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By P. B. Hearse, R. L. Flood

TQM is a term of which most metallurgists have heard and a system of which some have had first hand experience. This paper is designed to encourage further thinking on TQM and how it can effect your organisation. Consideration of organisational culture and objectives are a prime pre-requisite when planning for the implementation of TQM. It is argued that there is no "brand" of quality culture of TQM which can be applied en masse to the mining industry. Definitions ofTQM are proposed, and the essence ofTQM as being about increasing customer service, improving the quality of goods and services, and involving people in their work is discussed, in conjunction with the concept of Customer as applied to the metallurgical industry and TQM. The integration of TQM into Quality Accreditation Stan­dards is then discussed. Finally, examples of the benefits that may be achieved with Implementation ofTQM into metallurgical and operations groups is presented, along with an analysis of the difficulties of implementation into our businesses and operations.

Jan 1, 1995

By MD Cadzow, TW Quaife, DJ Lunt, TS Giraudo

The Macraes Gold Project, operated by Gold and Resource Developments NL, engaged Minproc Limited to assist with the evaluation of a pressure oxidation circuit, this being the key component of a recovery enhancement project. The initial study gave sufficient confidence in the process to enter into project execution. The project is the first to license Newmont Mining Corporation's pressure oxidation technology, which aims to improve gold recovery from the carbonaceous sulfidic flotation concentrate. This paper outlines the fundamental chemistry of the process followed by a description of the plant that was ultimately installed. A summary of the commissioning is given together with an overview of the production results for the first three months of operation. The project ramp-up was rapid, with design temperature and throughput being achieved within days of hot commissioning. Gold recoveries have exceeded expectations and the project has increased the nominal gold output at Macraes from 110,000 oz/y to 150,000 oz/y. Ongoing plant optimisation and problem solving, mainly associated with scale formation, is discussed.

Jan 1, 2000

By Claude Cunningham

AEL’s Electronic Delay Detonators are in routine use and growing in both volume and breadth of application in Africa. This trend will continue and grow internationally owing to increasing pressure on rockbreaking operations to conform to sustainable development principles. A fundamental breakthrough has been achieved, bringing production blasting into line with technologies, which leverage performance through tight monitoring and control. When moving from pyrotechnic systems, benefits are normally realized without having to adopt different timing patterns, but significant additional benefits are realisable by using the flexibility and precision of the electronic units to enter windows of timing previously closed. The higher price and increased care needed are a worthwhile investment, enabling operations to cross the chasm to stronger revenues, but the system must be robust and suited to the application and personnel. Economic models are vital for keeping track of the potential and achieved benefits of these systems. Some resistance can be expected from those who stand to lose income as a result of the improved efficiencies.

Jan 1, 2004

Case Study: Dragline Swing to Dump Automation By Peter Corke, CSIRO Manufacturing Technology/CRC for Mining Technology and Equipment (CMTE) Peter Corke presented a case study of a project to automate the dragline swing to dump operation. The project is funded by ACARP, BHP Coal, Pacific Coal and the CMTE and is being carried out on a dragline at Pacific Coal's Meandu mine near Brisbane. Corke began by highlighting that the minerals industry makes extensive use of large, mechanised machines. However, unlike other industries, mining has not adopted automation and most machines are controlled by human operators on board the machine itself. Choosing an automation target The dragline automation was chosen because: ò draglines are one of the biggest capital assets in a mine; ò performance between operators vary significantly, so improved capital utilisation is possible; ò the dragline is often the bottleneck in production; ò a large part of the operation cycle is spent swinging from dig to dump; and ò it is technically feasible. There has been a history of drag line automation projects, none with great success.

Jan 1, 1997

By Gabriella Mendez

Worthy of note in Miss Bailey's paper are her comments on the attitudes of mining companies and their managers where women were employed, she says, "..another possible pitfall is reverse discrimination where in an effort to avoid being branded as having shown a person favouritism, supervisors end up treating the person in a manner much less than they deserve. This is manifested in denying an employee such things as challenging work, educational opportunities, promotions, or in the case of staff, fair merit increases." and further she says, "It has been observed that the treatment of women in non-traditional roles such as mining is different than for men in the same environment. There are people who treat women worse and some who treat them better simply because they are of the other sex." These statements may sound unjustified to today's audience, and whilst we need to credit pioneering women with having tolerated, understood and worked towards improving the mining culture, the move towards total inclusion of women in the workplace is still growing.

Jan 1, 1995

By Alan Fricker, Bill Owers

Cyprus Gold NZ Ltd will be recovering residual cyanide from their CIT, operation in New Zealand. The process will use air to strip the cyanide from the acidified barren pulp. DSffi. Industrial Development, who were involved in the bench and pilot studies for Cyprus, have extended the concept to pregnant pulp. The stripping of pregnant pulp eliminates the substantial loss of cyanide through carbon catalysed oxidation during the adsorption stage. A 50% increase in cyanide recovery was obtained from an extensive laboratory investigation. The presence of a cyanide recovery circuit enables leaching to be conducted, without detriment, at pHs at least as low as 9, with consequential 50% reductions in the consumption of lime and sulphuric acid. There should be a small reduction in carbon consumption, and a significant improvement in the quality of the final effiuent, at least in terms of cyanide, cyanates, copper, zinc and sulphur. A small but significant increase in gold recovery can be expected too. There is a net economic advantage of NZ$1.20/tonne of ore by stripping pregnant rather than barren pulp.

Jan 1, 1990

By Stephen R. Brown

Current conditions in the gold market demand that mine and plant operators make budgeted production targets at the lowest possible unit costs. For those companies bringing new gold pro­duction capacity on-line, achieving budgeted production levels as quickly as possible after start-up is vitally important to mini­mize unit costs and to begin a positive cash flow. Whether the objective is to simply improve unit costs or successfully start-up a new, complex plant, success will be strongly influenced by the skill levels of the operators and supervisors. The only way to assure return on plant investment, and to survive during depressed metal prices, is to ensure that plant operators have the knowledge to effectively run the plant. Technology available in computer-based, multimedia training systems, including: inter­active animation, videos, voice-overs, schematics, and text can now be used to train operators at their own pace using plant-spe­cific information. Additionally, it has been shown that learning through multimedia provides a higher degree of long term reten­tion than more traditional learning methods.

Jan 1, 1998

The Newmont Waihi Operations mill has undergone significant growth over its life. Initially designed as a single SAG mill operation, the circuit has been progressively upgraded since 1988 from a nameplate capacity of 600 000 tonnes per annum to the current rate of 1.3 million tonnes per annum. With future mining potential there is renewed interest to increase the processing rate even further. Over the next twelve months five sustaining capital projects will be undertaken and two major eco-efficiency projects will be completed. With the exception of the large grinding mills, most equipment on a gold treatment plant is replaced after 10-15 years. Waihi Gold mine has been operating for 14 years and has just recently received approval to replace equipment in five main areas; carbon elution, carbon regeneration, scats crushing, intertank screens and variable speed drives. Each project has been justified on improved process efficiencies and operating/maintenance cost savings. The two eco-efficiency projects involve a water balance model and a cyanide optimisation project, both of which are Corporate key performance indicators (KPI).

Jan 1, 2002

By C. J. Pritchard

I commend the authors on examining an interesting method of shaft lining and attempting to improve safety in a dangerous environment by remotely installing the shaft lining. It is important, though, to not trade off shaft lining safety for long-term mine safety by lining an intake shaft with combustible material. In many operations, the mine utilities are installed next to the lining of the intake shaft, supplying a possible ignition source if damaged or overloaded. Although the polyurethane studied in the paper is of relatively high density, no mention is made of the flame retardency of the samples. When exposed to heat, small amounts of polyure¬thane will melt and bum but are extinguished when the heat source is removed. If large surface areas of combustible polyurethane - a tunnel or mine shaft - are exposed to ignition heat sources that are not removed or extinguished early, an uncontrollable, fuel rich fire may result with high carbon monoxide levels, low oxygen concentrations, and greatly increased burning rates that can have devastating effects on the ventilation system and miners' safety.

Jan 1, 1990

By Jefferson CB

Adaptive optimisation is the adjustment of operating conditions to maintain optimum process performance as the feed quality varies. This strategy has the potential to be economic- ally better than the maintenance of a constant optimum performance with a blended feed. Application of the strategy is hindered by practical difficulties and economic risks. A computer simulation of leaching processes has been used to identify ore-process systems which have the greatest potential benefits from adaptive optimisation. They are systems with low value feed materials and a broad distribution of reactivities, in pro- cesses which are sensitive to the operating variable that is being manipulated (e.g. residence time). Improvements of up to 13% in throughput and 5% in the economic operating margin can be achieved. The results are sen- sitive to the precise model which is used for the process kinetics. It seems that the kinetics of the last few per cent to react are particularly relevant. A realistic situation has been identified where a synergistic inter- action occurs in blended feeds which makes adaptive optimisation disadvantageous.

Jan 1, 1984

By M I. Jeffrey, J A. Rumbal, D M. Hewitt

Ion chromatography utilising an anion exchange column and UV detection has facilitated an improved understanding of sulfide mineral leaching in cyanide solutions. By analysing for sulfide, sulfite, thiocyanate, thiosulfate and metal cyanides it is possible to show that chalcocite dissolution is a non-oxidative process in which copper cyanide and sulfide ions are formed in solution. Further, the homogeneous oxidation of the sulfide ions by dissolved oxygen is slow, but catalysed by a surface of lead sulfide or pyrite. Polysulfides may also be formed as an intermediate oxidation product and these undergo further reaction to produce thiocyanate, thiosulfate and sulfite. The leaching of copper from a pyrite concentrate sample is shown to be rapid, and accompanied by significant iron dissolution; however, the iron is not believed to be from pyrite, pyrrhotite or chalcopyrite. The rate of iron leaching and cyanide consumption is reduced by maintaining low cyanide and high oxygen concentrations. Preoxidation or the addition of lead(II) ions does not reduce the iron dissolution from this pyrite concentrate.

Jan 1, 2007

By E G. Thomas

"This paper details the many improvements possible in narrow vein mining from the use of treated mining/milling waste as mine fill. Such fill can be: treated mill tailing, cemented or uncemented; development muck, treated or untreated, cemented or uncemented; andsome combination of these materials, or surface sands/gravels. Treatments involved may be both physical (optimisation of particle size gradings) and chemical (neutralision of potentially harmful milling chemicals).Potential benefits include a reduction in: back stress; vein closure; alternate ground support requirements; mining dilution; potential for surface subsidence; and extent of surface disposal of mining/milling waste, resulting in reduced environmental impact. Considering the usually small production tonnages involved, preparation and placement of a highly applicable fill material can be economically accommodated.Emphasis is placed on steeply dipping orebodies being mined overhand, although practice in the much less steeply dipping RSA gold/platinum-type orebody is also considered.CITATION:Thomas, E G, 2012. Mine fill in thin vein mining, in Proceedings Narrow Vein Mining 2012 , pp 215-218 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Mar 26, 2012

By C. H. Wilson, J. J. Jakosky

In recent years geophysical prospecting methods have become well established as important steps in economically initiating new mining ventures in the field of base-metal exploration, placer mining and water-supply problems. The value of these methods as applied to these problems has been greatly increased by new and improved instruments, and a greater degree of skill in laboratory and interpretative technique. Considerable success has been attained, with subsequent drilling checking the predicted depths within 1 to 5 per cent, on problems requiring information on thickness of fill material, depth to and contour of bedrock, extent and yardage of gravels to be mined, and location of hydrostatic water table. In these applications the geophysical work gives data comparable to drilling, and at a cost of about one-fiftieth that of drilling. Discussion of several surveys with accompanying illustrations showing geophysical methods applicable to both simple and complicated placer problems are contained in the paper. The electrical instruments for measuring electromagnetic field strength and surface potentials are described, and their use, coupled with that of other geophysical instruments in modern field procedure, is noted.:

Jan 1, 1934

By Launa G. Mallett, Charles Vaught, Kathleen M. Kowalski, Charles D. Litton, Michael J. Brnich, Ronald S. Conti, Henry P. Cole, William J. Wiehagen

How do people behave when they are trying to get out of a fire? Are escape activities different in each incident, or will most actions be predictable across events? Do persons make the same sorts of decisions whether they are responding as individuals or as group members? Because the social costs of fire-related deaths and injuries are likely to continue to rise, societal pressure for greater safety will also undoubtedly increase. There are, therefore, compelling reasons to further our understanding of action in fires. If human behavior in fire is studied scientifically and predicted according to some well-defined principles, the benefits will be significant. Design engineers could incorporate real-world findings into their plans. Equipment manufacturers could gain from insights into how their technology is actually used in fire emergencies. Safety personnel would have a better appreciation of what constitutes adequate evacuation procedures. Trainers could upgrade the content of their courses that teach escape skills. The result would be an overall improvement in the quality of fire preparedness and safety.

Jan 1, 2000

Having successfully applied computer techniques to open pit mining applications, many software developers are now using their skills to tackle the much harder areas of underground mine design, planning and production.Dramatic improvements in the performance to price ratio of hardware (including high resolution graphics screens), a better understanding of the techniques of surface and solids modelling (and their subsequent display), moves towards standard user interfaces and advanced concepts of representing grade distribution in the ore body have all contributed to the recent increase in underground mining software activity.This paper details the general requirements of a workable underground mining software system, providing a minimum checklist of desirable features and emphasises the importance of ease of use, flexibility and intuitive feel. Some relevant trends in hardware, software and application techniques are highlighted and comments made on areas which require further development or are only available in a small number of packages.Finally, a comment is made on the role of computer models to provide a unifying medium for tying together all aspects of underground design, planning and production.

Jan 1, 1992

By J. Lu

The impact of acid treatment in agglomeration/acid curing on copper extraction and acid consumption was investigated with respect to acid dosage and moisture. Without the addition of water, no agglomeration occurred. At an acid dosage above 15 kg/t, the acid was not completely consumed during acid curing. With the addition of 6.2% water, the particles agglomerated together. Copper, iron, magnesium and manganese were dissolved as sulfates and enriched in the fine fraction of the ore. The copper extraction and net acid consumption increased with increasing acid dosage. The copper extraction for acid curing with the addition of 6.2% water was higher than that without the addition of water due to the improved permeability and the increase in the contact with acid-soluble copper. During acid curing, the reaction of sulfuric acid with muscovite, abite and nacrite mainly took place on the surface of the particles while the reaction of sulfuric acid with clinochlore occurred not only on the surface but also inside the particles.

Jan 1, 2007

By Anthony J. Peach

With the new generation of so called "Super TBM", we would all expect to witness the implied super-performance. In some instances this is occurring, but one must ask why is it not occurring in the majority of applications? For hard rock TBM related projects, we are observing a decrease in the volume of projects in the previously traditional areas such as North America and Western Europe and an increase in Asia (Hong Kong, Indonesia, China, Korea etc). As a consequence less experienced contractors are acquiring the latest ultra high power equipment, without the knowledge necessary to achieve optimum performance. The interdependence of TBM and muck removal systems has been assessed with emphasis on the emergence of the continuously extending conveyor technology, as a means of achieving dramatic productivity increases. The Australian system assessed here at the time of drafting this paper holds the world record tunnel excavation production of 2,166 metres. A little considered aspect of the adoption of conveyors is the associated improvement in safety.

Jan 1, 1995

By McKee DJ

Many workers have observed an inverse relationship between final concentrate grade and valuable component recovery achieved by a flotation circuit, i.e. an increase in either grade or recovery may only be achieved at the expense of the other. The relationship is termed a "grade-recovery" curve and, in theory, limits the separation obtained by the circuit. However, circuit surveys in a nickel concentrator indicate that the operating "grade-recovery" curve of a circuit is not only determined by the nature of the ore and the circuit operating conditions, but also by the circuit design, particularly in terms of stage capacities. The surveys show that different capacity circuits can produce different operating curves for the same ore, and that capacity reallocation between stages has the potential to improve both grade and recovery. In particular, the relationship between circuit design and operating curve position is shown to be a function of the circulating loads generated by the circuit design, balancing the beneficial effects of recycling material against the proportion of plant capacity consumed by recycling.

Jan 1, 1986

By O. Ofor

Finely-ground hematitic ore, too high in silica (quartz) to be commercially viable, was treated by emulsion flotation. A three-component emulsion mixture was used at temperatures ranging from ambient (22° C) to 30° C, 40° C, 49 °C, 59° C and 68° C. The optimal emulsion dosage and composition at ambient temperature were used to determine that dosage for higher-temperature flotation tests. The crushed ore (100%, -8 mesh) was repeatedly washed with tap water, and the filtrate's ionic content was analyzed. The separation efficiency values (a measure of the selective separation and concentration of hematite from gangue minerals) demonstrated temperature dependence, with marked increases at temperatures above ambient. The optimal separation efficiency occurred within the range from 30° C to 60° C. The improved separation efficiencies at temperatures exceeding ambient are explained by quartz depression. This depression is attributed to: • the precipitation of quartz-activating cations, principally calcium and magnesium, at increasing temperature; and • temperature's effect on the collector's solubility and attachment to the aqueous hematite surface.

Jan 1, 1993

By F. M. Lewis, J. E. Goodman

TENNESSEE Copper Co. operates two ore concentrators, the London and Isabella mill. Copperhill, Tenn. In 1948 and 1949 the small ball mills and rake classifiers in the London concentrator were replaced by one large ball mill and one hydraulic classifier. This new ball mill was designed oversize so that it could be operated at slower than normal speed. The proper operating conditions were established and the results published.1 Later it was found that this mill operated more efficiently with a small ball charge.2 While this London grinding practice was being developed, the Isabella grinding circuit was not changed in any way. It remained a conventional two-stage rod mill-ball mill combination, the rod mill in open circuit and the ball mill in closed circuit with a rake classifier. Study of the data indicated that grinding cost could be lowered by converting to the London practice, but not enough would have been saved to warrant the expense of converting. No plan for improving this grinding operation could be developed.

Jan 11, 1957