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By S Harris, A Bossilkov

The Kwinana (Western Australia) and Gladstone (Queensland) industrial areas are among the few dozens of heavy industrial areas globally that demonstrate significant levels of regional resource synergies. Such synergies are also referred to as æindustrial ecologyÆ or æindustrial symbiosisÆ. Fundamentally they involve the exchange of by-products or sharing of utilities between companies in close geographic proximity to achieve competitive advantage and environmental benefit. A concerted research effort is currently underway to foster greater realisation of regional resource synergies in minerals processing intensive regions, in Australia and internationally. This paper summarises current insights from the foundation research into engineering tools and technologies and enabling mechanisms for regional resource synergy developments. Regional resource synergy developments were reviewed for 16 international and two Australian regions. It was found that Kwinana and Gladstone compare favourably with the well-regarded international examples of regional synergy development. Given the fairly strong evidence that self-organisation is critical for regional synergy developments, an implementation model has been proposed that captures entry points for synergy developments at the level of platform (industry collaboration), process (developing synergy opportunities) and project (assessing and implementing specific synergies). It was also found that regional synergies have so far developed in the absence of specific methods for identification and screening of synergy opportunities. Moreover, very limited attention has been paid to the associated technological and engineering challenges. The current technical research effort therefore targets: the development of a toolset for the identification and development of potential synergy opportunities; and assessment of technology needs and opportunities for regional synergies involving water, energy and materials recovery and reuse.

Jan 1, 2006

By John H. White

As production of ground limestone increased our Company found it had an enviromental problem with limestone dust from our hammer mills. With the quarry and processing plant situated within 1 klm of a small township of 5000 people dust collection became essential. Regulations under the Clean Air Act 1972 also had to be complied with. Prior to this any demand for lime flour had been met by the use of a small drier and ball mill. Both expensive to operate. Dust emitting from the mills would amount to over 4000 tonnes per year. The cost savings were obvious. We had a better product which was essentially a by-product. Faced with a surplus of a very useful, but difficult product to handle we considered the possibility of disposing of it on the agricultural market.

Jan 1, 1982

By Robert D. McKellar, Luke Frawley, Richard Okrasa

"The resource industries in Canada are facing increasing global competition and stringent environmental regulations. This has made it essential for companies to lower operating costs wherever possible. Electrical energy rep-resents one variable cost that may be better managed and utilized, providing the user with lower operating costs, improved productivity and better yields.The utility industry is also facing changes in the way it must do business. Utilities in North America are facing the prospect of deregulation that will eliminate the monopoly they have traditionally held. This will force them to strive for lower operating costs, to maintain a competitive position and to improve customer ser-vice so as to maintain their customer base.Ontario Hydro has been working with industry for several years. Many opportunities for cost savings have been identified involving energy efficiency, process improvements and the use of new electro technologies. One useful service that the utility can offer industry is to increase the awareness of potential opportunities suited to their operations. This paper will provide an overview of some of the projects that have been implemented and those that are presently being evaluated. An electronic data-base of electro technology applications that is under development will also be described."

Jan 1, 1996

By Robert D. McKellar, Luke Frawley, Okrasa. Richard

"The resource industries in Canada are facing increasing global competition and stringent environmental regulations. This has made it essential for companies to lower operating costs wherever possible. Electrical energy rep-resents one variable cost that may be better managed and utilized, providing the user with lower operating costs, improved productivity and better yields.The utility industry is also facing changes in the way it must do business. Utilities in North America are facing the prospect of deregulation that will eliminate the monopoly they have traditionally held. This will force them to strive for lower operating costs, to maintain a competitive position and to improve customer ser-vice so as to maintain their customer base.Ontario Hydro has been working with industry for several years. Many opportunities for cost savings have been identified involving energy efficiency, process improvements and the use of new electro technologies. One useful service that the utility can offer industry is to increase the awareness of potential opportunities suited to their operations. This paper will provide an overview of some of the projects that have been implemented and those that are presently being evaluated. An electronic data-base of electro technology applications that is under development will also be described."

Jan 1, 1996

By Nathan C. Rockwood

WHILE mining engineers have been searching in far corners of the country and of the world for hidden wealth there has grown up around us in nearly every city great wealth-producing mines calling for the investment of hundreds of millions of dollars and yielding products now sold for over half a billion dollars yearly-largely unknown and almost wholly neglected by mining engineers. But this neglect is explainable and excusable. They are industries of very recent origin-practically the growth of the last 25 years. They are in a very large measure the result of tremendous developments in engineering construction and the rapidly expanding use of portland cement concrete for structures of every description. Concrete as a material of construction is going through an evolution very much as did cast iron and other metals used in engineering; and this phase of the industry should appeal to the imagination of metallurgical engineers. At first iron was iron-a material of uncertain properties, owing both to small differences in chemical composition and in methods of manufacture. By successive steps iron was studied and knowledge of its properties developed-the striking effects of very small percentages of other minerals and of various heat-treatments.

Jan 1, 1924

By Thomas T. Read

AT this time of the year, engineering schools are releasing a group of young men who probably are, on the average, in much the same attitude of mind as a person arriving at the terminal station of a railway journey; namely, of having a general idea of his objective, but having to make a decision as to just where he is going and how best to get there. The man leaving the train can at first follow the crowd, but it soon breaks up, as one goes one way and one another, until he has to choose his own course. The recent graduate may do the equivalent of following the crowd by accepting the first position offered, but this only postpones a decision as to where he is going and how best to get there. So many young engineers ask for advice as to what to do that the following statement has been prepared as an attempt to make a general answer to such queries. The engineer taking his first job should realize two fundamental relations. The first is that in electing to be an engineer he has elected to be a hired man. A consulting engineer has more freedom than a man on a regular pay roll, but he is also a hired man; hired for briefer periods at a relatively high rate, but under the necessity of simultaneously doing his consulting work and developing new retainers. There is nothing derogatory in being a hired man (all doctors, lawyers and clergymen are hired men), but the tardy realization that he is one seems to give many an engineer a mental jolt that can be avoided if he accepts it from the beginning.

Jan 1, 1926

By M. Getz, G. Asbjörnsson, M. Evertsson, E. Clausen

The mining and minerals processing industry is gradually being digitalised to improve efficiency and reduce waste. One aspect of this transition is to ensure that relevant process-data in sufficient quality and quantity is given to the operator in the right format and at the right time to improve decision-making. Augmented reality (AR) can serve as a potential ICT-based support tool for human operators to achieve this goal. With AR, virtual information is combined with the real world in real-time. Therefore, AR technology has the potential to fulfil the need for improved data visualisation in Industry 4.0. This article is the result of a collaborative effort of Chalmers University of Technology and RWTH Aachen University to identify selected state-of-the-art applications of AR that are currently being applied in the mining and minerals industry or selected related industries. This paper aims to show opportunities for the application of AR in the mining and mineral processing industry with selected conceptual applications. This paper concludes with several requirements identified as necessary to implement the conceptual applications of AR in the mining and minerals industry. Keywords: Augmented reality, mining, mineral processing

Jan 1, 2020

Thank you for this opportunity to address your conference on 'The role of coal in the New Zealand energy market'. New Zealand's energy market has, in common with much of New Zealand, undergone major change following the market reforms of the Labour Government. As far as the energy sector is concerned this change has been for the better, as it has created for the first time in a very long time a 'true economic market' for energy in New Zealand. This is in marked contrast to the previous regime where: ò Electricity was state operated, subsidised and cross subsidised. ò Oil was imported and subject to a raft of taxes and duties. ò Coal produced by state mines was priced by cabinet committee, based on other energy prices rather than on the costs of production and delivery of the energy product. Today, with the establishment of the SOE's we have a market of competitive supply, where the customer has the choice of energy with prices based on the true costs of production and delivery. This can only be good for the customer as the cost is now based on the real costs of production, not on political whim. So where does coal fit in this brave new world of free market energy supplies? Well, opportunity, they say, knocks but once.

Jan 1, 1990

By Syamujulu. M

Subsequent to the unbundling of the Zambia Consolidated Copper Mines (ZCCM) and the privatization of its constituent parts, the Konkola Copper Mines (KCM) represents a third of the original conglomerate. Now run by private hands as a sub group of Vedanta Resources Plc of India, KCM is strategizing on how best to deal with the operational issues of the organisation to resolve some of the difficult, logistical, environmental, mineralogical and metallurgical problems being encountered to tum them into opportunities as the company turns around. This paper reviews the options being put in place to provide appropriate solutions and strategies including the treatment of the highly siliceous low energy copper belt concentrates in its mining operations in Zambia.

Jan 1, 2007

By Gabriele Eccher, Michele Caponero, Paolo Cucino, Roberto D’Angelis

"This paper describes the optic fiber structural monitoring system implemented for Pavoncelli Bis tunnel. The paper highlights the optic fiber sensors customization capabilities, how they smoothly fit precast concrete lining processes and TBM operations, and how a lifelong service monitoring can be achieved. An overview of readings’ evolution during excavation concludes the paper.INTRODUCTIONPavoncelli Bis is a 10 km hydraulic tunnel designed to by-pass the existing Pavoncelli tunnel which experienced severe damages during the 1980 Irpino-Lucano earthquake, in south of Italy (Barla 2009). Pavoncelli Bis excavation work commenced in 1988-90, however, when excavation approached pk. 0+583 in 1992, water percolations became more and more consistent and resulted in work suspension. The tunnel was eventually sealed at pk. 0+383, leaving a flooded section between pk. 0.383 and pk. 0+583. Work resumed in 2012 where EPB-TBM excavation was adopted to cross the flooded section and to overcome complex hydro-geological conditions in various lito-types and, in particular, in the Varicolori Clay-shales area (Figure 1).Consequently, stress evolution monitoring is extremely important during construction and during the service life of tunnel lining in clay-shales and in faults areas. In particular, the paper focuses on the monitoring system proposed for the newly EPB-TBM excavated portion from pk 0+583 onwards where optic fiber sensing technology was chosen for its reading stability and reliability in presence of water and its ability to be connected in series and remotely interrogated at kilometers of distance. FBGS OPTICAL FIBER SENSOR TECHNOLOGYFiber Bragg Grating Sensors (FBGS) are gaining increasing attention in the field of experimental stress analysis. Basically, Fiber Optic Bragg Sensors are strain-measuring devices and therefore provide many of the advantages of the well-known metal foil strain gages (Kreuzer 2007).Bragg gratings are written into so called single-mode fibers. These fibers consist of a very small inner core of 4 to 9 µm diameter and an outer part (cladding) of pure glass (SiO2) of 125 µm diameter. The difference of refraction indexes between inner core and cladding causes the light to propagate only inside the small core."

Jan 1, 2016

The concept of optical basicity is now being widely applied to rationalize and predict the chemical properties of slags. It employs signals from a probe ion to indicate the "state" or relative "freeness" of the oxygen ions in the slag, and hence provides a fundamental measure of slag basicity. Values of the bulk optical basicity of a slag can either be measured spectroscopically in samples of transparent solid glassy slag, or calculated very simply and accurately from the chemical composition of the slag. The way in which these values vary in different systems are illustrated as isoptical basicity lines on ternary diagrams, and the patterns obtained are discussed. The difficulties associated with assigning optical basicities to the oxides of transition elements are also reviewed briefly. It has been demonstrated that these bulk values can be used as the basis of a flux control model for steelmaking to achieve end-point chemistries much more reliably. Furthermore, several correlations have been established which allow the prediction of the slag-metal distribution of various solute elements. This approach has been used to predict the phosphorus distribution at the end of steelmaking, and also to custom design fluxes for the ladle and tundish to aid in the control of residual elements in the steel such as suphur, hydrogen and nitrogen.

Jan 1, 1990

By Jeremy Bosman, Johan de Korte

Traditionally the feed to coal preparation plants was de-slimed at 0,5 mm. The +0,5 mm size fraction was processed via dense-medium cyclones and the -0,5 mm size fraction was beneficiated with froth flotation, water-only cyclones or spirals. With the introduction of large diameter cyclones, the aperture sizes of de-sliming screens have progressively increased to about 3 mm in the belief that the larger cyclones are not able to effectively beneficiate coal which has a particle size below the ?breakaway? size. The efficiency of separation in the large dense-medium cyclones is improved by presenting a coarser feed to the units. At the same time, the capacity of the de-sliming screens is increased due to the larger screen apertures and in effect, the throughput capacity of the dense-medium section is increased. The 3 x 0,5 mm size fraction, which was previously processed in the dense-medium cyclones, is now added to the fine coal size fraction and processed by water-only methods such as Teetered Bed Separators (TBS) and spirals. Whether this practice is the most economical way to process the 3 x 0,5 mm size fraction requires further thought since the best processing route for the 3 x 0,5 mm size fraction will depend on a number of factors, amongst which are: o The washability of the coal and the amount of near-density material o Processing efficiency o Specification of the required product o The price paid by the customer for the product o The cost of processing the coal Breakaway size The ?breakaway? size is defined as the particle size below which the Epm of the smaller particles starts to decrease significantly. Bosman1 provides an approximate breakaway size versus cyclone diameter (Figure 1). It should be kept in mind though that the Epm of the small particles is a function not only of the cyclone diameter but also of feed pressure, medium density, medium viscosity, particle shape and density, top-size of particles in the feed, etc.

Jan 1, 2006

The capability for on-line measurement of the quality characteristics of conveyed coal now enables mine operators to take advantage of the inherent heterogeneity of those streams and split them into wash and no-wash stocks. Relative to processing the entire stream, this reduces the amount of coal that must be washed at the mine and thereby reduces processing costs, recovery losses, and refuse generation levels. In this paper, new approaches for optimal control of the segregation process, using time series models and empirical distributions, are presented and demonstrated using field data.

Jan 1, 1998

By Thien Sok, Yaojun Lu, Craig Gilbert, Jeremy Scott

Feedwells play a pivotal role in gravity thickeners, governing flow distribution, feed dilution, and flocculation condition during solid–liquid separation. This study presents an optimized design and digital prototyping framework for FLSmidth’s E-volute and E-Duc Feedwell systems, integrating advanced computational fluid dynamics (CFD) with quantitative criteria introduced at SME2024. Building on established FLS technologies, a series of novel configurations were developed and systematically assessed under full-scale and site-specific conditions. CFD provided quantitative insight into flow distribution, feed dilution, and flocculation efficiency, enabling iterative refinement of design parameters. The optimized feedwell demonstrated superior hydraulic performance, enhanced mixing, and improved flocculation outcomes. Beyond the specific design advances, the work highlights CFD as an effective and economical tool for digital prototyping, facilitating early identification of design limitations, reducing dependence on physical trials, and accelerating innovation. The methodology underscores the value of simulation-driven design in advancing feedwell performance and improving thickener technology.

Feb 22, 2026

Compressive crushing is applied in crushing plants used in mineral, mining, and aggregate in-dustry for fragmentation of rock materials. From a global perspective, the total volume of crushed rock is massive and corresponds to several billion tons. All societies have to fulfil a daily need of rock material products and its derivatives such as metals and minerals. The business for metals and minerals is global while the aggregates production is mainly a local industry. This paper presents a broader overview of optimisation with respect to product yield, use of natural resources and energy consumption. High level plant optimisation of compressive crushing plants is covered as well as real-time optimisation and optimisation of single production units. Each of three optimisation areas are presented and a discussion around how these three areas will be able to communicate with each other is given. Several models, e.g. process performance behav-iour with respect to wear, as well as fitness functions can be common for all three areas. Well-defined and representative fitness functions are of the utmost importance in order to assure that the optimisation results reflect the production targets. It is concluded that great benefits can be achieved by linking together different areas of optimisa-tion. The future for compressing crushing lies, without a doubt, in tailored processes both with re-spect to machines optimised for each customer, plant parameters and operation routines as well as an on-line adjustment, which takes into account current information and control possibilities.

Jan 1, 2014

By K H. Esbensen

Optimisation of a real-time at-line monitoring system for control of industrial granule coating quality is presented. The system is based on a fluorescence imaging system, because fluorescence originates in the interiors of enzyme granules but is significantly quenched by a polymer coating (which is needed due to environmental precautions). We have developed an image analytical system for direct prediction of coating quality, which is based on application of the Angle Measure Technique (AMT) for image complexity characterisation; AMT is briefly described. The first part of the presentation addresses pixel sampling strategies within a digital industrial image, inherent in application of AMT, in which the unfolded image is regarded as a one-dimensional object in analogy with 1D process sampling in Theory of Sampling (TOS). The effects of random, stratified and systematic pixel selections in the unfolded image are evaluated. Also factors such as the fraction of image pixels and the effects of specific unfolding strategies (there are three principal strategies, termed æchopÆ, æsnakeÆ and æspiralÆ respectively) are investigated. It turns out that unsuspected artifacts are sometimes produced, related to the specifics of the unfolding procedure, which interferes with a straightforward 1D TOS process sampling analogy. These artifacts have a wider interest û among others, for 2D sampling û and therefore receive special attention in this presentation. The optimal pixel selection strategy for the AMT algorithm is found to be systematic or stratified sampling (not surprising according to TOS) of 500+ initiating points, but need to be unfolded in the novel spiral- or snake-wise fashions in order to effectively counteract these artifacts. This also has a general impact on various suggested standard schemes for 2D grid-sampling, among others, from the geoscience realms. The second part of the presentation is directed towards optimal image analytical sampling of a continuous series of fluorescent images (imaging of conveyor belts of æinfinite lengthÆ), ie optimisation of process image sampling. The minimum number of images needed to uphold a sufficiently good on-line estimate of the quality control (QC) parameter in question is found to correspond to the relatively high sampling rate of 15 - 20 per cent, which can be shown to be related to an intrinsic very high measurement error level (25 per cent) of a mandated analytical reference method.

Jan 1, 2005

The technology of coal preparation, while based on similar processes to those in common useage in the 1950s, has improved significantly over the past 15 years primarily due to advances in process control. This technology at least offers the potential for most coal preparation unit operations to be optimised to a considerable degree. However, to maximise the overall yield of an operation from pit to port, factors often outside of the control of the preparation plant operator have a dominant effect. Specific factors include an in depth knowledge of the feed characteristics of the various sources of coal, the detailed mine scheduling to provide an appropriate blend to the plant, and the interim handling and stockpiling processes between the mine face and the customer.This paper summarises the criteria for optimising the yield for a variety of mining, processing and stockpiling options, based on the principle of operating at constant incremental ash. Pragmatic operating assumptions such as extension of the principle to operating at a constant density for gravity operations will be discussed. A means of optimising the compromise between maintaining specification product ash to the customer and maximising yield by always washing at constant incremental ash, without the benefit of a homogenised feed, will also be Presented.

Jan 1, 1992

By J. N. Stevens, M. Tulwin, P. J. Lawlor

All metals producers are on an unending search for a competitive advantage. They need to produce in the most cost effective way. Sometimes a new mill might be considered but in this paper we present examples of how this might not always be necessary. A detailed investigation by an equipment vendor who can consider the mill and or plant as a complete entity: mechanics, automation and process control can often find solutions that are both lower cost and can be implemented in shorter time frames.

Oct 1, 2019

By F Kock, Y Sulianto, T Trott, B G. Putland, D Morgan

"Northparkes installed and commissioned a secondary crushing circuit in 2010 to debottleneck the semi-autogenous grinding (SAG) mill constrained grinding circuits. Following further improvements to the circuit (inclusion of a double deck vibrating screen), the project successfully delivered finer feed to the SAG mill. The result of this project was an increase in the milled tonnes from 5.6 Mt/a in 2012 to 6.0 Mt/a in 2013.The increased throughput rates introduced new challenges with the circuit becoming power limited. How to best optimise the available comminution power, while delivering the optimal particle size to the flotation circuit was made the key optimisation objective. To achieve this objective, Northparkes initiated a project that included engaging comminution experts. Recommendations included changes to the SAG mill including mill lifter design, increased grinding media charge levels and reduced grinding media size with aim of producing a finer grind size.Northparkes implemented these recommendations along with some other changes to SAG discharge grates and the mill discharge vibrating screen. This achieved a substantial reduction in the flotation feed particle size distribution (approximately 20 microns) by utilising increased average SAG power utilisation, in turn resulting in a two per cent increase in copper recovery.With power utilisation now maximised, the next phase of optimisation has moved to the throughput-grind-recovery relationship and the cost benefit analysis of installing additional grinding power.Citation:Sulianto, Y, Trott, T, Morgan, D, Bell, T, Kock, F and Putland, B, 2016. Optimisation of Installed Mill Power Post-installation of Secondary Crushing Circuit at Northparkes Mines, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 331–338 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By D Horacek, I K. Sheppard

Ok Tedi is in a period of transition. By 2008 mill feed will consist of higher levels of high-grade but metallurgically challenging skarn ores. Additionally, the Taranaki pit will start production in 2008 along with the start-up of a new pyrite concentrator. Taranaki ores are very high in sulfur. Sulfur is captured in a pyrite concentrate prior to tailing entering the Ok Tedi River. These and other complex scheduling issues will need to be resolved over a critical three-year period. With these requirements in mind, Ok Tedi contracted AMC Consultants to develop a custom version of the Life of Business Optimisation System (LOBOS¬) to assist medium-term production scheduling at Ok Tedi. LOBOS utilities enable Ok Tedi planning engineers to:import polygon-based reserve data (Blast Masters) from MineSightÆs Interactive Planning Tools (IP Tools); graphically construct block sequencing and material flow constraints; edit constraints defining standard scheduling, processing and financial relationships; define dump and stockpile attributes; and assign capacities to production systems, plants, dumps and stockpiles. LOBOS converts Ok TediÆs production scenario into a mixed integer program (MIP) and submits the resulting model to IlogÆs Cplex MIP Solver. The Solver seeks an optimal production schedule that maximises net revenue per mill hour while meeting all constraints. This paper introduces Ok Tedi and its production requirements and relates these requirements to the facilities developed for an Ok Tedi version of LOBOS.

Jan 1, 2007