock temperatures and increased auto-compression. At the same time, advances in battery equipment technology are turning the possibility of a battery powered fleet into reality. The switch from a diesel fleet to a battery powered fleet offers several positive opportunities for the design and operation of a deep mine.The potential to reduce ventilation and cooling requirements due to battery powered equipment results in significant cost savings for mine development and infrastructure. Battery powered fleets are not subject to the same dilution requirements associated with diesel fleets thus allowing lower ventilation rates. At the low ventilation volumes possible with a battery powered fleet, surface refrigeration plants are limited with respect to the amount of cooling that can be delivered to the workface. Considerations for calculating the optimum air flow and cooling requirements are presented. Considerations for locating the refrigeration plant are also discussed. This paper presents these opportunities and considerations; including a case study comparing the ventilation and cooling system design with a diesel fleet versus battery fleet for a planned mine in Northern Ontario, Canada.CITATION:Harris, W, Arsenault, S, McGuire, C, Rogers, B and Witow, D, 2017. Diesel to electric – creating a positive paradigm in underground ventilation and cooling, in Proceedings Australian Mine Vent Conference 2017, pp 169–174 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 28, 2017