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By R Kjar

Globally, it is anticipated that the mineral sands industry will enter a period of short supply. Demand for both titanium dioxide and zircon is forecast to continue increasing, with new projects needed to come on-stream to fill the supply gap. Victoria is well placed under this scenario as a source due to the high quality of its mineral assemblage, its excellent resource grade and the globally significant size of its mineral sands resources.Australia’s mineral sands rich Murray Basin remains under-developed, especially at its extensive Victorian margins. Development to date has not progressed adequately for the reasons of technology difficulty, history of competition with other jurisdictions and the absence of a platform that requires development as a consideration for security of tenure. Victoria’s mineral sands potential is not just about the Murray Basin, in addition, there have been discoveries in the Gippsland Basin and prospective sites in the Gippsland Basin remain under-explored. Key problems included the lack of available ground for potential developers and the intellectual property of solutions to technological problems associated with the fine grained mineral deposits belonging to a previous developer (with patents now expired).As such, the timing is right to re-visit the potential of the Murray Basin as a site for long-term development with high returns based on current and predicted prices.In order to understand why Victoria’s earth resources in general, and mineral sands in particular, remain under-explored and undeveloped, the Department of Primary Industries initiated an internal review of its role in encouraging and supporting investment in the earth resources sector.As a result, the Victorian Government has committed to taking action to encourage effective ground turnover and acknowledges that a new focus on engagement with industry is needed to bring new investment to the State. The revision of the Mineral Resources (Sustainable Development) Act 1990 provides an opportunity for the government to better align its legislative processes with industry project lifecycles and facilitate access to valuable resources that currently remain undeveloped.Victoria has a track record in assisting projects reach development stage. Iluka currently has two operations in the State in addition to its mineral separation plant that is capable of processing HMC from its South Australian operations. Iluka is expected to ramp up its Murray Basin Stage 2 operations with the WRP mine scheduled to come on line in early 2012. Meanwhile, Astron is actively seeking partners for its Donald Mineral Sands project. The project is becoming increasingly attractive given the recent price hike in zircon; Astron has access to an estimated five to 6 Mt of zircon in its Donald WIM 250 deposit.Given its substantial and valuable mineral sands endowments, the State of Victoria should sensibly be the centre of future investment in project development. However, as previously mentioned this is currently not the case. The Government is therefore committed to implementing new measures that protect security of tenure but ensure that genuine companies can access endowments where they have a clear intent to work those resources.

Oct 5, 2011

This paper has been developed for æThe Race for SpaceÆ conference. It ranges over various aspects, all of which are within the umbrella of marketing. The question is posed because many engineers, tunnelling and other specialisations, frequently demonstrate an unwillingness to embrace marketing. The accurate reply is probably à ænot an engineer!Æ The paper identifies some of the possible explanations for this reply. The vast majority of the themes, ideas and principles are based on more than 25 years actual experience for the author with Engineers, Tunnelling and other disciplines. This experience has been gained with leading consulting engineering practices; some of the worldÆs largest construction contractors together with other organisations employing engineers in the public, private and tertiary sectors in the UK; US; Europe; the Middle East and throughout Australia and New Zealand. Experience has been gained in design offices; head offices and construction job sites in four contrasting continents. The most significant themes developed throughout this paper are as follows:æLetÆs go and do some ærealÆ work and leave the marketing to others!ÆæMarketing is just a æsoftÆ option and neither technically based nor true management!ÆNIMBY-ism (Not In My Back Yard) so leave well alone!Engineers regularly confuse services marketing -v- product marketing à a useful cop out, or a genuine cry for help?Marketing databasesæLetÆs get rid of the term æsellingÆ and replace it with the more acceptable à and less distracting for tunnelling engineers à 'marketingÆDistinction between benefits and features à in The Race for SpaceSales Comprehension Test, Benchmarking TestJack WelshÆs æmost difficult decision for a CEOÆHarvard Business ReviewÆs (HBRÆs) formula for performanceMany engineers are losing the balance in their lives Sustainable development and engineering æQuality work doesnÆt mean quality serviceÆMajor recommendationsRecommended references

Jan 1, 1999

By M Costa, L Polizzi

Process optimisation and continuous improvement are usually acknowledged when making a process more effective, efficient and transparent. During the last few decades, thousands of companies around the world have used total quality concepts in order to establish a continuous improvement process in their companies. Typically these companies apply some kind of Kaizen-type tools and expect results in the short term; however, the great majority of companies are poorly implementing these continuous improvement programs.Usually the most common reasons for failure of the program are lack of commitment from leaders, lack of discipline and engagement from the team to follow process and lack of clear targets for the program. When the results do not come at the expected timeline, it is common to simply drop the current process and apply a different approach from another company or consulting firm.This paper will explore some successful cases of companies that have invested time and effort to establish a reliable and sustainable process of continuous improvement. The focus will be case studies of mines and smelters around the world that use the plan–do–check–act (PDCA) cycle to increase productivity with the best services and lowest costs. The main tools and processes used by these companies will be discussed, as well as results achieved.CITATION:Costa, M and Polizzi, L, 2014. Introducing and sustaining a continuous improvement program in mines and smelters, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 55–62 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

By A C. Robertson

World urban expansion puts constraints on the available land surface area of our major cities both for accommodating people as well as providing infrastructure and services whilst at the same time attempting to preserve the remaining natural environment. Whilst consideration is often given to underground planning for private and public transport infrastructure, the author is of the opinion that the current lack of underground planning of our cities that are suitable for underground development will have major long implications when finally the need for underground space planning is critical and ultimately recognised. This paper identifies the need for our city planners to integrate surface planning and underground planning as a ‘total planning solution’ where the city plan incorporates the elements of underground space planning as identified in this paper. Investigations by the author reveal that there are very few cities in the world that actually incorporate underground space planning in their city plans. The author uses the City of Brisbane as a case study for the potential introduction of underground space planning as part of the city plan. Despite efforts by the author to include the planning concept of underground commercial development in the latest Brisbane City Plan 2014 as well as four underground space workshops in Brisbane over the past 20 year through the Australasian Tunnelling Society (ATS), underground space planning for the City of Brisbane, apart from infrastructure projects, is not considered of significance to the City of Brisbane.CITATION:Robertson, A C, 2014. Commercial underground space – planned development for the future, in Proceedings 15th Australasian Tunnelling Conference 2014 , pp 513–518 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 17, 2014

By P González, J Videla, E Córdova, I Gottreux

Currently, underground mining of deeper massive deposits with lower grades, harder rock conditions in high strength environments, entails difficulties in caving, fragmentation and seismicity of the orebody.So far, the use of preconditioning (PC) with hydraulic fracturing (HF) has shown positive results in terms of seismic response and caving performance, while PC combined with explosives aims to weaken the rock mass, causing an additional effect on fragmentation.In particular, mines commonly referred to as ‘supercaves’, operated by caving methods, have the need to integrate mine to plant processes, where rock fragmentation appears as a key tool. In fact, it implies making mining and comminution processes more efficient to the plant and for mines, it justifies the search of innovative solutions in drilling and blasting techniques to precondition the rock mass. The following paper aims to show the feasibility of numerical blast modelling to weaken the rock mass using explosives, mainly through sensitivity analysis applied to designs to minimise bias and uncertainty in the results. It is shown how the presence of structures, their geometry and in situ stresses influence or interfere with the PC method being used.From the work, it is concluded that better knowledge on the application of explosives weakening allows specialists to strengthen numerical models associated with every design and therefore previously validate their applicability, helping to understand complex phenomena such as the propagation of mechanical waves in non-elastic heterogeneous media. In this sense, it is understood that while there are studies (Sanchidrián, Segarra and López, 2006) showing that the transfer of energy in the rock mass could be even greater in a confined environment, the more competent rock mass and higher in situ stresses interfere mostly on the effectiveness of a technique using explosives.CITATION:Gottreux, I, Córdova, E, González, P and Videla, J, 2016. Preconditioning modelling and explosives effectiveness in block caving, in Proceedings Seventh International Conference and Exhibition on Mass Mining (MassMin 2016), pp 683–688 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2016

By D M. Frantois-Bongarton

Variograms can be powerful tools for the analysis and control of process streams and their sampling. Their uses and proper utilisation have been described somewhat unclearly to date, and their limitations and precautions of use are too rarely mentioned. The general meaning and properties of the variogram tool and its use in geostatistics are therefore reviewed in details to derive a critical view of its proper use for process control: what to expect from it and what it cannot deliver and which uses are illusory or potentially misleading. A summary of GyÆs seminal work accompanies this essay to put the concepts into historical perspective.CITATION:Frantois-Bongarton, D M, 2012. Review of variogram properties and remarks on its use in process control, in Proceedings Sampling 2012 , pp 175-180 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 21, 2012

By B P. Wrench, M J. Gowan, P J. Chapman

Embankment dams constructed mainly of sand or non-plastic fine soils are susceptible to liquefaction, particularly in high-rainfall, high-seismicity environments where there is sufficient water to saturate the materials and sufficient energy from an earthquake to cause liquefaction. This paper shows the process adopted to review the stability of an existing cross-valley, centreline-raised cyclone tailings sand embankment dam.The study showed that two-dimensional stability analyses did not sufficiently capture the potential for instability, overestimating the depth of the critical failure surface. Instead, three-dimensional modelling was required to provide a reasonable representation. Post-liquefaction stability analyses carried out using the three-dimensional model indicated an adequate factor of safety (FoS). The FoS under seismic conditions was still considered to be a concern based on pseudostatic analyses (but noting the limitations of the analysis method).Earthquake-induced settlements were estimated using an empirical approach based on case history records (Swaisgood, 2003). The post-earthquake event settlement was estimated to be in the order of 600 mm, which is considered to be acceptable for the embankment, taking account of the proposed long-term freeboard of more than 8 m under operating conditions and 2 m under the probable maximum flood condition.CITATION:Chapman, P J, Wrench, B P and Gowan, M J, 2015. Review of static and seismic stability of a cross-valley sand tailings embankment in a high-rainfall, high-seismicity setting, in Proceedings Tailings and Mine Waste Management for the 21st Century , pp 163–172 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 27, 2015

Lihir Gold Mine is situated in a dormant volcanic caldera on a small island off PNG. Not æextinctÆ but dormant. Current ground temperatures are up to 150 degrees Celsius with active geysers in the workings of the mine, pools of boiling ground water adjacent to low-grade dumps and hydrogen sulphide gas emissions. It is a unique mining environment by world standards. This paper will deal with the following issues encountered and managed by the operation:blasting in hot and reactive ground; management of sulphide gas emissions; disposal at sea of all mining waste rock; one dear to all Australian minerÆs hearts û dealing with landowner groups; and unusual human resource issues.

Jan 1, 1999

By J Zhou, X Bi, Y Yan, W Peng, H Yang, D Weng, P Li

Fortescue Metals Group (FMG) fines from Western Australia is a hematite and limonite mix characterised by high crystal water content. Due to its higher supply capacity and lower prices, the Wuhan Iron and Steel Corporation (Group) intended to use more FMG fines in the sinter mix. It is understood that sinter quality is closely related to its microstructure featured by the hardness and brittleness of different mineral phases, the content of micro pores, and trans-cracks. In order to maintain sinter qualities such as tumble index, reducibility and so on at higher FMG fines blend ratios, a research project was initiated to study the effects of the FMG fines blending ratio on sinter microstructure. Research results showed that at higher FMG fines ratios, the hardness of hematite and magnetite were both decreased while the hardness of calcium ferrite showed a tendency to decrease. The number of cracks that were generated during Vickers hardness measurement in various mineral phases decreased, but their length was shortened, and the variation of crack lengths increased. The contents of hematite and magnetite were also reduced and the reduction of magnetite was clearer. Also the content of calcium ferrite and pores rose and the magnitude of the increase of pores was greater. Among all the mineral phases in sinter cakes, the Vickers hardness of hematite was highest within the range of 879 N/mm2 ~ 942 N/mm2, and therefore the decrease of its content in sinter and the enhancement of its brittleness, ie the number of cracks increased, were harmful to sinter strength. In addition, the excessive increase in pores content is also not favourable to sinter strength.CITATION:Bi, X, Yan, Y, Zhou, J, Peng, W, Li, P, Yang, H and Weng, D, 2013. Study of sinter microstructure with various blend ratios of Fortescue Metals Group fines, in Proceedings Iron Ore 2013 , pp 331-336 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 12, 2013

By C Fong

Compliance Planning is an active approach to ensure mining operations align more closely to their longer-term plans. Through Compliance Planning, operations can not only measure their performance on intervals as short as intra-shift, but they can then apply corrective measures to ensure they remain as close as possible to the plans. Compliance Planning targets short-term and execution level teams, as these are the shortest duration planning divisions commonly found in mining operations. Compliance Planning combines live information with intelligent planning capabilities to provide a framework that enables mining operations to realise a significant improvement in reconciliation of plan to actual movements.

Jun 22, 2022

By S Sullivan

A recent review of resource reports lodged to statutory bodies found geological models with oversmoothed or unrealistic lithological boundaries, many of which do not represent geological appearance in the field, pit or underground drive. The underlying data is often too complex or messy to be incorporated into the resource model and is thus a simplification of reality, to the detriment of the mining operation and its shareholders. Volumes can be over- or underestimated and subsequent grade predictions can be misplaced, combining to cause over- or understatement in resource reporting to stakeholders and statutory authorities. Domain models can be improved with new modelling techniques such as machine learning. However, with poor data or improper use of machine learning techniques, the conclusions can be just as misleading as with current techniques. Machine learning rarely offers a single ‘right’ outcome, rather a range of possible outcomes from the data provided. But importantly it can take advantage of the full richness of data for more informed models. Machine learning also provides confidence in its predictions so that uncertainty in the resultant models can be quantified and passed through for risk assessment during mine planning and operation. This paper will discuss the factors accentuating complexity in deposit modelling: data diversity, structural controls, chemistry, data volumes, process workflows and external non-geological constraints. A case study illustrates the risk of reducing or ignoring complexity, which can result in an overly simplified geological model.

Mar 22, 2022

By H Arvidson, V Chamberlain, R Marinho, B Parsons, T Rowl, M Noppé, M Mattera

With the introduction of CRIRSCO (2019) based mineral asset disclosure, Regulation S-K part 1300, 2019 (S-K1300) by the United States (US) Securities and Exchange Commission (SEC), applicable to companies listed on the New York Stock Exchange from 2021, Mineral Resource is now required to be reported Exclusive of Mineral Reserve, referred to here as ‘Exclusive Mineral Resource’ (EMR). EMR is equivalent to reporting Mineral Resource additional to Mineral Reserve, which has been permitted in jurisdictions outside the US for many years. Despite this, there are no practical guidelines in the literature or relevant reporting codes and rules for Competent/Qualified Persons to refer to, which creates a risk that disclosure of EMR estimates across the industry will be inconsistent and potentially ambiguous for analysts, investors, potential investors, and other stakeholders.With the introduction of CRIRSCO (2019) based mineral asset disclosure, Regulation S-K part 1300, 2019 (S-K1300) by the United States (US) Securities and Exchange Commission (SEC), applicable to companies listed on the New York Stock Exchange from 2021, Mineral Resource is now required to be reported Exclusive of Mineral Reserve, referred to here as ‘Exclusive Mineral Resource’ (EMR). EMR is equivalent to reporting Mineral Resource additional to Mineral Reserve, which has been permitted in jurisdictions outside the US for many years. Despite this, there are no practical guidelines in the literature or relevant reporting codes and rules for Competent/Qualified Persons to refer to, which creates a risk that disclosure of EMR estimates across the industry will be inconsistent and potentially ambiguous for analysts, investors, potential investors, and other stakeholders.

May 24, 2023

In this paper, three types of value-adding in the minerals industry are discussed: downstream processing, improving the efficiency of existing processing and increasing the knowledge base and expertise of the staff. It is shown that, while downstream processing seems to offer a good way of improving Australia's trade position, there are a number of impediments to such development, notably, limited access to the appropriate technology and overseas markets. Transport costs can also be a problem. To reverse the situation will require more positive policies by government. In the meantime, something can be done towards adding value by increasing the efficiency of existing processes. Examples are given, showing how it might be possible to make economies in reagent costs in the gold industry, how innovative technology has led to more complete processing of a tailings dump, how research might lead to an increase in the throughput in the production of synthetic rutile and how it is possible to leach selectively from gold/copper ores.

Jan 1, 1995

By I Gipps

A vision of what the future mine involves all aspects of mining, ie orebody access, ore stoping, material transport, processing and waste material disposal. This paper examines one aspect of the future mine: rock extraction, stoping, automated for remote operation, high productivity and low cost. Concepts for the future require a re-think of the mining process and ROES® re-examines how bulk stoping of ore can be undertaken and how this should be redesigned to accommodate the possibilities that exists with remote control and automated operations.ROES® is a new mining system for underground mines and quarries utilising a shaft located close to or within the stope for the ore breakage process. The system is designed to exclude personnel from contact with production drilling, explosive placement and detonation so all of these tasks are remotely controlled or automated. Survey of the shaft, stope back and broken rock within the stope will occur, following each blast, by remote control or automated techniques. The survey will include excavation geometry, rock fragmentation, geotechnical characterisation and estimation of ore grade. Blastholes will be surveyed before placement of explosives and, with the survey data, the optimal explosive placement and blast timing will be determined with the best available information.ROES® is designed for application in open stoping or sublevel caving in disseminated, geologically defined, thick tabular or narrow vein ore bodies. Technologies developed for ROES® will also have potential applications to caving operations, reducing the risk of frozen ore and poor fragmentation. In a typical sublevel open stope application, ROES® will reduce the stope associated development by half and will allow ore to be brought on-stream sooner and at lower cost. Other savings will flow with the centralisation of mining activities and operational data, reduction in mining fleet, reduction in ventilation requirements, improved occupational safety and reduced mine complexity.

Nov 22, 2011

By E M. Wightman, C L. Evans

A recent survey of mineral processors undertaken as part of the International Mineral Processing Council (IMPC) Education Commission identified mineralogy as one of the key skills required for mineral processors (the other key areas being comminution, flotation, physical separation, sampling and extractive metallurgy). Past experience in a number of operations has shown what can be achieved when the data outputs from mineralogical tools are coupled with people with the right skills who can transform the data into actionable information. This paper reviews what has been done successfully in plant operations over a period of more than four decades and gives examples of a range of applications with both long and short-term objectives. The examples demonstrate the usefulness of mineralogical data – both basic and complex – in optimising mineral processing operations, whether the data are applied in a simple analysis or in more complex modelling. Similarly, the examples show the range of options available for operations to access the mineralogy information they need – through in-house experts and equipment based in centralised technology centres, through on-site equipment and experts or through external laboratories and consultants.The examples from industry highlight the huge potential benefit of including mineralogy as an integral part of operational best practice and raise the question of why more operations do not utilise what should be readily available data. Successful application of mineralogical data requires skilled people to generate relevant data of the required quality, together with skilled people to interpret the data (this may be the same person). And, as in any project, corporate recognition of the value of this approach to best practice is required to ensure continuing support. With fewer university courses providing courses in process mineralogy to undergraduate mineral processing engineers and chemical engineers, there is an increasing lack of knowledge about what mineralogical information is needed, how to get the required data and, equally importantly, how to turn the data into useful information.CITATION:Evans, C L and Wightman, E M, 2018. Understanding minerals in mineral processing – the basics and beyond, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 363–376 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

By T N. Little

The author contends that geoscience is presently under-utilised in the rock fragmentation by blasting process. Before we can set standards in this area, the following is required: mine geologists need to gain a better understanding of the blasting process and the blasting team needs to obtain a better appreciation of geology. Both groups need to be informed of what can be done to improve blasting outcomes, why it is necessary and how it can be achieved. By working closely together, both the geoscience toolkits and blasting expertise can be applied and focused on priority blast sensitive issues, with potential to improve mine economics and safety. Finally, and ideally, mine geologists need to take a leadership role in raw rock mass data collection and data management, and invited to take an active role in rock mass related behaviour data collection, integration and presentation.This paper attempts to provide insight into all these prerequisites for setting a new standard for collaboration and mutual learning in this strategic opportunity area. The potential for blasting to leverage downstream processes is highlighted. Blasting objectives and blast design principles are introduced along with the required rock mass related inputs. Some hazardous geological materials and environmental conditions are described, along with how they can affect operational complexity.Four case examples are used to illustrate the need for closer liaison between geology and blasting professionals. The first related to grade control blasting, aims to demonstrate how a blasting geology approach can add significant value. Case example two demonstrates how geological models and bench face analysis can assist with fragment control. The third and fourth case examples involve an overview of two case studies where timely geological and geotechnical knowledge input and intervention into blasting activities may have reduced losses due to blast initiated open pit slope collapses.CITATION:Little, T N, 2017. Geoscience input into blasting operations – let’s set a new standard, in Proceedings Tenth International Mining Geology Conference 2017, pp 375–384 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 20, 2017

By R Moller

Reconciliation at large iron ore operations is a complex and time- consuming process. Often the volume of data and the large range of different stakeholders makes the process almost impossible. Up until recently geologists and engineers at these operations would spend hours cutting and pasting data in and out of monster spreadsheets, diligently comparing how resource/reserve models, grade control and survey pick-ups compare to what was actually produced. In 2003 the Sishen Iron Ore Mine in South Africa broke this cycle by implementing SnowdenÆs Reconcilor software. The implementation of a dedicated reconciliation system required a number of existing practices to be changed, with the involvement of stakeholders right across the mine. Data sources had to be clarified and validated, terminology had to be standardised, processes needed to be documented and some methodologies needed to be updated. This was a task that required significant effort by Kumba personnel so that the system could be successfully implemented. This paper provides a case study of the reconciliation system implementation at Sishen. It is a story of an operation that evolved from using a number of fragmented reconciliation processes to using a unified automated system. This paper outlines the key estimates and measurements that are used for reconciliation, details the characteristics of an automated web-based information management system to facilitate the process and provides some insights about the benefits that have been gained though the use of a rigorous reconciliation process.

Jan 1, 2005

By N Kawashima, R St C Smart, A M. Robertson

This paper focuses on a case study at a base metal mine located in a tropical semi-arid area of Western Australia (WA). It is demonstrated that understanding the geochemical nature of the mine tailings forms an integral part of innovative management strategies developed throughout the life-of-mine (LOM) when planning for mine closure. The tailings are currently stored at an above-ground valley fill tailings storage facility (TSF) and one option for long-term management under consideration is leaving the tailings in situ at mine closure and covering using the concept of an enhanced æstore and releaseÆ cover system.Extensive geochemical and mineralogical studies have found that the geochemical behaviour of the tailings in the TSF is significantly more benign than initially predicted. The sulfide content of the tailings is primarily pyrrhotite, which can be acid-forming, acid-neutral or acid-consuming depending on a number of factors including redox conditions. Tailings pore water at depth is pH neutral with excess alkalinity, low concentrations of dissolved metals and elevated sulfate concentration.Recent geochemical tests on tailings samples indicate that a reduction in the acid potential and a corresponding increase in the neutralising potential of the tailings, through partial removal of pyrrhotite at the ore processing stage, has the potential to further reduce the long-term risk of potential impact to the environment from any TSF seepage. The current work program investigates whether partial removal of pyrrhotite is feasible and secondly, whether this approach is necessary to produce a significantly better outcome at mine closure.CITATION:Robertson, A M, Kawashima, N, Smart, R St C and Schumann, R, 2012. Understanding tailings geochemistry - Continuous learning and innovation when planning for mine closure, in Proceedings Life-of-Mine 2012 , pp 287-292 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 10, 2012

The Chamber of Minerals and Energy of Western Australia Inc (CME) is the peak resources sector representative body in Western Australia. The paper gives a summary of the role and objectives of the CME, including its history, structure and key program areas. Particular attention is given to the role of the CME in the Eastern Goldfields of Western Australia. The paper details the types of CME membership that are currently in existence. The paper argues that a strong and vibrant CME is vital to secure the resources sectorÆs growth and development in future years.

Jan 1, 2006

By R Tooher, S J. Oliver

The operation of copper flotation circuit is a challenging task for the site metallurgists and plant operators. To optimise the performance requires meeting both grade and recovery objectives. These plants have numerous pieces of equipment that are monitored by hundreds of sensors. The challenge is to review these sensors and adjust the numerous control inputs to maintain peak operational efficiency for extended periods. There is also a need to respond to equipment failure. These challenges lead to in operational inefficiencies and can result in a reduction in revenue.This paper details an overview of an operational assistance tool implemented at Newcrest's Telfer plant’s copper flotation circuit. This tool is based on a digital twin of the plant. A digital twin is a model of the plant that is simulated in parallel to the normal plant operation. It is fed with the plant data in real time to provide a prediction of plant operation. The model outputs directly generate the metrics that are used to assess the plant performance, and these are compared with the metrics calculated from the actual plant’s operation. Deviations between the model estimate and the plant’s actual performance are used to gather insight into plant health and alert the operator to poor performance. The operators gather more information regarding the root cause by reviewing the model’s inputs that have deviated outside their normal operating range. An evaluation of the plant performance, following the commissioning of the digital twin, showed an overall reduction of acid soluble copper in the tails.This paper discusses the implementation of a digital twin of the plant to monitor plant performance during live operation. It will include details on data collection and cleansing, data reduction techniques, model development, and real-time implementation. The results of the case study of an implementation of a digital twin at Newcrest's Telfer copper flotation plant will be used throughout the paper.CITATION:Oliver, S J and Tooher, R, 2018. Optimising flotation plant operation by using a digital twin in the control room, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 93–100 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018