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By Aalbers J. P A

The State Electricity Commission of Victoria (SECV) operates 13 excavators, 3 travelling stackers and 4 mobile slew conveyors in their three open cuts in the Latrobe Valley. The majority of these machines have been designed and constructed to a German design code current at the date of order. The SECV has always ensured that the machines were manufactured and erected to the appropriate standards. The SECV has a policy of having all machines inspected by an independent inspector every two years. These inspections are based on those carried out in Germany. The inspections have been carried out by inspectors from Germany who have the necessary experience to do similar work in German open cuts. Major faults found during the inspections have been repaired, however,the gradual breakdown of corrosion protection system has continued. The structures on some machines have areas of bad corrosion. This, coupled with wear on major mechanical equipment, would require an extensive outage to overhaul the machines. Refurbishment of Hazelwood Power Station will result in higher levels of production and extended life for the station. This will require improvement in the total output from Morwell Open Cut (MOC). To meet this increased coal demand, the open cut equipment will need to operate more efficiently and for a longer period of life.

Jan 1, 1989

By D Alexander

For nearly 100 years, the flotation plant metallurgist has often wondered what is happening æbeneath the frothÆ. To assist in unravelling this mystery, new technology has been developed as part of the Australian Mineral Industries Research Association (AMIRA) P9 project, to measure gas dispersion characteristics (such as gas hold-up, superficial gas velocity and bubble size) in industrial flotation cells. These measurements have been conducted in a large number of cells of different types and sizes by researchers from the Julius Kruttschnitt Mineral Research Centre (JKMRC) and JKTech. A large database has been developed and the contents of this database are described in this paper. Typical cell characterisation measurements show a wide spread in values, even in the same cell types and sizes performing similar duties. In conventional flotation cells, the typical gas hold-up values range from 3 - 20 per cent, bubble sizes range between 1 and 2 mm, and superficial gas velocity ranges from 1 to 2.5 cm/s. The ranges of cell characterisation measurements given in this paper will enable plant personnel to compare their operation to other similar types of operations from around Australia and the rest of the world, giving opportunities for further improvement to flotation plant operations.

Jan 1, 2005

By N Kusuma

Recoverable copper and gold estimates for resource models and ore control routing decisions at Batu Hijau were initially based on flotation testwork from several commercial laboratories. Due to the greater number of copper and gold assay grade available, regression relationships were developed between assay grades and flotation recoveries. Other recovery controlling variables such as oxidation and lithology were included to improve the regression models. With additional drilling, more flotation work was carried out and the regression models were revised to include the new flotation data, also alteration classification and in situ pH. The regression models were replaced in favour of spatially derived models for ore control and short range mine planning. To harness local variability in the block model, blast hole flotation testing is carried out in unison with routine grade assaying. Recovery data are processed (kriged) simultaneously with grade assay data prior to ore polygon delineation. Short range mine planning utilises this model in conjunction with a spatial recovery model derived from drill core flotation data. Long range mine planning utilises the æhybridÆ recovery model whereby the globally robust regression recovery models are overprinted by a spatial (kriged) recovery estimate where flotation data density is adequate (Phase II reserve).

Jan 1, 2002

By Batterham RJ

A 'research model' can be used to investigate cause and effect relations and generally improve the understanding of extractive metallurgical processes. As such, it is a useful research technique which complements the traditional methods of laboratory and plant measurement. The procedure of model development is iterative and involves observation of the process, hypothesis of phenomena, prediction using mathematical descriptions of the phenomena and comparison of predictions with real-world measurements. Lack of agreement of predictions with real-world measurements usually indicates an inadequacy in the hypotheses and necessitates revision. Experimentation has an integral role in the process of model development but its emphasis is different from that when experimentation alone is used to study processes. Since a process as a whole is investigated by using a model, experimentation is restricted to the study of specific phenomena to aid the description of these in the model, to the characterisation of the raw materials (for initial values of the model parameters) and to the measurement of physical and chemical constants required in the model equations. Similarly, plant measurements are made for the purpose of comparison with the model predictions not to establish cause and effect relations. This makes plant experimentation much simpler and cheaper'since most measurements-can be taken during normal operation.

Jan 1, 1984

By A Thornton, D Engelhardt, J Woodg

Grinding is a critical part of nearly all mineral processing operations. It is the largest consumer of energy on the mine site (and thus indirectly a producer of greenhouse gas through the generation of electrical energy at the power station). Since comminution is one of the main consumers of electrical energy worldwide, efficient control of grinding mills is of paramount importance. Mill Auto-Pilot is a control system developed for SAG mills to stabilise load and power and improve the efficiency of control and increase throughput. A dynamic, mechanistic model of the grinding circuit is used to determine circuit parameters which can not normally be measured using conventional instrumentation. The circuit model is built from models of the unit operations (such as conveyors, SAG mills, cyclones, sumps, etc), and so captures the dynamic complexities and interactions of real circuit operation. CSA Mines at Cobar NSW accepted an offer to be the reference site for Mill Auto-Pilot and the system was installed in March 2004. In this application the model is used to predict mill load mass, mill solids residence time and cyclone underflow density. These parameters are used to control mill load, power and mill discharge density. The outcomes of the introduction of Mill Auto-Pilot at the CSA Mine are discussed.

Jan 1, 2004

By P Trotta

The majority of water to the Olympic Dam mine and the nearby townships of Roxby Downs and Andamooka is supplied from the Great Artesian Basin (GAB). There are no permanent local water sources available to Olympic Dam. The use of water from the Great Artesian Basin by Olympic Dam receives considerable attention by BHP Billiton and is extensively regulated by the Government of South Australia. Olympic Dam has robust business management systems in place to ensure the sustainable use of water from the GAB including ISO9001 and ISO14001 systems to deliver the targeted outcomes and obligations of the Olympic Dam Environmental Management and Monitoring Program. The management systems ensure that Olympic Dam retains accountability for its water demand from the GAB over the life of the mine. This accountability has delivered continuous improvement in water use efficiency driven by operating discipline, implementation of water saving projects, using water on a fit for purpose basis including substitution from non-GAB sources, and risk management to prevent and mitigate water supply disruptions to Olympic Dam and Roxby Downs. Since the establishment of Olympic Dam, BHP Billiton has funded a reduction in GAB water flow from bores, previously going to waste, that is greater than the annual average flow used by Olympic Dam.

Jan 1, 2009

By Steinbrucker G

Improvements in mining by the application of electronics necessitates analy-sis of the objectives and problems. A detailed analysis has shown that increased tunel-ling performance is one of the most important objectives. In mining, the environmental conditions for machines, their handling and servicing are very hard. Therefore a health monitoring system for tunnelling machines in hazardous areas has been developed. This system measures operational parameters, such as-flow, pressure, temperature, etc., de-rives forecasts of possible failures from these values, and assists maintenance person-nel. Important data are transmitted to a surface computer via telephone cables. Health monitoring is based on the cognition that slow deterioration of characteristic parame-ters, e.g. fluid loss, are symptoms of wear. Sudden changes of machine parameters indi-cate sudden destruction. Computer technology is very advanced, but transducer technolo-gy has not,been able to keep pace. Filling the yawning gap in the mining industry is a challenge to technology and requires special techniques. Machine monitoring and automa-tion in underground mining is still in its infancy. A lqt of development and research work is still necessary. The risks are great-The expected benefit due to increased min-ing performance (up to 5 %) justifies the risks in development.

Jan 1, 1985

By Hutchings SG, Skimmings T

This paper describes the results of the field application tests at Miike Colliery on the integrated automatization of the longwall mining system for medium thick coal seam. The purpose of the research is to develop an automatic longwall mining system which can be controlled accurately from outside of the face, and the ultimate goal is an eliminate of men from the face. Presently, the field test is being conducted in Yotsuyama mine following to a success in the performance test on surface. Remote Batch Control System for shield supports has been adapted to operate all supports from the control panel located at the entrance of the face. Remote monitoring and control system of the drum shearer has also been tested. The system makes it possible to operate the shearer either at the main gate or full automatic. Productivity and safety will be substantially improved as those systems enable to eliminate all workers from the face under the severe working conditions with high ground pressure and hot and humid atmosphere due to increasing mining depth. So far, we have been satisfied with the results of the field test and those system will be an effective countermeasure to operate the face with a high risk of rock-burst.

Jan 1, 1987

By Atalla YM

Steel rolling mill product finishing pro cesses gradually become or often already are unsuited for current production and marketing conditions. Indications are made as to what has been done to (i) rectify situations of this kind and, (ii) to reduce both product finishing time and costs. The principal features of two separate case studies are reviewed, these being (a) the finishing-end of B.H.P.'s Newcastle o.2 Merchant Mill and, (b) a mixed functions finishing yard and warehouses group (known as he Merchant Mills Loading Yard) which has been perating for a number of years. The areas in ach case are identified as a system while the arious functions, principal product streams nd processing equipment are respectively iden- ified as sub-systems and system elements. etails are given of the models used in each Sub-system dependency on the system as a le is traced by means of an information and ision analysis or by time studies and the sonableness of the system elements is deter- ed by computer programming or by simple com- ison methods. The-accumulated data is used derive improved mill finishing-end or Load Yard,functioning concepts according to pro- rules whilst at the same time considering

Jan 1, 1975

By A Tomsett, R Kidd, Z Casley

Bivariate recoverable resource estimation aims at predicting the recovered metal for a secondary variable when a cut-off is applied to a primary variable. The choice of a consistent geostatistical model is advisable to allow a robust estimation from exploration data of the primary and secondary metal recovery functions on a generic selection block (selective mining unit û SMU) within large panels. Ore processing decisions at Lihir Gold LimitedÆs Lihir Gold Mine are based on the gold and sulfur estimates of SMUs from production (grade control) data. The predictive model from exploration data at Lihir is based on the estimation of a recoverable resource for gold by Uniform Conditioning (UC), with an estimate of the sulfur grade being provided by Ordinary Kriging of panels. While univariate UC is adapted to the diffusive nature of the gold mineralisation (Ladolam orebody) at Lihir, the independent estimation of sulfur, through ordinary kriging, fails to capture the potential spatial correlation that exists between gold and sulfur mineralisation. This paper presents a practical implementation of bivariate UC, which better represents in the resource model the spatial correlation between gold and sulfur. Incremental economic gains through improved definition of material categories and scheduling are investigated, and the particular impact on the process of geological interpretation and domaining is emphasised.

Jan 1, 2009

This paper investigates dry drilling as a feasible alternative to meet current requirements for improvements in mining productivity in an increasingly competitive world.A field test program was conducted in the surface facilities of a hard rock mine in Sudbury, Canada, to investigate the potential use of dry drilling in underground bulk mining as a conceivably faster and more economical method than wet drilling. The test work consisted of the monitoring of advance rates and bit life while a series of 165 mm diameter holes, wet and dry, were drilled with compressed air at both mine (0.69 MPa) and high (1.72 MPa) pressure levels. The results indicate that penetration rates can be increased by approximately 24 per cent by drilling dry with high air pressure and by approximately 27 per cent by drilling dry with mine air as compared with wet drilling under the same conditions. Dry drilling also has the effect of increasing bit life by up to 69 per cent. An economic analysis for typical hard rock mines indicated that drilling productivity and cost savings can be increased by approximately 23 per cent when dry drilling is utilised.The testing program indicates that dry drilling has the potential to become a feasible technique with regard to performance, productivity and costs.

Jan 1, 1991

By Shoobridge PH, Firkin GR

The Imperial Smelting Process blast furnace (ISF) of the Sulphide Corporation Pty Limited zinc/lead smelter at Cockle Creek, New South wales, has in recent years greatly increased its consumption of low grade feed materials, and as a consequence has experienced periods of unstable furnace operation. Routine examination of production sinter, including softening characteristics and micro- examination, showed that the problems had been caused by an increasing silica content in sinter. The silica entered a low melting point glass phase containing calcium and lead oxides. The relative volume of this phase increased until it formed a continuous matrix in the sinter structure and this made the sinter more likely to soften at lower temperatures. Premature softening caused loss of operating stability in both the shaft and hearth of the ISr. The required sinter structure for ISF smelting was found to consist of a network of intermeshing, refractory crystals which provided skeletal strength for sinter lumps even after the glass phases had begun to soften and melt. With an understanding of the importance of microstructure and softening temperature of zinc/lead sinter and the progressive identification of those factors in sinter production which affect the microstructure, a significant improvement in stability of operations has been possible.

Jan 1, 1980

By Esaki M, Nishimura K

This paper describes the results of the field application tests at Miike Colliery on the integrated automatization of the longwall mining system for medium thick coal seam. The purpose of the research is to develop an automatic longwall mining system which can be controlled accurately from outside of the face, and the ultimate goal is an eliminate of men from the face. Presently, the field test is being conducted in Yotsuyama mine following to a success in the performance test on surface. Remote Batch Control System for shield supports has been adapted to operate all supports from the control panel located at the entrance of the face. Remote monitoring and control system of the drum shearer has also been tested. The system makes it possible to operate the shearer either at the main gate or full automatic. Productivity and safety will be substantially improved as those systems enable to eliminate all workers from the face under the severe working conditions with high ground pressure and hot and humid atmosphere due to increasing mining depth. So far, we have been satisfied with the results of the field test and those system will be an effective countermeasure to operate the face with a high risk of rock-burst.

Jan 1, 1987

By Giuli M, Barnaba P, Sacerdote R, Tammaro F

Following a theoretical consideration of the effect of flooding, fluidisation and softening on blast furnace blowing limits, results are presented which show the effect of these parameters on operation. Industrial trials on Oscar Sinigaglia No. 4 BF are reported and results compared with those obtained theoretically and in the laboratory. It is shown that in these trials the furnace operated at levels of fluidisation very much (80-90%) below those theoretically calculated whereas in some cases (high proportion of sinter) actual hot metal output was near the calculated flooding limit. However, it was observed that as the sinter percentage decreases also actual productivity becomes lower than the one caused by flooding. This gap, which increases as other ferrous components (essentially acidic) replace the basic sinter was explained by the softening of the burden under bosh conditions. Softening indices measured on the individual materials yield support to this explanation. Coke rates data show that for approximately every one percent increase in the basic sinter in place of blended sized ore, a coke rate decrease of 1.1 kg/thm results. For acidic pellets this value is 0.6 kg/thm. Results of breakdown and reduction characteristics are also given and their indices compared with actual pt oduction. Measures to improve operations are proposed.

Jan 1, 1975

Discovered in 1954 and mined since 1966, the X41 copper orebodies have produced over 143 Mt @ 3.3 per cent copper. By June 2002 the production from these orebodies had depleted the Mineral Resource to 36.6 Mt @ 2.8 per cent Cu (including 31.5 Mt @ 2.5 per cent Cu combined 2002 Ore Reserve). Mine production will ramp down to cessation beyond ten years. The 2002 Copper Business Study was commissioned to review the status of the Mount Isa copper business and to optimise the long-term strategy of the operations. The study resulted in a vastly improved geological and geostatistical model, and financial studies led to the optimisation of mine cut-off grades. Utilising these new models, a near-mine target generation workshop was conducted by the copper stream geology team. The workshop focussed on exploration for new ore sources and the extension of existing orebodies to supplement the Mineral Resource inventory for future conversion to Ore Reserves. Several prospective targets were identified and the Conceptual Northern 1100 Drilling program was subsequently designed. This paper shall discuss the practicalities of near-mine target generation in Mount Isa, the issues faced when locating and preparing drill sites in a mature mine environment, and the preliminary results of the drilling program so far.

Jan 1, 2003

This paper describes modern long-term mine scheduling and gives an example of its application. It then discusses the obstacles to the implementation of such schedules.

Sep 26, 2011

By M S. Powell, M P. Bueno

The commonly used SAB, SABC and run-of-mine (ROM) ball mill circuits can achieve high throughputs with good operating stability. However, these circuits consume a substantial amount of grinding media, which can have a substantial impact on the OPEX and the æcarbon footprintÆ, specifically when viewed as an æembodiedÆ energy input. On the other hand, fully autogenous (AG) circuits can operate at much lower operating costs, but with limited throughput. The control of AG mills, fed by ores with hard and soft components, can also be challenging, due to the sensitivity of the mill to the ratio of hard to soft components.In this paper, a multi-component modelling approach was used to demonstrate that the harder component should be used as grinding media, and its use should be kept to a minimum to avoid reduction in the mill throughput. There is an optimal blend of hard to soft, and any optimal blending condition is both ore-dependent and mill-specific. Establishing this blend is challenging, and consequently discourages the use of autogenous mills. The new modelling approach addresses this challenge by providing a quantitative prediction of the influence of blending soft and hard components in a mill. This prediction can then be used to establish the required blend for maintaining a stable and efficient operation in autogenous grinding mode.CITATION:Bueno, M P and Powell, M S, 2012. How to use hard ore components as grinding media, in Proceedings 11th AusIMM Mill OperatorsÆ Conference, pp 31-36 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Oct 29, 2012

The theme of my address to your Institute, indeed its name, is "The Mineral Industry - What Next?" Knowing that I was required to make four appearances, and not wanting to be too repetitious, I wrote a rather long speech of which I will deliver various sections at different places, with a common introduction. Specific areas I have addressed are "Exploration", "New sources of minerals and energy", and "Mining and metallurgy of the future".

Jan 1, 1984

At many locations in Australia the decommissioning of mining operations will require the disposal of excess water. If the water is contaminated its disposal may be restricted by government guidelines. The timing of water disposal may be critical to the schedule of close-out. The uncertainty of the annual rainfall input to the water storage and disposal system may determine the success or failure of close-out. The uncertainty associated with any outcome can be used to determine the reliability of the system, or inversely its risk. The technique of Monte Carlo simulation, using the uncertainty in annual rainfall, is applied to quantify the risks associated with water disposal as part of the requirements for close-out in two case studies. In both case studies it is assumed that water disposal is via evaporation only. The first case study is the Nabarlek operation, located about 270 km east of Darwin. This project is required to complete the engineering work associated with its close-out by December 1995. The second study investigates the situation of close-out for the Ranger Uranium Mine, about 250 km east of Darwin. It should be noted that the Ranger mine was examined as part of the annual update of its contingency rehabilitation plan and the probability of implementing the plan is extremely small. The probability of success for the Nabarlek case varied from less than ten per cent to greater than 95 per cent depending on the management strategy. Four possible strategies were investigated for the Ranger mine with the chance of success varying between 20 and 95 per cent. The estimation of the evaporation rate and the area allocated to evaporation was critical in both cases. By applying seasonally based evaporation pan coefficients determined on site, rather than an average monthly value of 0.75, the chance of success was improved by up to 35 per cent for Ranger. Simulation modelling is able to provide information on the likely response of mine water management systems and the level of risk. This information is required to efficiently plan and manage the disposal of water for close-out.

Jan 1, 1994

By E Philippa, J Vitanza, C Hawtin, B Miller

B Miller , E Philippa , C Hawtin and J Vitanza

Mar 22, 2022