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By T Baard, A Pieters

This paper deals with the design and implementation of a 17 MW (nominal) surface cooling installation at Impala Platinum No 14 shaft located in Rustenburg, North West Province, South Africa.The cooling requirements included the installation of a surface ammonia refrigeration plant complete with the storage of hot and cold mine service water for underground use. It was also necessary to install a surface bulk air-cooling facility, which cools 400 kg/s of ventilation air going to the underground workings. Primary cooling is to the surface bulk air cooler. The cooling duty of a surface bulk air cooler is heavily dependent on the ambient wet-bulb temperature. Because of the daily wet-bulb temperature variation in this part of the world, use was made of a cold thermal storage facility of four million litres. The excess chilled water is stored during the night, for use by the main drilling shift during the day. This keeps the refrigeration machines as close as possible to full load during the summer, thus maximising the use of the capital expenditure. This paper discusses the control philosophy used to maximise the cooling output, as well as the thermal process. The project consisted of two phases resulting from the underground development phases of the mine. The first phase started in January 1999 and was commissioned by the end of the same year in record time. The final commissioning of the second phase took place at the end of 2002. The most difficult part of the construction phase was the tunnelling of a subsurface air duct from the bulk air cooler to the operating vertical shaft. This was done without disruption to the hoisting of men, material and ore in the shaft. Owing to the size of the refrigeration machines, the ammonia quantities involved and the application on a mine (no ammonia can go underground, either in the service water or in the mine air) special precautions had to be taken. South Africa has developed high standards for ammonia refrigeration plants used on mines, which will be partially dealt with in this paper.

Jan 1, 2005

The basic rule for correct design of a sample plant is that all parts of the material being sampled must have an equal probability of being collected and becoming part of the final sample for analysis. However, this rule is often ignored in the design of sample plants to save capital costs. This is false economy, because the samples taken are likely to be seriously biased and the precision may be compromised. The introduction of bias is particularly serious, because no amount of replicate sampling and analysis will reduce bias once it is present and it is often quite difficult and expensive to subsequently rectify the problem due to space limitations around the primary sampling location. This is also true of secondary and tertiary sampling stages, particularly in terms of the relationship between particle size and retained sample mass. The best strategy is to seek expert sampling advice and design the sample plant correctly at the outset.

Jan 1, 2005

By D Hill

In the Ngakuru area zeolite deposits occur in late Quaternary lacustrine vitric tuffs of the Ngakuru Formation and two of the deposits are being mined. The Ngakuru Formation overlies the Ohakuri Ignimbrite dated at c. 240 ka, and is overlain by younger alluvial sands and gravels. Individual zeolite deposits contain 50 - 80 per cent zeolite over a thickness of up to 45 m in thinly stratified vitric tuffs and are localised along NE-trending normal faults. Glass shards in the tuffs are replaced by the silica-rich zeolites mordenite and clinoptilolite. Amorphous silica (opal A), opal-CT, Kfeldspar and smectite are also present. The zeolites and other minerals are very fine grained (<10 8m), with open meshes of crystals that result in high porosities (52 - 70 per cent) in mordenite-rich tuffs. Zeolitic tuff samples typically have cation exchange capacities of 80 to 110 meq/100 g and internal surface areas of 25 - 58 m2/g, which combine to give high liquid and odour absorption capacities. The first zeolite deposit (Mangatete) was found in 1992, and this and the Twist Road deposit are worked by quarry benching into the side of hills. The zeolitic tuffs are dried and crushed to produce a variety of products including adsorbents for soaking up oil/chemical spills and animal wastes, animal feed supplements, water treatment, and sports turf and slow release fertiliser. The Ngakuru zeolite deposits formed at shallow depth (<100 m) along fault zones from reaction of glass-rich tuff beds with groundwater-diluted geothermal water during the late Quaternary, and are as young as 8500 yr BP from 14C dating of plant material in sinter associated with the Mangatete deposit.

Jan 1, 2005

Brisbane based and listed on the ASX, Eastern Corp is pursuing the development of coal projects in New Zealand. There are various reasons why New Zealand coals are of interest û substantial resources, stable political/economic environment, close to Asian markets. In just over 12 months, Eastern has secured an operating coal mine (Cascade) and a prospective exploration area (Whareatea West), both on the Denniston plateau region, on the south islandÆs west coast. A key focus of activities is the development of relationships with key stakeholders and the promotion of the local economy.   Certain barriers may exist to the entrance by foreign companies into the New Zealand coal mining sector. These include geological challenges provided by the heavy faulting of the coals, port and rail infrastructure constraints, and the ægreenÆ factor.

Jan 1, 2005

Scale build-up in titanium palladium alloy spent electrolyte heat exchangers in the residue treatment plant commissioned at Risdon, Tasmania in 1971 was shown to be a mixture of manganese dioxide and anhydrite (CaSO4). The manganese dioxide was deposited as a result of thermal decomposition of permanganate ions present in the spent electrolyte. It was shown that deposition of manganese dioxide and associated anhydrite scale could be prevented by prior reduction of permanganate ions to the manganous (Mn++) state by the addition of ferrous ions. In the plant this was conveniently accomplished by injecting into the inlet line to the heat exchangers sufficient zinc plant solution containing ferrous sulfate to decolourise the spent electrolyte. This action prevented deposition of such scale for another 21 years, until the heaters were finally decommissioned in March 1992. Measurements indicated that addition of the reducing solution lowered the anodic potential of the titanium alloy by 200 - 300 mV (depending on the solution resistance), but that it was still +300 to 400 mV with respect to a standard calomel electrode. It was shown that, if necessary, a small impressed current could be applied to provide anodic protection. Before scale deposition was overcome by the addition of ferrous sulfate solution, badly scaled heat exchangers were cleaned by recirculating a solution of hydrogen peroxide in spent electrolyte or dilute aqueous sulfuric acid, after laboratory testing of a variety of possible solvents for the scale. Corrosion tests indicated that attack on the titanium alloy by the acidic peroxide cleaning solution was insignificant.

Jan 1, 2005

By J Harmse

This paper deals with the modernisation of the brakes on an electrically coupled Blair multi-rope hoist and covers the removal of the old calliper brakes and hydraulic control system, and its replacement with brake discs, disc braking units and hydraulic control systems. The paper covers the braking requirements of the hoist, which is made up of two electrically coupled single-drum hoists, together with the theory behind the choice of brakes and control systems supplied. The paper also covers the project logistics that were required in order to install and commission the new brakes and control systems with the minimum disruption to production on the only rock hoist on a major production shaft. Items covered include the modifications to civil works, pre-installation of bearing lubrication systems, brake discs and hydraulics and the interfacing of the new hydraulic control system to the existing electric control system. It had to be designed to be compatible to a new electric drive and control system due for installation at the end of 2005.

Jan 1, 2005

A metallurgical balance drawn around a mineral processing plant or smelter must involve all process streams crossing the plant boundary. Modern sampling theory, as formulated by Gy, and sound statistical method can be used to determine the uncertainties in the observed assays for the set of balance analytes and in the mass flow rates of the process streams for the balance period. These uncertainties can then be used together with the material balance equations to arrive at adjusted component mass flows that satisfy the material balances exactly. To determine whether or not the data is consistent with the level of uncertainty in the data and with the material balance equations, a goodness of fit test is applied. This goodness of fit criterion is the principal tool to quantify the quality of the material balances. The mathematical structure of the statistical material balance problem poses a number of challenges. For example, while the variances of the adjusted component mass flows do not vanish, the variances of the sums of the adjusted component mass flows about each balance node do vanish, simply because the balancing computation demands that the balances close exactly. Even though it can be shown that the variances of the adjusted component mass flows are always lower than the estimates for the corresponding unadjusted component flows, it is still not possible to construct a confidence interval on the component mass flow into (and out of) a balance node using the adjusted component flows. On the face of it, such a confidence interval is exactly what is most desired from the balance calculations. The problem arises because the balance problem is a data adjustment rather than a parameter estimation problem. It is possible, however, to calculate the recovery of a component to a product stream and determine a confidence interval for the recovery value. It is also possible to calculate an uncertainty in the mass flow of any balance species in any process stream, before and after balancing.

Jan 1, 2005

By S C. Dominy

The Bendigo Goldfield is located in the state of Victoria, Australia, and is one of a number of quartz-reef fields that make up the greater Central Victorian Goldfield. At Bendigo gold particles are characterised by their very coarse nature, ranging from below 100 to over 10 000 ¦m in size. Some 60 per cent of the gold occurs in particles greater than 1000 ¦m in size. This characteristic ensures that the mineralisation is very challenging to both sample and evaluate. Diamond drilling provides a measure of geological structure, but is a poor measure of in situ grade, understating it by up to 75 per cent. Drilling combined with on-reef development, bulk sampling and geological interpretation has been used to define Indicated Mineral Resources. For grade control, a balance had to be sought between sample representivity, cost, turn around time and practicality. Sampling of extreme nugget effect deposits generally requires the use of bulk sampling in order to be representative. However, the cost and turn around time is significant. As a result, a 50 kg micro-bulk sampling system has been introduced that attempts to overcome these problems by providing a fast, practical method that can discriminate between ore and waste. As the mine passes into production, grade control will increasingly become dependent upon geological data collection and interpretation.

Jan 1, 2005

By J Austin, R Bitencourt

Differences between the long-term model (LTM) and mine geology system (MGS) grade control block-outs on a blast block scale can impose difficulties to planning crusher feed grade and tonnes on a monthly to weekly blend basis. Detailed geological input to short-term planning has been integral to improve the performance and reduce risk in six-week to three-month production schedules and local variability in tonnage and grades is often not accurately represented in the LTM. The challenge of producing to combined target specifications from different mine sites in an integrated mine to ship business has been reduced with the creation of blast blockout-based short-term model. These short-term blast block models (STBBM or STM) are robust predictive tools created for upcoming benches of current mining areas by firstly collecting data from the pit in the form of bench and face mapping and projecting the structure and stratigraphy down to the next bench. A wire-frame of the projected contacts based on material destination from production blockouts is created and then checked against the LTM. Blast block data from the bench above including assay results and material logging is extracted and validated according to the projected wire-frames (geozones). Individual blast blocks and a full block model are created for each bench production defined by the STP (bench plans). Data output from the STM is in a compatible format for import into scheduling specific software packages. Additional information is incorporated into the STM to allow querying of drill penetration rates, predicted powder factors, material hardness and feed type to further aid in the production planning process and cost forecasting. To date, reconciliation of the STM has been pleasing and certainly an improvement on the LTM, especially in areas where variability is higher due to geological complexity. Short-term predictions derived from in-pit geological observations allow mine planners to more confidently decide on mining block sizes and schedule tonnages and grades, reducing the risk component attached to developing production schedules based directly upon long-term orebody models and mine plans.

Jan 1, 2005

By M Dunglison, P M. Cameron

Simultaneous mass-balancing of a mineral processing flow sheet results in adjustments to each data point that reflects the accuracy and precision across the full set of data. In this way, all the good work that goes into designing the sampling and analysis protocol for each sample point is leveraged in order to produce a æbetterÆ set of balanced numbers for every sample point in the circuit. Few operating plants employ whole of circuit balancing techniques to produce reported operating results. This situation is changing with the application of mass balancing technology which utilises redundant data for production accounting and metal reconciliation from product to ore source across multiple phases and multiple time periods. Mine and plant data can now generate credible information to improve productivity. Mine and plant personnel can now use consistent data sets for review and planning. Decisions based on balanced data can be made quicker and with increased confidence.

Jan 1, 2005

By G A. Partington

Recent research has highlighted the potential of a relatively new style of gold mineralisation related to granite intrusion. New discoveries in Alaska, Central Europe and Asia and Eastern Australia with total resources of 1600 t Au offer attractive targets for regional exploration in areas which may have been overlooked in the past. A spatial information system was developed to target granite-gold systems in eastern Australia and the West coast of New Zealand, using well constrained geological and exploration models derived from current research. Target areas were recognised in Queensland, New South Wales, Victoria, Tasmania and on the West Coast of the South Island of New Zealand that have similar spatial data relationships to known granite gold mineralisation elsewhere in the world. The second phase of the modelling better constrained the regional scale target areas by including more detailed geological, geochemical and geophysical data in the GIS to develop prospect-scale targets and to allow the acquisition of tenements over these areas. A geological review of each target area was carried out in the field to put the GIS models into context. The fieldwork has highlighted the potential for this style of mineralisation in New Zealand and will increase investment in mineral exploration and development in New Zealand in the near future.

Jan 1, 2005

In Finland fogging in mine ramps is a common problem. Fog forms when warm and humid exhaust air moves upwards the ramp, where the skin temperature of surrounding wallrock decreases to about 10¦C. Changes in fog thickness and lengths of fog-filled parts of the ramp depend at least on climatic conditions outside, diesel equipment usage in the mine, and the length of working sequence at a time. In this study fogging problems in three different mines, namely Orivesi mine, Louhi mine and PyhSsalmi mine, with different ore types, different layouts, and different depths are presented and compared. All these mines use diesel equipment and the ramp is used as an exhaust air route. In two of these mines the ramp is used as a haulage road and in the other for supply and repairing, checking, and surveying purposes. Measurements of humidity, temperature, air velocity, and dust content were performed in these mines. The measurement results, as well as field observations are presented, compared, and discussed. The results show that fog is observed in areas with high relative humidity values when air temperature and dew point temperature are less than 3¦C apart from each other. Air velocity values were high in many areas. In addition, measured particle concentration values were mainly high in areas, where fog was observed. A short literature review of recent fog formation studies is also presented. It demonstrates the complicacy of the fog formation process. Similarities and differences concerning fog problems in the ramps are found and presented. As already a lot of new information is gained, the continuation of research is considered plausible to find more economical ways of solving and preventing this problem in the future.

Jan 1, 2005

By P Bonniwell

As a part of the Newcrest, Telfer Expansion Project, a consortium of Australian, Canadian and South African Mining Contractors in joint venture have been contracted to develop the hoisting shaft. The parties namely; Byrnecut Mining Pty Ltd, Murray and Roberts RUC and Thyssen Mining Construction of Canada Ltd have combined their individual expertise to excavate the shaft. There is a particular emphasis on the use of proven shaft sinking techniques from North America and in particular integrating electric hydraulic drilling equipment and personnel from the Canadian Mining industry. The Telfer hoist shaft when completed will have a finished diameter of 7.1 metres and extend to a depth of 1170 metres below the collar. The shaft will be fully concrete lined and will later be equipped for hoisting ore from the Telfer deeps at a rate of five million tonnes per annum. The shaft when completed will be the largest shaft ever completed in Australia on a volumetric basis. This paper will examine the technical aspects of the shaft sink, as well as exploring the integration of personnel and equipment from the frozen prairies of Saskatchewan, Canada into an operation in the Great Sandy Desert of Western Australia. What are the spin-off benefits for the development of other shafts within Australia?

Jan 1, 2005

By G M. Hoffmann

Utilisation of lower grade (Jigging technology has progressed to a point where SishenÆs 50 to 60 per cent Fe run of mine (ROM) material, once considered as waste, can be beneficiated to produce a saleable 64 per cent Fe product. This has been confirmed through appropriate beneficiation testwork. Consequently, Sishen can now produce saleable product from material not currently included in the resource definition, significantly increasing the resource base of the mine and ensuring higher resource utilisation. Mine planning utilised the geological models to produce detailed planning schedules, reflecting the current and SEP plants separately, optimised to comply with product specifications of both the current and SEP plants and to confirm the viability of the low-grade resources identified as SEP feed material. The SEP product specifications have been derived by optimally matching iron ore market requirements with the revised resource base. A 64.0 per cent Fe lump product and a 63.5 per cent Fe fine product are the optimal SEP products. The SEP plant will be able to produce 10 Mtpa at an average yield of 60 per cent and a lump to fine ratio of 62:38. The plant consists of five major sections: namely crushing, material preparation, beneficiation, final product handling and quality control services. Maximum integration with the current Sishen plant was considered. Kumba currently has an agreement with Transnet to rail up to 23.5 Mtpa through the Sishen Saldanha iron ore export channel (IOEC). Transnet and Sishen Iron Ore Company have signed a Definitive Agreement that deals with the expansion of IOECÆs capacity, which increases KumbaÆs entitlement from 23.5 Mtpa to 35.0 Mtpa. The detailed enviro-legal impact assessments for the SEP indicated that the project has low enviro-legal risk as a result of it being a brownfields project incorporated into the current Sishen operations.

Jan 1, 2005

Froth flotation is widely used for the separation of particulate materials in the world. It is a complex process whose operational behaviour in process plants is difficult to predict. A comprehensive phenomenological dynamic flotation model was presented at the 1982 IMPC. This model uniquely linked the particle/bubble interactions and water transport phenomena to the flotation cell hydrodynamics. The model was used as a dynamic framework to analyse and develop process optimisation strategies. New developments in mineralogical characterisation, real time information management systems and data validation simplify the implementation of flotation technologies for mine to mill grade recovery optimisation. With recent developments in software programming, dynamic simulation enables process engineers to develop process alternatives interactively. This paper presents such an implementation of current process analysis tools and an updated froth flotation dynamic model. It demonstrates how this new environment can be used to improve our technological knowledge of flotation, eg alternative bubble/particle attachment and detachment microprocesses can be incorporated. The dynamic flotation model has several manipulated variables (such as feed flow rate, per cent solids, aeration, wash water flow rate, frother flow rate, specific power energy (impeller speed/delta pressure), cell geometry and tails flow rate) and evaluates the dynamic effects of these variables on grade and recovery.

Jan 1, 2005

By H Jalalifar, N Aziz

In the ten years since the University of NSW proposed a pillar design methodology for bord and pillar operations, the Australian coal mining industry has changed substantially. What was primarily a bord and pillar design approach is now being applied to chain pillar design in longwall mines where the requirements are substantially different. The dimensions of chain pillars can impact on tailgate conditions (roof, rib and floor), seal performance, and surface subsidence. The status of chain pillar design practice in Australia is reviewed, with a focus on defining pillar strength, chain pillar loading, and assessing the performance of the roof/pillar/system. A new pillar strength equation is proposed for Australian coal that applies for all width/height ratios. An alternative analysis of probability of failure of chain pillars is presented.

Jan 1, 2005

By S Pigram, G J. Jameson

This paper is concerned with the tracking of particles in the froth phase of an aerated water/glycerol mixture. Experiments have been carried out in a specially designed laboratory flotation cell that allows formation of a deep froth. Phosphorescent tracer particles of various sizes were injected into the centre of a froth column where they were excited by ultraviolet lights, positioned at the back and front of the column. The motion of particles was captured on a digital camera with a green filter. The images from the digital camera were then transferred to a computer and an image analysis program was used to convert the colour intensity to the concentration of particles at each location within the froth. The tracer technique was used to determine the dispersion of hydrophilic particles and the variation of the concentration of solids with axial and radial positions.

Jan 1, 2005

Callie underground gold mine is part of the Newmont Tanami Operations, and is now the primary provider of ore to the Granites processing Mill. The Callie underground mine has produced in excess of 7.6 million tonnes (Mtpa) of ore, since production began in 1998, with a current production rate of 1.9 Mtpa. Callie underground uses sublevel open stoping with extraction through a combination of primary and secondary stopes. The primary stope filling strategy utilises cement aggregate fill (CAF) to allow full recovery of secondary stopes. The Callie backfill operation has had a continuous testing program in place during this time, which has resulted in a great deal of information available for post fill analysis. All CAF placement into primary stopes for Callie has been via surface boreholes and this has given Callie mine an understanding of some of the issues related to borehole design, type of linings to use depending on angle, depth and quantity of fill into stopes. Finally backfill barricades at Callie have undergone a number of changes during the time to optimise the design based on whether CAF or sand fill is used. This paper discusses the CAF backfill practices and testing methods used for backfilling operations at Callie.

Jan 1, 2005

By AMIRA P588 Research Team

This contribution summarises new knowledge and data, obtained during a three year ARCAMIRA funded research project, on the mineralogical and geochemical characteristics of hydrothermal alteration associated with low sulfidation, gold-silver epithermal deposits. These data are used to develop exploration vectors for use at both deposit and district scales, plus techniques have been established to distinguish ore grade epithermal systems from barren or low grade systems. Deposits investigated were Ladolam, Papua New Guinea, Gosowong and Mt Muro, Indonesia, Cerro Vaguardia, Argentina and Bimurra and Twin Hills, Australia.

Jan 1, 2005

By D Ziaja, W Jaspers

A brief history of the development of pneumatic flotation cells from early in the 20th century to the present day and a comparison to conventional cells demonstrates the efficiency and simplicity of design and operation of the ænew generationÆ of pneumatic cells. Recent successful testwork on phosphate minerals in the USA and a variety of coal types in Australia confirm the utility and efficiency of the design. The key aspects of this technology are improved recovery and selectivity with lower capital expenditure and operating costs.

Jan 1, 2005