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The Mount Whaleback iron ore deposit at Newman, Western Australia comprises the largest known continuous iron ore deposit in Australia, originally with a Measured Resource in excess of 1700 Mt of hematite ore. The deposit occurs within the Hamersley Province which forms part of the Pilbara Block in the NW of Western Australia (Figure 1). The Mount Whaleback iron ore deposit, together with a number of discrete iron ore bearing satellite orebodies in the Newman district, contributes to the Newman Lump and Fines products. Extensive quality control systems are utilised from mining to shipping to ensure that each product meets a narrow geochemical target grade range.

Jan 1, 1997

By A Vakili

Dilution is associated with considerable direct and indirect costs in underground open stoping operations. As shown in previous works, an improved ability to predict dilution enables the economic risks associated with unplanned dilution to be reduced. Depending on the width of the orebody and depth of mining, the economic performance of an open stoping operation can become even more sensitive to dilution. It is shown in several well-documented studies that as little as 1 per cent of additional dilution can impose millions of dollars of lost profits per annum. Optimisation of a stoping operation is therefore largely dependent on the ability of the operation to minimise dilution. This can only be achieved through sensible analysis of past and future performance of mined stopes using the most appropriate recent available technologies and tools. This article presents a new design process that utilises advanced geotechnical numerical modelling and various other analytical tools to assist with a more robust mine design of open stoping operations. The focus of this design process is on geotechnical factors affecting dilution during the life-of-mine. A recent application of this optimisation method for a mining operation is presented in this paper as a case study. Through the application of this method and various other operational improvements, the mine was able to deliver more consistent production and lower operating costs over its life-ofmine outlook and was able to reduce dilution by up to 50 per cent and achieve sustainable record high production rates.

Mar 29, 2023

The Australasian Institute of Mining and Metallurgy (AusIMM) is a professional society for all those associated with the activities of the mineral industry. Differences of opinion exist within the membership of the AusIMM on the role it should play in the future as a professional society in a changing industry and world environment. This same dilemma is concerning other professional societies of which the author is a member. Some of the activities and priorities of the AusIMM are reviewed in order to clarify a frequently expressed opinion that it identifies with and supports industry at the expense of representing the interests of its individual members. By definition and by action this is certainly not the case and it is concluded that all activities whether seen to be industry or member orientated serve to benefit both. The AusIMM plays a most important role in integrating and promoting the interests of all sections of the mineral industry whether corporate or individual and the Presidential activities in education this year provide an excellent example of this.

Jan 1, 1997

By C te Kloot, Z Liu

Blast performance and the resulting drawpoint condition and volume of oversize has the potential to impact operator safety and mine productivity. Underground measurements showed that approximately 14 per cent of production rings in the Ernest Henry Mine (EHM) sublevel caving (SLC) operation had either overbreak in the brow or left collars. There were also oversize rocks reporting to approximately 30 per cent of drawpoints, which accounted for over 7 per cent of total production and significantly impacted production rates. A series of trials were conducted in 2015–2016 at EHM to test changes to certain charge parameters in an attempt to optimise blasting results and, in particular, reduce oversize and overbreak. The detailed analysis conducted included field observations, hole surveying, blast monitor analysis and blast modelling. There were a total of nine charge parameters tested in the project, which fell into two major categories: energy distribution and inter-hole delay. These were based on observations made in establishing baseline data and those parameters most likely to have a significant impact on overbreak and oversize.Key results from the project included oversize reduction and improved brow conditions when energy distribution was reduced through changing charge lengths in certain holes in the standard charge plan. Similar benefits were also seen when the inter-hole delay between blastholes was reduced from 50 ms to 25 ms. Based on these results both changes were made to the standard production ring charge plan at EHM.Moving forward, the aim is to continue monitoring the results from the changes made on all levels to ensure efficiencies are being realised and sustained. A 3 per cent improvement in oversize as a percentage of total tonnes and improved brow conditions not only has a positive impact on production rates, but removes people from any potentially hazardous situations and contributes to a safer working environment.CITATION:te Kloot, C and Liu, Z, 2017. The evolution of production blasts at Ernest Henry Mine, in Proceedings 13th AusIMM Underground Operators’ Conference 2017, pp 33–38 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Oct 16, 2017

By A D. Strand

The Coeur dÆAlene mining district in northern Idaho, USA is the second largest producer of silver in the world. The Proterozoic Revett Formation hosts most of the mesothermal Ag-Pb-Zn vein ore in the district; it consists of informally designated lower, middle, and upper members. All three members show up to an order of magnitude of southward thickening across the regionally significant Osburn fault. Changes in thickness of the Revett Formation across the Osburn fault reflect a major, down-to-the-south, crustal-scale fault that:was active during sedimentation, was periodically reactivated during the structural and metallogenic history of the district, and likely provided first-order control over regional fluid flow during mineralization events. Where vein structures intersect favourable strata, they produce rich ore; where vein structures cross unfavourable strata, they are poorly mineralised or barren. The most favourable host rock in the district is quartzite, which accounts for the large production from the quartzite-rich Revett Formation.The district has five main types of hydrothermal alteration:feldspar destruction, hydrothermal bleaching, carbonatisation, sulfidation, and silicification. Feldspar destruction is the most extensive and pervasive type of alteration, involving the district-wide absence of feldspar from Belt Supergroup rocks. Hydrothermal bleaching results from the destruction of hematite; it forms alteration envelopes that extend for tens to hundreds of metres into the wall rocks around many of the mineralised veins. Siderite alteration is most diagnostic of mineralisation, forming alteration envelopes that extend for tens to hundreds of metres into the wall rocks around all mineralised veins. Fine-grained arsenopyrite and/or fine-grained pyrite commonly form alteration zones adjacent to high-grade ore shoots that extend for metres to tens of metres into the wall rocks. Widespread silicification is most easily recognised by the presence of numerous quartz veins.

Jan 1, 2002

By H Kurth

High specification Prompt Gamma Neutron Activation Analysis (PGNAA) has been successfully applied to conveyed flows at iron ore operations since 2002 to representatively measure ore quality for improved quality management and process control. While the PGNAA technique has changed little since that time, significant improvements have been made in measurement capability. Elements previously unable to be measured well or at all using this technique are now measurable and one of these is phosphorus. Aluminium and magnesium are also key elements in addition to calcium and silicon in determining sinter basicity in ironmaking. Other elements measured routinely in iron ores include iron, carbon, potassium, sulfur and manganese. The benefits of representative measurement cannot be overstated as iron ore mining operations in South Africa, Europe, Australia, Asia and the Americas have discovered. The technology is applicable to any conveyed flow where elemental analysis in real time assists with quality management, from raw materials in ironmaking through to scrap steel in steelmaking and coal quality for coke-making. Major benefits are realised when raw material processing is optimised and this often includes diversion of material meeting a required quality so it can bypass unnecessary processing. This includes waste rock which can be diverted from a plant feed stream in 30 sec increments or ore that meets product quality being diverted to bypass beneficiation. Analysers are successfully utilised to identify ore types that assist with upgrade optimisation in jig plants; measuring feed, product and discard flows to also account for metal content. Product flows to stockpiles help manage production flows and stockpile qualities for different products and assist in blending ores into trains or ships to confirm specification compliance. Technologies can be used in magnetite processing but are predominantly used in hematite and goethite ore processing operations. The paper details examples of the above applications at various operational sites providing estimates of economic benefit as well as operational improvements.

Sep 18, 2023

By J J. Cilliers, K Hadler

Air is fundamental to flotation; not only is it required to collect the valuable particles, but it also controls the froth stability and consequently the separation performance for a given feed. Froth stability can be described and quantified in numerous ways, which are subtly different. Air recovery is one such measure of froth stability which accounts for both the stability of the bubbles and the mobility of the froth. The benefit of using air recovery as a measure of froth stability is that it exhibits a peak as air flow rate is increased, and this corresponds to the air rate at which the optimal separation performance is obtained. As such, it provides a single target value for optimising air flowrate for a given set of feed conditions. Use of air recovery, however, has one potential drawback: accurate measurement of the inlet air flow rate to a flotation cell is required. This can be problematic for operations, particularly where calibration of air flow rate is carried out infrequently or where there is no air flow rate measurement, such as for many self-aerated flotation cells. To this end, we present an alternative method for determining the peak in air recovery (PAR) air rate.We introduce a simplified method for determining the PAR air rate using trends in froth velocity and overflowing froth height, both of which are readily measured using existing froth image analysis systems. We will show, using industrial data, the application of this simple technique to find the optimal air flowrate for flotation cells. We will also discuss other alternative techniques for air rate optimisation that have the potential to improve separation performance using existing technology.CITATION:Hadler, K and Cilliers, J J, 2018. How to find the optimum air rate for flotation cells, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 377–384 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

By Parker A. J, Ruane M, Wadley L. G B

Copper, sulphur, nickel, cobalt, palladium, silver, and gold can be recovered from the copper sulphide precipitated from the "copper boil" of the Sherritt-Gordon nickel process used at Western Mining Corporation's Kwinana nickel <refinery. The method is based on an oxidative ammonia leach of copper, nickel, and the precious metals at temperatures below 40°C to produce, in part, elemental sulphur, in the residue. This is followed by heating to decompose thiosulphate and remove some ammonia with precipitation of some of the copper, palladium, gold, and silver. Addition of sulphur dioxide to pregnant liquor precipitates copper, as either Chevreul's salt or copper(I) ammonium sulphite, together with the remaining gold and silver. Less than 10 per cent of the dissolved palladium and less than 1 per cent of nickel and cobalt precipitate to this stage.In one option, the Chevreul's salt is dissolved in a solution of copper(II) sulphate, acetonitrile, and water to generate a solution of copper(I) sulphate. Gold and silver do not dissolve. The solution of copper(I) sulphate is thermally disproportionated by distilling acetonitrile to give exceptionally pure copper powder, with desirable characteristics for powder metallUrgy. Nickel, cobalt, and ammonium sulphate are recovered from the motherliquor of the Chevreul's salt precipitation by return to the Sherritt-Gordon process, where recovery procedures already exist. Palladium is recycled for eventual removal as a sulphide with the gold and silver.In the other option, solid copper(I) ammonium-sulphite is <thermally disproportionated in water at 150°C to copper powder.

Jan 1, 1978

By M Scoble, W S. Dunbar

This paper reviews methods for grade estimation in short-term mine planning for block caving. Two particular tools are used: Ordinary Kriging and Simple Kriging with moving averages. It is also considered the influence of draw characteristics on the grade estimation process. Reference is made to mine case study data and analysis. These demonstrate that operational grade estimation is not a trivial process. It must take into consideration: the grade variability (in terms of ore and dilution), sampling interval, geological and geotechnical characteristics, geometrical layout and draw characteristics. Significant improvements appear possible in short-term planning if variogram analysis, as well as kriging methodologies, are introduced into the operational grade estimation process.

Jan 1, 2000

Jan 1, 2004

By J Tien, J Huang, N Haque, M O’Brien

Coal preparation is an integral part of producing coal for thermal powerplants and metallurgical processing plants. Coal processing plants use various unit processes to separate gangue and ash content from mineral coal, thus increasing the specific energy content.A flow sheet and a simulation model was established for a typical coal processing plant using Microsoft Excel. This model used the mass balance and split factors for run-of-mine (ROM) coal, tailings and water usage from a typical, generic coalmine.The common method of coal preparation initially involves several stages of crushing to reduce the size of coal. It is then sent to the processing plant for further washing. The typical method in Australia for coarse coal material processing is the use of dense medium cyclone (DMC) (Kininmonth and Baafi, 2009). Flotation cells are used for processing of fine coal. The fine products are utilised for coking coal only. In our case study, the intended coal product is for thermal powerplants. Therefore, the fine coal processing utilised spirals instead of flotation, which is typical for the industry.CITATION:Huang, J, Haque, N, O'Brien, M, O'Brien G and Tien, J, 2016. Development, simulation, economic and environmental evaluation of a coal processing flow sheet, in Proceedings Life-of-Mine 2016 Conference , pp 48–51 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jun 28, 2016

By C N. Hatton, K Ward

Tailings operations are inherently reactive as operations personnel continuously contend with a concentrator reject feed (tailings) transient in physical and engineering properties, which places a constant constraint on capital and operational spending. It requires a unique skill set to manage the prescribed distribution of tailings under unenviable conditions. Enter the tailings operator, an oftenundervalued commodity and untapped resource that can provide benefits beyond the rigors of dayto- day operational support. Experience consistently demonstrates that skilled and committed operators can serve a vital function in the safe construction of a tailings storage facility. It takes a village to raise a tailings dam. An important part of this process is establishing a culture of operational accountability and ownership. Operator development training is nothing new. However, we find that many of the intrinsic operator skills are left unexploited, and an operator's experiential knowledge base and creativity are commonly overlooked and underutilized. With proper training and guidance, these skills can be harnessed, contributing to safe dam operations. Operator engagement, when properly facilitated, provides tangible benefits ranging from improved tailings engineering properties to reduced closure costs. One important benefit is helping transitioning tailings management from reactive to proactive. There are many processes involved in the reactive to proactive transition process. One element of that process includes engaging operators in the tailings management process and facilitating legacy ownership. The core of operational legacy ownership is measured and described using five-stage operator engagement rubrics. Levels of operator engagement are presented with a description of the incremental benefits of each stage. An important part of legacy engagement is providing the tools to operators necessary for managing the tailings. Therefore, the approach identifies specific methods used by operations personnel to control tailings distribution and in-place properties. The end goal of leveraging operator engagement is to facilitate committed ownership and transition tailings management from an inefficient, reactive process to an improved, cost-effective, proactive practice.

Jul 1, 2021

The methods used by the Anglo American Corporation for analysis of long-term metal markets and prices are described. The principal factors affecting the relationships between production costs and metal prices are analysed. These are firstly the type of market, - speculative or consumer commodity, free market or subject to price control; and secondly the rate of growth of demand for the metal. It is shown that virtually all metals will have relatively low rates of demand growth for the foreseeable future, due to market saturation, increased economisation, substitution and product obsolescence. Metal prices have a clear dependance on production costs, however forecasting future costs is by no means simple; amongst other things, account must be taken of changing exchange rates, inflation rates, and the potential for operating more efficiently. The paper concludes by giving brief assessments of the long-term future for aluminium, copper, zinc, nickel and tin.

Jan 1, 1986

By O Jones

Longstanding occupational health challenges of the underground hard-rock mining sector require both an analysis of historical data to assess evidence of linkages between the source of the problem and subsequent illnesses, as well as investigating the means by which health risks to workers can be eliminated or minimised. This paper refers briefly to a recently established National Health and Medical Research Council (NHMRC) sponsored Epidemiological Study into the incidence of Lung Cancer, contracted by mineworkers in Western Australia (WA) due to the inhalation of diesel exhaust fumes from 1996 to 2012. Thereafter it reviews current knowledge of the nature of the challenges facing those responsible for the health and wellbeing of underground hard-rock miners in WA, commencing with the recent categorisation of diesel exhaust as ‘Carcinogenic to Humans, Group 1’, by the World Health Organisation’s (WHO) International Agency for Research on Cancer (IARC). An attempt is also made to explore how the challenge has changed with the adoption of more advanced engine technologies, including the increased generation of ultra-fine volatile organic and other nucleates, submicron carbonaceous agglomerates and toxic gases.The compounding effect of using the mine decline access entry as both the primary ventilation intake and haulage-way is also discussed, as is the need to develop a more appropriate metric for regulating diesel engine emissions. Finally the paper refers to ongoing in-mine research pursued by the National Institute for Occupational Safety and Health (NIOSH) at its Diesel Laboratory in an underground limestone mine near Morgantown in the USA.CITATION:Jones, O, 2015. Diesel exhaust and the underground miner in Western Australia, in Proceedings The Australian Mine Ventilation Conference, pp 167–172 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 31, 2015

By J P. Barkas

World demand for iron ore is far from peaking, and the substantial price decline that has captivated commentators since early 2014 is not the result of widespread misreading by producers of the prospects for global market growth. Recent price movements provide little useful insight into the industry’s longer-term fortunes, apart from reminding mining companies that their businesses need to be robust against the volatility and inescapable cyclicality of mineral commodity markets. It is timely to take a strategic view of the history and longer-term prospects for the iron ore industry and of Australia’s place in it.CITATION:Barkas, J P, 2015. Perspectives on the long-term outlook for iron ore, in Proceedings Iron Ore 2015, pp 3–6 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

By A Mehrani, F Zamani, A Dehghani

Vibrating screens play an important role in the dry classification circuit of Gol-e-Gohar iron ore processing plant. This circuit was designed to classify the autogenous mill discharge and produce a suitable feed, with K80 about 450 ¦m, for dry magnetic separators. Three parallel vibrating screens produce more than 50 per cent of the separatorÆs feed. The efficiency of the magnetic separator is greatly affected by feed size distribution. In this work, the JKSimMet 5.1 software was used as an analysing tool to assess the flow rates and USIM PAC3 software as the simulation tool to control and optimise the vibrating screens. Samples were collected and the circuit was mass balanced. Then the vibrating screen was simulated and adjustment parameters such as cut-point, bypass and imperfection factor were determined. The product streams of vibrating screens can also be predicted.

Jan 1, 2007

By R Lastra, Y Choi, C Hamilton, P Kondos

Hydroseparation (http://www.cnt-mc.com) was used to concentrate sized fractions (from <38 ¦m to 150 ¦m) of various ore products ahead of carbon-in-pulp (CIP)-treatment. The resulting size-by-size concentrates were mounted as monolayer polished sections and subjected to automated unattended precious metal searches by image analysis (see Lastra, Wilson and Cabri, 1999). Systematic variations in Au-deportment permit quantification of Au reporting as discrete grains from fresh-feed through to pressure oxidation (POX)- and CIP-feed. Application of hydroseparation, image analysis and assays to characterising tailings (from <10 ¦m to 106 ¦m) from four mine sites is also described. Results are encouraging enough to predict that the combination of hydroseparation (HS) and automated image analysis could become a standard methodology for study of precious metal ores and metallurgical products.

Jan 1, 2008

By Wright JK, Turner RE, Batterham RJ, Morrison AL

Simulation can play an important role in the design, optimization and control of complete industrial processes, the most appropriate method depending on the particular application. Most commonly, process models or simulators are means of representing the process which are either purely mathematical or physical. Mathematical models, however, almost invariably need to be based to some extent on experimental data or require experimental verification before they can be used with confidence. Ways in which experimental and mathematical modelling techniques can be combined to best effect are discussed, with reference to the simulation of iron ore induration and direct reduction processes. A novel method is presented for the simulation of direct reduction shaft furnaces. Small scale apparatus has been developed in which ore or pellet samples are subjected to the changing environment of the industrial process. The time dependent conditions (solid temperature and gas compositions) are provided by a mathematical representation of heat transfer and the conservation of mass and energy in the process Simulated.

Jan 1, 1986

By Penrose E. K

With the exception of occasional periods, when up to 80% of oxidized ore was treated, the G.M.K. plant treated all sulphide ore until October, 1939. The treatment was, briefly, as follows:The ore was ground to approximately 17% plus 200 mesh Tyler and agitated in cyanide solution, after straking. After agitation, the pulp passed through two stages of counter-current decantation washing in Dorr thickeners and was filtered once, to complete the precyanidation stage.The precyanide filter cake was repulped with flotation circuit solution and floated in a Denver Sub A flotation machine, consisting of twelve cells. The concentrates were roasted, cyanided and filtered four times before disposal to the' dam. The flotation tailings were thickened to conserve water and pumped away to a separate dam.The average results of flotation operations for the six months before October, 1939, are shown in Table 1.

Jan 1, 1942

By A Hutton, C Dick, D Fletcher

Mine and facility closure planning is a dynamic and rapidly evolving landscape. In this landscape, mining companies and industry consultants are generally good at estimating the associated earthworks and rehabilitation costs, because it is æcore businessÆ. Through our extensive work in mine closure, we have found that the safe and cost-effective demolition of mining related infrastructure is often grossly underestimated. Or alternately, it is simply assumed that the returns on scrap steel and the sale of re-usable plant will cover the related costs. With fluctuating steel prices and no guaranteed buyer for the assets, the estimated monetary return is often unreliable and in many cases unrealistic. On this basis this logic is fundamentally flawed. We have found that on most occasions this has meant that closure cost estimates fall well short of what the actual costs are to close the mine.GSSE and Liberty Industrial have worked on over 60 mine closure projects in Australia and overseas of varying scales and across a range of commodity types. An evaluation of these projects has shown that costs associated with the safe demolition and removal of a mining related infrastructure is in the order of 20 - 30 per cent of the total cost at closure. We believe it is one of the top three risk areas associated with mine closure planning and cost estimation, alongside bulk earthworks and the capping of tailings and waste rock storage facilities.Our paper uses examples from recent projects to demonstrate all aspects outlined above. We have also endeavoured to address the following key points related to the demolition and removal of mining related infrastructure:If companies fail to plan appropriately, complicating factors such as contamination, hazardous materials, mobilisation/demobilisation, geographical location, decommissioning standards, site constraints and weather, can add considerable costs to the project and result in variations for the demolition contractor.Closure planning often assumes infrastructure that is no longer required can be utilised by a third party and/or the new land holder. We intend to show that unless adequate consultation and planning is undertaken, this is not beneficial to the mining company, the environment, or the local community.CITATION:Fletcher, D, Hutton, A and Dick, C, 2012. The æsmoking gunÆ of detailed mine closure cost over-run - A review using case studies of the real costs associated with the demolition and removal of infrastructure in mine closure, in Proceedings Life-of-Mine 2012 , pp 325-332 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 10, 2012