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By S Lee, I Sohn

The ferrous and non-ferrous metallurgical industries have been utilising slags, fluxes and mattes for process optimisation and quality improvements at high temperatures. Understanding the fundamentals of the thermodynamics and kinetics of chemical metallurgy regarding slags, fluxes and mattes has been essential to the technological developments of these optimisation and improvements. This work will discuss how these fundamentals have been studied in the reactions involved and implemented in the ferrous industry from primary refining to continuous casting. In particular, the chemical driving forces that allow these reactions to take place and the limitations of the kinetics that require optimisation to enhance the reactions. In addition, the future research direction for slag technology innovation and the role of these fundamentals will also be described.

Jun 19, 2024

By A Annor, L J. Chen

The production of paste backfill has typically been accomplished through the adaptation of existing technology. Thickeners and disc filters have several drawbacks when applied to production of tailings paste backfill. Personnel at CANMETÆs backfill research laboratory in Sudbury, Ontario, Canada have been carrying out research into and development of methods to produce paste backfill using total mill tailings since 1991. Using a silo for production of paste is not a new concept but has been refined to a marketable level. This technology is based on a fluidization principle that assists in settling the tailings to an homogenous state in a silo. Other developments include patented de-watering technology for use in the silo to speed the settling of the solids to a suitable solids content, optimisation of silo geometry, and instrumentation related to paste backfill production and transportation. The advantages to fluidisation technology are in reduced capital cost, reduced operating costs and in the environmental benefits of using full plant tailings over classified tailings or alluvial aggregates. Another major advantage is in the ability of this technology to be retrofitted to existing hydraulic backfill plants to further reduce capital cost. This paper details the development of the new technology as well as the associated cost savings over other technologies. It will also look at the research and development of unique components that make this technology work.

Jan 1, 1998

By L van Latum, A Koh, I Thomas

Haul truck drivers are at a high risk of developing fatigue due to the monotonous nature of the work and demanding shift rosters. In the mining industry, fatigue is identified as a major contributing factor in several fatal accidents a year. A number of fatigue detection devices are now available, that can contribute to improved fatigue risk management in the mining industry. This paper describes the technology and algorithms behind one particular product which is both predictive and un-obtrusive to the operator. The Advisory System for Tired Drivers (ASTiD), was developed by Fatigue Management International (FMI) in collaboration with the Loughborough Sleep Research Centre (LSRC), both in the United Kingdom. While this system includes a model of the human circadian rhythm as a bias for predicting expected fatigue risk by time of day, it also uses yaw data generated by a solid-state gyroscope in the horizontal plane. Algorithms analyse this data to determine the level of monotony of actual driving conditions and to detect changes in steering control caused by driver fatigue. During normal levels of attention, a haul truck driver applies continuous, small adjustments to the steering wheel. As the level of fatigue increases, steering adjustments become less frequent and more erratic. Differentiating between these modes of control in the highly variable mining environment is accomplished by chromatic processing of the gyroscope data. This paper will go into some detail explaining the principles behind chromatic processing and the specific application of these in detecting fatigue in haul truck operators.Technology in itself is not the solution to addressing operator fatigue, but it plays an important role in ongoing monitoring and maintaining awareness with mining personnel. Furthermore, the specific principles behind ASTiD technology support a risk-based approach to fatigue management, allowing optimisation of the mining operation for productivity as well as safety.

Sep 26, 2011

By C T. Dunbar, P A. Walker, G E. LeJuge

A programme of blast improvement was initiated at the Mt Whaleback iron ore mine by BHPIO management in early-1998. One component of that work was the need to improve wall control blasting practices to better achieve the designed pit slope elements. This paper describes the geological conditions in which pit walls are developed, the mine operating equipment, the blast design concepts applied to minimise blast damage, the techniques applied in an assessment of the blast performance and the operational procedures developed to ensure that the blast concepts are effectively implemented in the production environment. Substantial changes have been implemented in both technical and operational aspects of the mining operation in order to achieve the improvements in pit wall condition, in particular recognising the need for a more flexible approach to limits blasting in response to highly variable and complex geology. The benefits to the mine are not only an improved wall condition, but increased confidence on the part of mine management that mine plans may be implemented on design and on schedule.

Jan 1, 2001

Gas well tests were performed on 17 wells in the Roma area. The procedure used in the test programme incorporates an initial isochronal test followed by what is described as the "two flow drawdown" technique. The second flow of the two flow drawdown test was conducted for sufficient time to allow transient investigation of the surrounding reservoir. This combination of tests allows the evaluation of stabilized production capacity in addition to the determination ,of several important reservoir characteristics.It also provides a qualitative indication of reserves, by reflecting the presence or absence of reservoir boundaries within the drainage area affected during the test.

Jan 1, 1968

The following is based on two examples of emission control with coal fired power stations as practised in Germany at Heilbronn Block 7 power station and the Rheinbraun coal combined power station with integrated high-temperature Winkler system (HTW). Heilbronn Block 7 demonstrates the successful emission control of sulphur and nitrogen oxides and the (HTW) system the reduction of the specific carbon dioxide emission. Both were sparked off by legislation which demanded certain emission control standards. Since the early eighties environment protection has been a matter of heated public debate in the European Community. A recent survey in Germany showed unemployment as being the only subject matter more frequently in the minds of people than environment protection. A new kind of forest devastation in areas away from industry has caused investigations by several government departments and private enterprise. Because of lack of conclusive evidence so far, the principle of PRECAUTION has replaced the CONCLUSIVE evidence as a base for new legislation concerning the environment. The new legislative standards for nitrogen oxide emissions in Germany for example have reduced NOx emissions of power stations from 1000 mg NOx per cubic metre of flue gas in the beginning of 1983 to 200 mg NOx per cubic metre of flue gas in April 1984. These new standards were enshrined in legislation when research provided some evidence linking nitrogen oxide emissions through photo-chemical reactions with forest devastation. Thirty European countries signed a treaty in 1983 expressing their concern about air pollution and their willingness to co-operate with each other in controlling large scale emissions.

Jan 1, 1991

By J Harris, J Li, M Shi, P A. Kirsch, D Sprott

Australia has an enviable global reputation as a leader in health and safety outcomes in the hazardous industry of mining, in part due to an increased application of risk management regarding operational planning and mining practice. In 2010, the Australian Coal Association Research Program (ACARP) initiated a major project, RISKGATE, to build, capture and deliver a national body of knowledge to assist companies with the management of risk in coal mining. The online system contains information for tyres, collisions, fires, isolation, strata underground, ground control open cut, explosions, explosives underground, explosives open cut, manual tasks, slips/trips/falls, outbursts, coal bumps and bursts, human–machine interface, tailings dams, occupational hygiene and inrush. In 2014, RISKGATE is developing content for fitness for work (fatigue, drugs, alcohol, physical well-being, psychosocial well-being).This paper analyses underground mining fatalities in Australia and the United States since 2002 and introduces RISKGATE with a focus on the knowledge base for management of hazards in underground operations. Through capturing coal industry expert operational knowledge, RISKGATE provides a cumulative corporate memory at a time of high personnel turnover within the mining industry. This coal-based body of knowledge is a platform that can be evaluated and implemented for other mining domains and high-risk industries within the energy supply chain.CITATION:Kirsch, P A, Shi, M, Harris, J, Li, J and Sprott, D, 2014. RISKGATE and underground operations, in Proceedings 12th AusIMM Underground Operators’ Conference 2014 , pp 11–18 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Mar 24, 2014

By N Lewis

Recent major urban trunk sewer infrastructure projects in Melbourne have involved construction of nearly 10 km of tunnel boring machine (TBM) driven tunnels in a range of geological conditions varying from soft alluvial soils to hard volcanic rock. To provide both construction and permanent access to the new trunk sewer network, a total of 17 shafts between 5 m and 13 m in diameter, and up to 64 m in depth have been constructed. This paper describes the design and construction of the temporary shaft support systems for the shafts.The range and variability of geological conditions at each shaft site required the adoption of the following shaft support systems across the projects – jet grouting, sheet piles, diaphragm wall, secant pile, contiguous pile, reinforced shotcrete rings and rock bolts.Groundwater control, settlement, TBM launch and reception chambers at the shaft base, chambers and TBM launches at mid-depth of shafts, connection shafts between new and existing sewers and bypass pumping shafts are among the challenges that have been met.This paper reports on the some of the challenges involved and experience gained in developing design and construction solutions for large diameter shafts that are excavated within varying geology in Melbourne over the past three years.

Mar 8, 2011

Marble deposits of dolomitic variety are available in large quantities in India and for extracting these deposits diamond wire saw cutting machine is mainly used. Cutting performance of the diamond wire saw machine depends on rock parameters, machine parameters and operational parameters. Rock parameters related to physico-mechanical properties, such as, compressive strength, tensile strength, shear strength, modulus of elasticity and abrasion resistance of marble play role in determining cutting rate and beads wear rate. Thus, this study was undertaken to determine the relationship between different physico-mechanical properties and cutting performance. This work also aimed at enhancing the cutting performance of diamond wire saw in dolomitic marble deposit. Study was conducted in the field at three different zones having deposit of soft, medium hard and hard dolomitic marble. During the study, cutting rates and wearing of diamond beads were recorded in the field. Physico-mechanical properties were determined in the laboratory. The results obtained were subsequently evaluated by using statistical analysis. Study revealed that these properties of marble play a significant role in the performance of diamond wire saw machine. Predictive equations for the wearing of diamond beads and cutting rate were developed based on regression models. Results of this study will be of ample use for operators of wire saw to achieve maximum cutting performance and for manufacturers in designing the diamond beads.

Dec 6, 2010

Visual computing opens the design process to a wider audience and allows rapid communication of mine plans to all stakeholders. The integration of software and hardware technologies that take advantage of a graphical environment will continue to improve both long-term and short-term mine design (Figure 1). A good design must be adaptive to respond to decision changes as the mine develops and more information becomes available. The constraints on mine design predicate careful analysis in order to operate the mine as efficiently and safely as possible.Continuous improvement in mining is assured by developing innovative technologies that target mine survey, drill and blast, modelling, short-term design and pit and stope optimisers. The design life of a mine has to be sufficiently long to ensure the mine is commercially successful, justifying the high start-up capital costs. Being able to execute a plan so that it honours the design realises the rewards of computerised mine planning and the long-term investment in data acquisition.

Sep 26, 2011

By P Mikula, B Darlington, J Graham, P Young

In underground mines experiencing dynamic events, there is an ever-present challenge to design and maintain a capable ground support system. One key component of ground support systems is surface support, which serves the essential roles of retaining failed rock and transferring forces generated by surface displacement to rock bolts or other support elements. Observations underground show that in many instances, standard mesh panels alone do not provide sufficient dynamic support to retain substantial bulking failures imposing displacement onto mesh, and in such cases Mesh straps and W-straps may be employed. Determining the performance of surface support elements proves to be difficult, with a multitude of variables at play in the underground environment. Quite comprehensive work has been completed on laboratory testing of surface support systems; however, very little work has been conducted on in situ dynamic testing of Mesh straps and W-straps. In 2019 in Western Area’s Flying Fox Mine, in situ dynamic testing was conducted on a series of Mesh straps and W-straps using Sandvik’s in situ Dynamic Test Rig (DTR). The testing regime applied impact energies from 5.1 to 15.3 kJ to Mesh straps and W-straps. The performance of the straps that did not fail was a maximum absorbed energy of 9.3 kJ and 14.2 kJ for the Mesh straps and W-straps respectively. The testing successfully demonstrated the ability of Sandvik’s DTR to test not only rock bolts, but also surface support elements, creating new testing and research possibilities. The testing also provided important design guidance data that is not practicable to obtain using laboratory dynamic testing facilities.

Nov 29, 2022

I have chosen this subject in view of the fact that, while there are many and ample opportuuities of getting reliable assays made, there are but few who are in a position to obtain reliable data on the sampling of minerals and metals my long experience at Port Pirie, where, for five years, I had charge of the Refining and Sampling Mill, showed me how important it was that a correct sample should be taken.Weighing; This, to the ordinary layman, seems so simple that no expert knowledge is needed, but in actual practice there are hundreds of pounds to be lost by the lack of knowledge in this department.(1.) There is the matter of weighing in large or small quantities.(2.) The class of weighing machine used.(3.) The accuracy of weights used.We all know that, say, 1000 tons of ore cannot be weighed in one parcel; but the fewer the weighings the less loss to the seller (and usually wishes it weighed in small lots carefully) for it is a well known fact that the most sensitive scales take a certain weight to show distinctly the indication of the balance, or, in other words, what is known as "the pull of the scales." As for instance, 1000 tons weighed in lots of 1 c. each, taking the pull of the scale as being equal to 1 lb., would give a result of 9 tons loss to tbe seller, and as most of the ore sent to Customs works is worth 5. -£20 per ton-this would mean £180 loss to the careful man.

Jan 1, 1901

By Y-B Kang, J H. Park, J Park

In order to understand the effect of oxygen injection into the molten metal on the valuable metals (VM) recovery and interfacial phenomena, several high-temperature experiments were conducted using a high-frequency induction furnace with a quartz tube as the reaction chamber at 1673 K. Copper-based waste printed circuit board (PCB) that contains some impurities was selected as the end-of-life resource. CaO-SiO2 based pre-fused slag and oxygen gas were used in present works. The composition change and microstructure of the samples were analysed. As oxygen was injected into the system, impurities were rapidly removed. After the removal of impurities, continuously injected oxygen lowered interfacial tension between liquid slag and liquid metal. Lowered interfacial tension induced Cu loss into the slag.

Aug 21, 2024

By M E. Watson

Minimising dilution and ore loss is an important part of ensuring profitability of a gold mining operation. White Foil open pit gold deposit is a low-grade deposit and therefore managing ore quality is a high priority. Ground movement through blasting can displace ore and waste boundaries up to 10 m from their in situ location and therefore requires stringent ore movement monitoring and adjustment. There are currently only two options for monitoring blast movement – utilising visual targets (commonly lengths of polypipe) but this has widely been replaced by electronic blast movement monitors (or BMM). Regardless of the technology used, the basic principle is to compare the pre- and post-blast locations of the targets to determine the movement of the rock mass during blasting, which is then used to determine the final location of ore and waste boundaries.The Blast Movement Technologies (BMT) BMM system has been used at White Foil since June 2014. The system has been effective and reliable during that time; however, the annual cost of using the BMM system is greater than other monitoring alternatives. As such, the open pit geology team conducted a study comparing the BMM system against the conventional polypipe technique. The objective was to quantify the profit and loss that would occur based on the ore block transformations from both methods. Eight blasts were selected where polypipes were installed in additional holes adjacent to the BMM monitoring holes. The resulting movement vectors from the respective methods were used to create post-blast ore blocks by transforming the in situ ore blocks. While polypipe is a cheaper alternative, the BMM system tracks ore and waste boundaries more effectively resulting in better quality control, enhanced ability to minimise dilution and ore loss thus maximising profit. For these eight blasts, it is calculated that the BMM system resulted in A$664 978 extra profit through a reduction of ore loss. The total cost of a yearly BMM package was recovered in the first two blasts of this study. The primary reason for the difference is that polypipe had a poor recovery rate of 32 per cent compared with 92 per cent for BMM at White Foil. Therefore, the data used to transform the ore blocks was less representative, resulting in inaccurate post-blast ore block boundaries when using polypipe.CITATION:Watson, M E, 2017. Blast movement monitors or polypipe? A study into cost-effective blast movement monitoring at White Foil gold mine, Western Australia, in Proceedings Tenth International Mining Geology Conference 2017, pp 433–440 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 20, 2017

By A J LYNCH

It was Harold McMillan, Prime Minister of England 30 years ago, who used the phrase "The Wind of Change" to describe political events in Africa in his day. So well did this phrase capture the spirit of the time that it echoed around the world, and the echo has never stopped. Change is the constant factor in the society in which we live and everyone of us has had experience of the effect which it has had on our professional and personal lives. Change will not stop, it will continue at an increasing rate and the questions we must answer are how do we prepare ourselves to meet the challenge of future change and how do we take advantage of the opportunities which it will bring? It is these questions which I wish to discuss in this address.

Jan 1, 1989

By S A. Ravishankar, W Perez

Flotation is one of the main concentration processes to purify kaolin clay via the removal of naturally occurring impurity minerals containing Ti and Fe. Currently, there are two types of collector chemistries used in the industry to float coloured impurity minerals. These are traditional tall oil fatty acids (TOFA) and specialty hydroxamate (AHX) based collectors. AHX based collectors have long been known to be the most selective collectors to float Ti and Fe based coloured impurity minerals (CIMs) as compared to TOFA based systems. AHX based collectors provide, not only improved selectivity and simplified process, but also more importantly, make it possible to treat certain kaolin resources that do not respond to standard TOFA systems. However, the relatively higher cost of straight AHX collectors has restricted broader application of these collectors in kaolin clay and other oxide flotation applications for a long time. Recent technological advancements, in both making and formulating AHX products more economically, increased the usage of these collectors in kaolin applications. Modified AHX products offer more economical alternatives and process options to provide high purity kaolin clay products for specialty applications based on cost-performance criteria. In this paper, the flotation performance of a series of newly developed AHX formulations is provided along with the characteristics of AHX flotation in general. In addition, flotation performance of earlier AHX collectors is provided based on published literature as background data.

Jan 1, 2005

By R McCarthy, P Darvall

FerrAus Limited's Robertson Range and Davidson Creek iron ore projects are located on the far eastern margin of the Hamersley Province, approximately 100 km to the east of Newman, Western Australia. The deposits are primarily formed of bedded haematite-goethite-limonite mineralisation within the Marra Mamba Formation, comprising a total combined resource of 164 Mt at 58.6 per cent Fe. The deposits represent relatively new discoveries for the Hamersley Province. The potential for mineralisation at Robertson Range was identified by Rio Tinto Exploration in 2000, while Davidson Creek remained untested until 2007. One of the main reasons for this is that these deposits are almost exclusively concealed beneath Tertiary sediments and recent transported cover making them difficult targets for conventional, prospecting style exploration. Since commencing exploration in the project area, FerrAus has collected nearly 20 000 stations of gravity data within the Robertson Range and Davidson Creek project areas, with most of this data collected at a 50 100 m station spacing. Gravity has proven itself to be an effective technique at predicting the position of the target host stratigraphy and has been a key driver in the exploration for concealed iron ore deposits. However, there is not always a perfect correlation between the position of gravity anomalies and concealed ore. The response of deep haematite bodies may be masked by low-density cover rocks, while other dense lithologies may be the cause of gravity anomalies which appear similar to the Marra Mamba targets. Hence, effective use of the gravity data requires interpretation in a geologic context with an understanding of the capabilities and limitations of the technique.

Jan 1, 2009

The AusIMM/AMIC code for reporting Reserves seeks to improve the calibre of professional reporting on this subject. But have they gone far enough? Should the code appreciate that the degree of reliability of estimates required will vary with the type of mining planned? How does one "confirm continuity" as required by the code? The aim of optimum development drilling is to achieve appropriate ore zone definition for acceptable estimates of reserves and their economic extraction. Can this procedure be in conflict with the code? How does it affect finance decisions?

Jan 1, 1989

By P Thompson, D Rose, S Yu, W Baum, R Zahn, D Meadows, G Hall

Opportunities to improve mill operations are often cited by mining companies and recognised in many concentrators spread throughout the world but are not always followed through. Copper-molybdenum concentrator operations are challenged by a continuously increasing list of detrimental factors. They include deteriorating ore characteristics and poor mineralogical information on deeper ores, water quality and availability, steel wear and increasing power costs. Rapidly declining productivity, sustainability and environmental factors, new taxes, mining industry global skill set shortages, to name but a few, must also be considered. The days of maximising value by just increasing production or simple cost cutting are fading and will not be sufficient for the future of more complex mineral processing operations and larger plants. As a result, FLSmidth’s Global Process Technology Group has launched a plant and process optimisation program based on mineralogical and metallurgical surveys.Copper-molybdenum concentrators of the future need a paradigm shift. Modelling and simulation tools alone are not the answer to complex mineralogical associations and larger scale equipment and operations. Detailed area by area review aimed at identifying process constraints in terms of equipment and operating practice in conjunction with robust diagnostic work, ie mineralogical and metallurgical characterisation, are mandatory for process optimisation. The navigational beacon, for all operations who want to remain competitive, will be ‘process efficiency’. Since the use of automated mineral analysers has become more readily available and reliable, mineralogical-metallurgical plant surveys have proven themselves as the most efficient tool for optimising plant performance.The following paper will illustrate how operations can move toward eliminating under-performing flow sheets, fixing run-away flotation conditions, maximising individual process equipment performance, preventing shortcuts in Bond work index testing which may cause the failure of comminution models and minimising costly and time-consuming ‘debottlenecking’. As previous plant surveys have shown, the net project cash flow can be increased by 50 to 200 per cent if a combination of robust ore characterisation and plant process mineralogy is performed. The combined plant survey approach has been demonstrated successfully in a multitude of operations. This includes the use of key ore types in concert with statistically sampled process streams, bench-scale metallurgical tests and automated mineral analysis on a size-by-size basis.CITATION:Meadows, D, Hall, G, Rose, D, Thompson, P, Baum, W, Zahn, R and Yu, S, 2014. Copper-molybdenum concentrator surveys using mineralogy and process benchmarking tools to improve overall plant performance, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 315–322 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

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

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

Aug 24, 2015