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By Y Xie, D Willingham

Predictive maintenance (also known as ‘condition/health monitoring’) refers to the intelligent monitoring of equipment to avoid future failures. In contrast to conventional preventive maintenance, the maintenance schedule is not determined by a prescribed timeline; instead, it is determined by analytic algorithms, such as machine learning, using data collected from equipment sensors and/or via simulation.Predictive maintenance offers the following benefits for operators and equipment manufacturers:- reduces equipment downtime by identifying issues before failure, thereby enabling convenient scheduling of equipment service and extending equipment lifetime- determines the root cause of the failure, enabling appropriate service to be performed without utilising resources to determine a diagnosis- avoids the unnecessary costs of maintenance and unexpected failures- improves safety and product quality.Algorithms and data are critical to predictive maintenance success. Sensor data is first preprocessed using advanced statistical and signal processing techniques; it is then combined with predictive modelling techniques, such as machine learning, to estimate equipment health.Once tested, predictive maintenance algorithms may be used in an operational setting within an IT environment, such as a server or cloud. Alternatively, algorithms may be implemented in an embedded system directly on the equipment, allowing for faster response times and significantly reducing the amount of data sent over the network.CITATION:Willingham, D and Xie, Y, 2017. Predictive maintenance modelling for bearing-based equipment, in Proceedings Iron Ore 2017, pp 627–630 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 24, 2017

By Winrove G. S, Herdie G. J, McCarthy C. A

Production of hot metal from the Hlsmelt Research and Development Facility at Kwinana, Western Australia commenced in October 1993. The stand-alone facility is a unique, coal-based, integrated ironworks equipped to process iron ore fines to pig iron and simultaneously undertake a wide range of research tasks. The data generated will be used to verify the commercial potential of the technology and to set the design and operating parameters for a full-scale production plant. The design, construction, commissioning and initial operation of the HRDF has required many innovative and practical solutions to be developed and implemented by the international group of organisations contributing to the Hlsmelt Project. Initial operation has produced results which demonstrate the potential of the unique process technology associated with the core plant smelting unit. The recent achievement of post-combustion levels of 60 per cent with heat transfer efficiencies greater than 85 per cent demonstrates that the performance obtained with the Small Scale Pilot Plant in Maxhutte, Germany can be reproduced at a larger scale. The results presented in this paper support the thrust for further intensification and future commercialisation of the process.

Jan 1, 1995

By L Grigorov, G J. Jame, A V. Nguyen

The dewetting kinetics between a small air-liquid interface and a silica (negatively charged in water) planar surface in solutions of dodecylammonium chloride (cationic surfactant) has been investigated using the Scheludko cell and digital high-speed video microscopy. The gas-liquid interface was created at the bottom of a small silica capillary of the cell and then was moved towards the silica planar surface. After the rupture of the liquid films between the interfaces, the expansion of the gas-liquid-solid three-phase contact (TPC) line was observed and recorded using a digital high-speed video microscope system, operating at 1000 frames per second. The surface tension of the surfactant solution was measured using the pendant drop technique. The equilibrium contact angle was measured using the Scheludko-Minings method with a silica micro-sphere. The TPC radius was determined as a function of time and compared against the available hydrodynamic and molecular-kinetic models. The experimental data are described very well by the molecular-kinetic model for the TPC line motion. The hydrodynamic model is in agreement with the experimental data only for a short time after inception of the three-phase contact expansion.

Jan 1, 2005

By A V. Nguyen

Spherical calcium dioleate particles (~10 ¦m in diameter) were used as AFM (atomic force microscope) probes to measure interaction forces of the collector colloid with calcite and fluorite surfaces. The attractive AFM force between the calcium dioleate sphere and the fluorite surface is strong and has longer range than DLVO (Derjaguin-Landau-Verwey-Overbeek) prediction. The repulsive AFM force between the calcium dioleate sphere and the fluorite surface does not agree with the DLVO prediction. Consideration of non-DLVO forces, including the attractive hydrophobic force and the repulsive hydration force, was necessary to explain the experimental results. The non-DLVO interactions considered were justified by the different interfacial water structures at fluorite- and calcite-water interfaces as revealed by the numerical computation experiments using molecular dynamics simulation.

Jan 1, 2005

By J Demchak, L M. McDonald

The duration of acid mine drainage flowing out of underground mines is important in the design of watershed restoration and abandoned mine land reclamation projects. People conducting land reclamation projects usually employ remediation strategies once (reshaping land, revegetating soils, and installing water treatment) with the hope that these methods will adequately improve water quality for a long time, with little planning for future changes. An understanding of changing acid water conditions from underground mines over time will help in designing efficient and cost-effective treatment methods. Past studies have reported that acid water flows from underground mines for hundreds of years with little change, while others state that poor drainage quality may last only 20 to 40 years. Several factors are important in making a prediction of drainage quality over time, such as inundation or flooding history, coal seam characteristics (primarily sulfur content), residence time of water in the mine, time since mine closure, mining method and amount of coal remaining, collapse of roof and other disturbances within the mine, and subsequent nearby surface mining. More than 150 above-drainage (those not flooded after abandonment) underground mine discharges were located and sampled during 1968 in northern West Virginia, and we revisited 44 of those sites in 2000 and measured water flow, pH, acidity, alkalinity, Fe, Al, and sulfate. All 44 discharges were from mines in the Pittsburgh and Upper Freeport coal seams, and both seams have been extensively mined in this area during the past 70 years. We sampled during the same months (June to October) as were sampled in 1968, and we found no significant difference in flows between 1968 and 2000. Therefore, we felt that the water quality data could be compared and that the data represented real changes in pollutant concentrations. There were significant water quality differences between year and coal seam, but no differences between disturbed and undisturbed mines. Average acidity declined 79 per cent between 1968 and 2000 in Pittsburgh mines (from 3342 to 702 mg/L), and 56 per cent in Upper Freeport mines (from 1189 to 519 mg/L). Iron decreased an average of about 80 per cent across all sites (from an average of 345 to 69 mg/L), while sulfate decreased between 50 to 75 per cent. Pittsburgh seam discharge water was much worse in 1968 than Upper Freeport seam water. Twenty of our 44 sites had water quality information during 1980, which served as a midpoint to assess the slope of the decline in acidity and metal concentrations. Almost all parameters showed an exponential rate of decline in acidity, iron, and sulfate.

Jan 1, 2003

By Middlebrook PD

The problems of education and research in the extractive metallurgy area are being tackled by the University of Melbourne through activities centring on the Department of Chemical Engineering. The establishment of the G.K. Williams Laboratory and the enhance- ment of the teaching of material relevant to extractive metallurgy in the Chemical Engineering course aim-at providing graduates and experienced researchers for the industry and at providing a strong research group carrying out industrially significant research in the area of pyrometallurgy.

Jan 1, 1986

The placer gold industry has experienced a roller-coaster history incorporating four major boom eras. The first, 'hand-methods' boom arose in the mid-19th Century from application of an old idea in new places around the globe. The subsequent hydraulic mining, bucket dredging, and 'hydraulic excavator-portable plant' booms each arose from application of new ideas in old places around the globe, ie in places where gold had been found during earlier booms. The new ideas that heralded the second, third and fourth booms were all significant advances in excavation technology. These enabled the industry to target the known deposits that were too deep, too wet, too small, or too low-grade for recovery by earlier boom methods. Relatively few new deposits or new deposit styles arose from the 'history book' exploration approach, so the number of known deposits to which each of the boom methods were applicable was limited. Consequently, the first three booms were each followed by significant periods of industry decline, and the fourth boom is currently waning inNew Zealand. Further decline is not inevitable and can be avoided by changing to a knowledge-based exploration approach similar to that adopted by the hard rock gold industry in the 1970s. Such an approach could easily herald the next placer gold boom.   Most of the relatively coarse, easily won alluvial gold in proximal and medial reaches of the active placer systems is gone. However, a substantial alluvial gold resource remains in the distal reaches of active systems, and in ancient placers formed onshore and on the continental shelf during previous sedimentary cycles. The resource in these deposits probably exceeds the total New Zealand placer production to date. Successful development of these placers requires application of robust geologic models for the formation and distribution of the placers through time, and advanced exploration technology that has not been used before in New Zealand. Nevertheless, the knowledge and technology required to explore and mine these deposits is available now. Many of these deposits contain a large proportion of problematic gold types that are difficult to recover with the commonly used gravity technology without sustaining significant losses. Despite advances in recovery technology in last few years, too much emphasis is placed on the incorrect assumption that gold size is the primary control on recovery efficiency. Other gold particle parameters, especially particle shape, exert a much greater control on whether gold will be saved or lost to the tails, and must be considered in the design of recovery technology and configuration of recovery circuits.

Jan 1, 2003

Strip mining offers the advantages of high productivity from both human and capital resources as well as high rates of production. Experience suggests that it will be advantageous to extend strip mining to the maximum pos- sible depth in order to minimize costs and maximize the recovery of the in situ coal reserves. Highwall and spoilheap stability pose significant problems. Deep working in strip mines is likely to produce a change from methods which are based upon the elevation of material followed by dumping, to methods involving elevation and horizontal transport. There is considerable scope for optimizing the types of machines and minimizing the amount of double handling.

Jan 1, 1975

By Finlayson J. F

The advantages of rapid and accurate analyses are becoming appreciated in many industries today and have resulted in a great increase in the number of samples received by their laboratories. This has caused some firms to consider the installation of one or more of the instruments available for analytical chemistry. In this country there are relatively few people with experience of instrumental methods and it is difficult for a firm considering the installation of such equipment to assess the advantages which instruments may give them, and to decide which instruments, if any, will be of most use to them. The object of this paper is to give a brief survey of instrumental methods in the field of inorganic analysis. Instrumental methods of analysis have numerous advantages when used correctly. They enable extremely rapid analyses to be made in many cases, e.g., analysis of refined lead by purely chemical means takes about two days whereas spectographically the analysis can be completed in approximately one and a half hours. The accuracy ofinstrumental methods, generally between 1 and 5%, is higher than most chemical methods for small percentages of impurities. Furthermore, if the instrument can be calibrated against absolute standards the errors are usually random and not biased to one side of the correct result. The sensitivity is high, enabling in many cases the detection and determination of smaller percentages than can be detected chemically. This high sensitivity enables and, in some cases, requires the use of very small samples, and results in considerable savings in reagents, allowing the analysis of considerably more samples without undue loss...

Jan 1, 1951

An automatic control system of a longwall roof support is dis-cussed. Hydraulic automatic control systems for longwall roof support have not met all requirements for such systems. Utilization of standard hydraulic elements to form a system that would-comply with all demands leads to a very complicated structure with a large number of hydraulic hoses within and between adjacent supports. So, only simplified systems have been made. This paper describes the multifunctional valve that per-mits realization of any desired logic functions, while maintaining a com-pact form, and analyses its application as a fully hydraulic automatic control system of a roof support.

Jan 1, 1985

By R L. Brathwaite

The gold-scheelite-quartz lodes of the Wakamarina valley were the most productive of the mesothermal gold-bearing areas in the Marlborough Schist. Most of the production came from the Empire City and Golden Bar mines which worked the Golden Bar lode. Only 134 m of its 1800 m strike length are accessible, in the No.2 level of the Golden Bar Mine. A fault has downthrown the Golden Bar Mine section by = 47 m and displaced it left-laterally by 18 m. The lode is a typical ribbon-banded mesothermal vein, averaging c. 1.75 m wide, and enclosing narrow horses of schist country rock. It is composed of bands of milky æbuckÆ quartz with thin laminae of schist. Scheelite occurs in short strings of grains within quartz on the footwall side of the lode and also in small quartz-carbonate veinlets in the foot wall and hanging wall schist. The lode quartz contains only localised traces of pyrite and arsenopyrite. They are more abundant in the wall-rock schist.   The Golden Bar lode lies within a steeply dipping normal fault, which, on its footwall side, is adjacent to a 40 m-wide, shallow-dipping mylonite shear zone. Within 1 m of the lode, the shear foliation has been dragged down to nearly parallel the lode footwall. Wall rock alteration is manifested by a marked increase in K and Rb, which correlate with abundant illite/muscovite and K-feldspar within 2 m of the footwall of the lode. Amphibole, stilpnomelane, and pumpellyite show a progressive decrease towards the lode. As and Sb increase close to the lode, but are at background levels within the lode itself. Enhanced Cr (150-430 ppm) in the quartz, relative to the schists (~40 ppm), suggests that the source hydrothermal fluids passed through and leached mafic rocks, such as the metabasites from the hanging wall of the lode (~400 ppm Cr).

Jan 1, 1995

I The South Platform of the Gippsland Basin is an extensive area of shallow basement covered by a relatively-thin Late Mesozoic-Cainozoic section. Although the sporadic exploration to-date has not resulted in any hydrocarbon discoveries, the area is under-explored and its taste potential has not yet been fully evaluated. The best potential appears to be in areas underlain by the Golden Beach Megasequence where structures are mainly related to basement fault blocks.

Jan 1, 1992

During the past 18 months a rock mechanics project has been in operation at Renison Limited. The project was established to identify and investigate key problem areas that would affect future production at the Renison mine. An in-house approach was adopted, using shall compact equignent, to investigate ground behaviour. Information on the rock stress field was considered to be particularly important for an understanding of ground behaviour. A high horizontal stress component exists, which enables large flat dipping spans of hanging wall to be opened up, with support being provided by post pillars. The amount of support provided by these post pillars has been found to be low.

Jan 1, 1982

By Yusuf R

Many heap and dump leaching processes involve competitive, complementary and sequential reactions between multiple minerals and reagents. A comprehensive model has been developed to deal with these complex chemical interactions which is based on diffusion control of the reaction rates. All of the mineralogical and chemical data are obtained from representative samples of the ore or the chemical literature. These properties have been incorporated in a general way, making the model applicable to a range of ore-process systems. The simulation is used to predict the absolute reaction rates and can be used before any leach tests are carried out on the ore itself. The applicability of the model and some tests of its validity are presented.

Jan 1, 1984

By Ward S. C, Gardner J. H

In 1990, Alcoa of Australia Limited was elected to the Global 500 Roll of Honour of the United Nations Environment Program for the environmental management and rehabilitation of the bauxite mines in Western Australia. This award placed Alcoa in the international best practice category. The story of constant improvement spans more than 20 years from a 'trial and error' start to a strategically focussed and research driven program today. The main driving force has come from within the company, against a set of strong corporate values and a well publicised Vision based on 'excellence through quality'. Along the way public opinion, action group protests, increased legislative controls together with the professional competence of internal and external environmental resources have all played a part in arriving at the level of current environmental management and mine rehabilitation performance. There were numerous lessons learned here during the evolution and maintenance of best practice. These included: I . To work diligently in obtaining a vision or strategic intent on mine site rehabilitation and environmental management - don't be easily dissuaded.

Jan 1, 1995

The geology of an area in north-western New South Wales, bounded by the South Australian and Queensland borders, latitude 32° S. and longitude 14° E. is discussed.The area involved includes sixteen 1:250,000 standard military sheets and covers approximately 96,000 sq. miles.The geology of the Willyama Complex is not dealt with but a small area of metasediments previously included in this unit is separated and a possible correlation with Precambrian to the east is suggested. Torrowangee Group sediments are described and the problem of nomenclature using a glacial implication is raised.Nine areas of proven Lower Palaeozoic sediments are considered and their relationship to the boundaries of the Bancannia Trough outlined. It is possible that some exposures not yet substantiated by fossil evidence may prove to be Lower Palaeozoic rather than Precambrian in age.The sediments of the Lachlan Geosyncline in the area of the Cobar massif are described and new concepts on the age and distribution of some of the established stratigraphic units are introduced. The absence of rocks of Middle Silurian age probably indicates the time of a major orogeny in this area.Lithology, thickness, and distribution of the Upper Devonian sediments is considered and some of the more recently found fish plate localities are listed.Mesozoic sediments occur in isolated areas of Lower Jurassic age and in the Great Australian (Artesian) Basin. A four-fold subdivision of sediments of the basin has been possible in some areas but lack of sub-surface information at present, precludes the possibility of correlation with the type sections in Queensland.Units in the Cainozoic are subdivided and a five fold subdivision of the Quaternary, at present being used throughout western New South Wales, is described.

Jan 1, 1969

By Manlapig EV, Lawson F, Clarkson CJ

A low grade middling sample from Mount Isa, Australia, assaying 31.7 per cent zinc, 12.9 per cent lead and 14.5 per cent iron was leached under atmospheric pressure in sulphate and sulphate-chloride solutions with ferric ions as oxidants. About 96 per cent of the contained zinc was dissolved into a 0.5 M H2SO4 - 0.5 M Fe2(SO4)3 solution at 90¦C within three hours from a five per cent by weight slurry density mixture. The leaching process is very temperature-dependent, suggesting a surface chemical control. In the latter stage, the leaching rates levelled off and the leaching was most probably controlled by both surface chemical reaction and diffusion processes. The addition of chloride ions in the leach solution resulted in an increase in the leaching rate. About 95 per cent of the lead sulphide contained was converted to lead sulphate which precipitated and remained in the residue. Essentially no lead remained in solution and the low chloride concentration did not affect the precipitation of lead sulphate. Half of the iron orginally present remained in the residue as pyrite although essentially all the cadmium and 90 per cent of the copper initially present were dissolved. Some three per cent of sulphide sulphur was oxidised through to sulphate, about 67 per cent was converted to elemental sulphur which can be recovered by solvent extraction, the rest remained in the residue mainly as pyrite. Ferric sulphate and sulphate-chloride solutions can be used to effectively leach finely ground lead-zinc middlings and other bulk sulphide concentrates. A complete separation of zinc from lead and silver has been demonstrated.

Jan 1, 1993

Cordeaux Colliery is more logically sited than the historic escarpment Corrimal Colliery, on the same reserve. At Cordeaux the modernisation of mine plans and equipment and the introduction of high production longwalls have created a record achieving producer of both steelmaking and export coals.Further changes achieved have been in employee related attitudes and performance, enhanced by business strategies and total quality control and particularly benefiting from innovative employee input With this present example of co-operative effort Cordeaux Colliery will continue to improve through management of total quality. resources, development rates and customer satisfaction.

Jan 1, 1991

Structure is the most important control on the location of hematite deposits in the Hamersley Province in the Pilbara region of Western Australia. Unravelling the structural history of mineralised areas, however, is complex because the Province underwent three orogenic events, and three regional extension events followed the main episodes of compression. Steeply E to ENE dipping normal faults immediately predated deposition of the Beasley Quartzite of the lower Wyloo Group after the Ophthalmian Orogeny. Steeply NE and SW-S dipping normal faults predated deposition of the McGrath formation of the middle Wyloo Group, following the Panhandle Orogeny. The resulting interpreted rift was subsequently reactivated and tilted during the Capricorn Orogeny. Late NE trending normal faults are confined to the eastern half of the Province. High-grade hematite deposits occur in rocks that range from intensely folded (Mt Whaleback, Giles Mini) to rocks with less, or only little deformation (Paraburdoo, Channar), suggesting that folding had at best limited influence on ore genesis. In contrast, extensional normal faults are always associated with high-grade hematite deposits, and in particular faults that link the underlying dolomites of the Wittenoom Formation with the overlying iron formation, thus providing a pathway for mineralising alkaline fluids.

Jan 1, 2005

By Laage L. W

line fires pose a serious threat to the safety of all underground personnel. Early knowledge of the location of a fire in a complex underground mine would greatly reduce the associated risks by enabling miners to choose the safest escape routes, rescue teams to concentrate searches where survivors would most likely be found, and fire fighters to select the most efficient route to the fire and the most effective fire fighting strategy. Once'the fire's location is known, other related aspects of the fire can also be inferred, such as intensity, fuel, and growth Rate.

Jan 1, 1988