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Thank you for the invitation to address The AusIMM Young LeadersÆ Conference here today. When I first saw the conference theme û æadvancing technologies and their future applications in the mining industryÆ û my interest was sparked because there is little doubt that technology and technological advances will determine the relevance of this industry in the future. And the people seated here today are major players in determining the minerals industryÆs destiny.During my 20-year association with the mining industry, I have observed a number of significant changes that have been delivered as a result of the vision of technical specialists. These changes have built a more competitive industry, a more socially acceptable industry and most importantly an industry with ever-improving safety performance. The purpose of my address is to attempt to provide a context and foundation for other presenters over the following two days. Today, I wish to try to answer the question, æWhy do we invest in new technology in the mining industry?Æ, via: a brief history lesson, a review of the needs of the business, a look at the process for improvement, and finally an example from WMC ResourcesÆ current technology portfolio. I would like to take a very brief walk back in time. During the iron and bronze ages, whilst our ancestors IÆm sure never spoke the phrase ænecessity is the mother of inventionÆ, I am sure they lived by it. Undoubtedly more so than we do today. The roots of geology, mining and extractive metallurgy grew out of the need for better tools in order to get access to the basic necessities of life. It was their superior ability to generate and deliver these ætechnologyÆ improvements that underpinned great civilisations such as the Egyptians, Romans and Incas. The application of mineral technology improvements by these civilisations was crucial to their success, it was their competitive advantage at the time. Many historical texts include detailed descriptions of both mining and processing fundamentals that formed the basis of many of todayÆs operations and processes. However, it is technological improvements to these fundamentals, as well as the development of new technologies, that have preserved the fundamentals as viable options for the industry today. Even in my time in the industry, there have been substantial improvements in the way business processes operate. When I first started working in a gold mine in WA in the late 1980s, the office had one PC (a 286 processor). All data was managed by paper and then often re-typed into other databases. Electronic mine design and process control was in its infancy. Today, massive amounts of data are recorded, analysed and acted upon almost without any human interaction. Our industry today has far different challenges than those described by Argricola. These are many and diverse, but new technologies are required to address three distinct classes of need: 1. Societal needs: physical needs for food, shelter, recreation and leisure; community and political needs for less waste, less emissions, better safety and working conditions, less energy consumption and sustainability. 2. Individual needs: intellectual needs to create innovative technical and organisational ideas. 3. Wealth generation needs: investor needs for maximising operating efficiency and value growth. Each new technology, to varying degrees, fulfils one or all of these needs. In many cases, the driver of a technological development was to fulfill only one of these needs, but after it was implemented, the development actually fulfilled each need. I would like to expand on these needs.

Jan 1, 2003

Understanding multiphase particulate systems is essential for the further advancement of mineral processing technology. Characterisation, analysis, and simulation of these complex systems provide a fundamental basis for the development of improved mineral processing technology. One of the more recent tools that can be used to help provide a foundation for improved mineral processing technology is high resolution cone beam X-ray micro computed tomography (CT). During the past ten years point-projection X-ray micro CT systems have been used for 3D visualisation and quantitative analysis of multiphase particulate systems. Analysis of packed particle beds containing as many as 30 000 particles can be accomplished in less than three hours with special software to establish the 3D characteristics of each particle in the population and the spatial organisation of the packed particle bed. Now, due to advances in X-ray optics, the resolution afforded with point-projection micro CT systems has been improved by at least an order of magnitude using a lens-based X-ray micro CT system. The development of software tools for the 3D characterisation, analysis, and simulation of packed particle beds using high resolution X-ray micro tomography (HRXMT) is discussed including examples of application in the areas of comminution (particle damage and preferential grain boundary fracture), exposure/liberation analysis (liberation-limited separation efficiency, including coal washability), and filtration/heap leaching (pore network structure of packed particle beds and simulated flow using the LB method of computational fluid dynamics).

Sep 13, 2010

By R. L. Grant

During the last decade or more , experimental research on commercial detonators used for initiating the detonation of dynamite and other high explosives has led to important improvements . Developments , especially in the United States , have been directed toward improvement in the construction of detonators to make them safer to manufacture and use . More suitable and safer initiating charges also have been found . Although for many years mercury fulminate was unrivaled as the initiating charge for dynamite , during the last decade it has been replaced to a large extent by less sensitive , more efficient, and cheaper combinations of ignition , priming , and base charges . Commercial detonators were once of relatively simple construction and almost universally identical . Today they are technically complex, with special nodifications for particular uses ; they have developed along different lines n various countries and even among the several manufacturers within any one country .

Apr 1, 1943

By T. Schmidt, J. Merza

"This study considers two lead/zinc/silver orebodies which have historically had a problem with pyrite, pyrrhotite and sphalerite contamination in the lead circuit. The problem was previously addressed with high dosages of sodium cyanide as the primary depressant. However, large amounts of cyanide led to environmental problems in the effluent, especially during winter months. The objective was to reduce cyanide consumption while maintaining or improving overall lead grade and recovery via the reduction of the undesirable sulphides.Extensive laboratory and mill testing was necessary to determine the optimal operating parameters for continuous plant application. Evaluation of data received from this testing has shown that selective addition and optimization of the dosage of Unimax SD100 to specific areas of the flotation and grinding circuits has resulted in improved Pb grade and recovery. Parameters such as pH control, regrind operation, the cyanide/Unimax ratio and sulphide mineral content may also affect the performance of the depressant. Each factor is discussed and optimal operating conditions were determined based on the testing.Results are presented for two case studies. Both indicate that Unimax SD100 improves the lead grade/recovery curve by increasing iron and zinc rejection while reducing cyanide consumption and the resulting environmental concerns. 1. Hart"

Jan 1, 1992

By Per-Martin Sandgren

LKAB's ores have specific mineralogical properties that make them especially suitable for the production of super-grade concentrates. Conditions are particularly good for this purpose at Malmberget, where a concentrate for high-purity sponge iron production has been produced for many years. Until 1978 the approximate assay was 71.2 % Fe and 0.45 % SiO2. Since then the assays have been improved by process modifications to approximately 71.5 % Fe and 0.20 % SiO2. Scope exists for still further improvement. In recent years the production of fractioned concentrates has been started. The material lies within the size range 74-125 µm and the approximate chemical analysis is 71.6 % Fe and 0.30 % SiO2. Other special products are under discussion. The Malmberget ores are also suitable for the production of high-purity direct reduction pellets with a SiO2 content below 1 %.

Jan 1, 1981

By David M. R. Stone

Underground mining in the gold industry is gaining popularity in Nevada, and with it the use of cemented rockfill is becoming mainstream. Even with today?s high metal prices, however, mining companies are very sensitive to the margins they realize, and are constantly looking for ways to reduce costs or improve efficiencies. Given that the backfill is one of the largest cost centers in underground mining, mines are constantly under pressure to reduce backfill costs. This paper will present an overview of the factors that impact cemented rockfill quality in Nevada mines based on the authors many years of consulting experience. Cemented rockfill quality can be linked directly to binder consumption, hence programs aimed at improving quality generally result in lower binder costs, better performance in the fill (hence less dilution), and improved safety. The paper will conclude with the key elements of a comprehensive program of backfill quality assessments and backfill QA programs. Comparative laboratory and minesite data from a number of operating and proposed mines will be presented.

May 1, 2007

By Frank E. Cash

As a part of its safety program the United States Bureau of Mines has fostered the development, use, and improvement of portable electric mine lamps. Although there is still need for better illumination in mines and the replacement of open lights has been slow, improvement in electric cap lamps and increase in their use indicate one phase of recent progress toward safer and more efficient mining This report is the result of a recent survey of electric-lamp installations in the Alabama mining; district; it shows the misuse, increase in use, and relation to certain classes of accidents of these installations.

Jan 1, 1935

New Developments in Spirals and Spiral Plant Operations Records indicate that spiral separators have been utilised in mineral separation for over 100 years. The Spiral's predecessor, the sluice, has been in use for centuries in different forms and a spiral can be thought of as a sluice wound around a column. The spiral separator is distinguished from the straight sluice, and other flowing film separators, in uniquely introducing centrifugal motion. The elegance of the spiral concept was embraced due to significantly improved separation efficiencies, ease of operation and tolerance of variation in feed conditions. Advances in spiral technology have improved the metallurgical performance, modernised the materials of construction, increased unit capacities and simplified operation. These advances have ensured that spirals continue to play a major industry role amidst other advancing and competing technologies. Recent developments in spiral and spiral plant technology include: the launch of the VHG spiral model, specifically aimed at feeds with very high levels of high-density mineral particles; the introduction of a high capacity wash water spiral model; and innovations in feed stabilisation and control. Details of these developments are presented together with the resultant operational benefits including feed stabilisation, product control and improved metallurgical performances.

Sep 13, 2010

By Ronald D. Rothchild

This report describes the results of a study of longwall ignition hazards and specific suppression systems to minimize each of the major hazards. The major ignition hazards were identified by conducting a literature search and conversing with knowledgeable individuals in the United States mining industry. Three classes of potential ignition suppression systems are discussed: triggered suppression systems for face ignition, passive suppression systems, and control of ignition hazard in the gob. The triggered suppression systems included protection for the shearer, head and tail gates, welding equipment, and the shearer power cable. Passive systems include improved ventilation and water sprays, and charges in the shearer head. Gob protection can be improved by isolating the gob from working areas and by introducting inerting agents into the gob.

Jan 1, 1976

By B King

Processing expansion options and mining fleet purchases are major cost items that receive due focus in most cost management analyses. If these items are not needed, they can significantly reduce a project’s short-term capital spend and improve profitability and value to shareholders. When conditions change prior to purchasing equipment, the purchase may no longer represent the best decision for the project.This paper outlines a structured approach for making major cost decisions to improve the value of a project, determining which items should be kept and which should be eliminated.CITATION:King, B, 2014. Cost management optimisation, in Proceedings Orebody Modelling and Strategic Mine Planning Symposium 2014 , pp 7–12 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 24, 2014

By S Lee, I Sohn

The ferrous and non-ferrous metallurgical industries have been utilising slags, fluxes and mattes for process optimisation and quality improvements at high temperatures. Understanding the fundamentals of the thermodynamics and kinetics of chemical metallurgy regarding slags, fluxes and mattes has been essential to the technological developments of these optimisation and improvements. This work will discuss how these fundamentals have been studied in the reactions involved and implemented in the ferrous industry from primary refining to continuous casting. In particular, the chemical driving forces that allow these reactions to take place and the limitations of the kinetics that require optimisation to enhance the reactions. In addition, the future research direction for slag technology innovation and the role of these fundamentals will also be described.

Jun 19, 2024

By A. Galley, R. Tosdal, F. Robert

The Canada Mining Innovation Council (CMIC) Exploration Innovation Consortium developed a 10-year business case for developing new discovery criteria, exploration techniques, and better data management and analysis to improve exploration success in deep, remote, and covered terrains. Within this context, the CMIC devised a five-year project proposal to create improved multiparameter exploration tools to detect ore systems and more efficient vectoring toward high-grade mineralized cores. The Footprints project was approved March 2013. More than CAD$13 million funding was provided through the CMIC-led joint sponsorship from 30 companies and the Natural Sciences and Engineering Research Council. Consistent industry leadership and integration of dedicated industry and academic expertise has the project on track for reaching its well-defined objectives.

Jan 1, 2014

By A. Martins, L. Goulart, E. Araujo, R. Batista, A. Costa e Silva

Steel cleanness is of great importance to the performance of almost all steel products. From very clean steel for bearings to long products used in civil construction, processing variables – in special those in steelmaking operations- must be properly balanced to achieve adequate cleanness for the desired performance. With the present complexity of steels as alloy systems, it is not efficient nor appropriate to develop these processes on empirical basis alone. Computational thermodynamics can greatly improve process development to achieve the desired cleanness level at reasonable costs. In this work, examples of these calculations and their applications to real steel processing are presented and discussed. The advantages, limitations and areas in which improvement in these calculations is desired are highlighted and discussed.

Jan 1, 2015

By Y. Kusuda

Since 1981, the Annaka refinery has recovered zinc from zinc leach residues by the Waelz Process. The important considerations of this process are the prevention of the growth of coating accretions in the Waelz kiln and the improvement of the zinc volatilization rate. In this paper, simulation predictions and the results of the industrial operation regarding the prevention of coating accretions in the Waelz kiln and the improvement of the zinc volatilization rate at the Annaka refinery are reported and compared.

Jan 1, 2006

By Congling Shi, Marek Borowski, Yue Wang, Jianwei Cheng, Xixi Zhang, Xuan Xu

As the first barrier to prevent accidents caused by explosions in underground coal mines, the integrity and stability of mine seals have great effects on mine workers’ lives and underground production safety. In this paper, the mechanical responding performance of typical mine seals under the impact load are studied by using numerical simulation method. By such simulation studies, the safety of different seals subjected to the explosion load is evaluated. Seals’stability are also investigated under effects caused by various influence factors including thickness of mine seal, cutting depth into surrounding rocks, rock type, and the roof-tofloor convergence under given the explosion load. The research results can provide theoretical basis and reasonable improvements for mine seal’s construction practices for improving its anti-explosion performance.

By B. G. Kelley

The MIDREX® Direct Reduction Process was developed during the 1960s by the Midland-Ross Corporation, which had pioneered shaft furnace technology and stoichiometric gas reforming for use in processing minerals. In 1969, the first MIDREX® Direct Reduction Plant was built in Portland, OR. Since then, 49 additional modules have been sold in 18 countries. For the last ten years, over 60 percent of the world's direct reduced iron has been produced in MIDREX Plants. During the quarter century since commercialization, many technical improvements have been made, including larger shaft furnaces, in-situ reforming, greater heat recovery, improved catalysts, and hot briquetting. Midrex continues to enhance the technology in the areas of economy-of-scale, energy efficiency, alternate fuels, and raw material flexibility.

Jan 1, 1998

By C. Kuehmann, B. Tufts

QuesTek Innovations has applied its Materials by Design® methodology to computationally design a new ultra high-strength corrosion resistant steel. Ferriurn® S53 eliminates the need for toxic cadmium coatings currently used on conventional steels in landing gear systems. S53 has the strength of 300M steel, and corrosion resistance similar to 15-5PH stainless steel. S53's corrosion resistance improves stress corrosion cracking resistance and reduces susceptibility to hydrogen embrittlement, improving component reliability and providing an opportunity for extended overhaul and repair intervals. Ultimate tensile stress is 1965 to 2000MPa. S53 was designed to be mechanically equivalent to 300M, with the key addition of intrinsic corrosion resistance. Alloy design, microstructural characterization, and mechanical properties are discussed herein.

Jan 1, 2006

By H. A. Hoffman

Competition from an all-flotation plant, with demonstrated economies and efficiencies, plus a change in smelting contract and introduction of improved cyclones lead to conversion from gravity-flotation. Detailed descriptions are given of equipment installed and procedures used at St. Joseph Lead's Federal mill. Future plans include further quality control by instrumentation in all aspects of the mill operation. Also planned are improvements in materials handling systems. Competitive conditions will continue to dictate improvements and changes in the mill flowsheet. The advent of all-flotation mills in the Lead Belt was introduced by the Indian Creek mill in late 1953. This modern and efficient plant then became a pattern for the other mills in this area to re-evaluate their circuits in an effort to develop flowsheets that would improve operating conditions and metallurgy. The Indian Creek mill demonstrated that all-flotation would require considerably less operating and maintenance labor than the combination of tabling and flotation that was common in the Lead Belt at that time. Two significant changes occurred in recent years to allow all-flotation to be seriously considered in other Lead Belt mills. One was a change in the smelting contract which did not require gravity concentrate. Another was the development of cyclones which provided classification of the flotation feed in a very small space. Since the Federal mill was the largest concentrating plant in the Lead Belt it was felt that the greatest savings could be made by investigating the all-flotation possibilities at this mill. Interest was stimulated by the milling and ore dressing Depts. to determine if this mill would be converted without undue cost, provided the metallurgy could be improved. Accordingly, laboratory tests were initiated to learn what metallurgical benefit could be derived. Numerous tests were run which indicated that grinding to all-flotation would improve the tailing by as much as 0.02 pct Pb. This was quite significant when multiplied by the tonnage of ore treated. Projecting the added cost of power for extra grinding and flotation, and the additional flotation reagents required, plus additional new equipment that would have to be purchased, it would still add up to a considerable saving. The all-flotation mill would reduce man power by some 30 pct, and make a metallurgical improvement. Operating costs could be reduced bv 2$ per ton. The metallurgical improvement would amount to 4$ per ton, for a total of 6$ per ton of ore milled. An estimate of the cost of the conversion was set at $250,000. With the savings as estimated this could be paid off in about two years. On paper it therefore seemed attractive enough to justify a mill test. MILL TESTING One section of the Federal mill was made available for use as a separate test circuit. Cyclones and density controllers were borrowed from the Viburnum and Indian Creek mills. Denver flotation cells were obtained from the Desloge mill that was then shut down. Two 10-cell groups of Fagergren flotation machines, consisting of eight roughers and two cleaners in each bank, were segregated from the remainder of the plant. The 9x12-ft rod mill was continued as a primary grinding mill. The two 6%x12-ft mills on this section were converted from rods to balls, and the speed increased to 22.0 rpm. Cyclones were installed to close the circuit of these ball mills. The ground pulp from each of the ball mills was fed separately to its own bank of flotation cells so that two completely separated test circuits could be run in parallel. This test circuit operated on a three-shift basis from Dec. 22, 1959 to Mar. 21, 1960. The first few weeks were occupied in developing conditions for proper metallurgy and trouble-free operations. Results were rather erratic but as the ore dressing laboratory and the mill operators became more familiar with conditions they were able to obtain expected results, which could be duplicated day after day. The last five weeks of testing indicated the best results and are tabulated in Table I. During the first two weeks a Denver unit cell was used on No. 1 flotation circuit. Even though it recovered almost one half of

Jan 1, 1962

By Mictck Rataj

Methods of rock reinforcement in Australian coal mines are being advanced progressively through the better understanding of rock failure mechanisms around roadways and the-development of improved bolting hardware and installation techniques. It has been recognised that to improve the performance of rock reinforcement systems, the stiffness of the system as a whole has to be improved. New style bolts and accessories together with high pre-tensioned roof and cable bolts are being developed as a result. A number of the new techniques used to stabilise the roof, especially in weak roof/high horizontal stress areas have been site proven and are now currently used on a routine basis as a means of improving development rates and gate road stability during longwall retreat.

Jan 1, 1997

By Frank E. Cash

Published or available data on safety in quarries are few except those pertaining to blasting issued by manufacturers of explosives. During the past 25 years the quarrying industry (including various types of quarries producing many different materials) has had a markedly improved accident experience. The downward trend has not been phenomenal or has it been uniform from year to year, owing to occasional major disasters; but from the information at hand it appears that improvement during the 25-year period has been definite.

Jan 1, 1941