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The competitiveness and future growth of the Australian mineral resources industry face a number of challenges. The paper addresses key factors likely to influence the attainment of high performance and continuous improvement including organisational leadership, management/employee relations, technology, safety, health and the environment. Business practices such as benchmarking, Total Quality Management and re-engineering to achieve process and performance improvements are commented on. Future success for the industry will largely hinge on global business skills, a sustained focus on Quality principles and achieving performance through people.

Jan 1, 1997

By M Monaghan, B S. Gregory

The Geita Gold Mine is located 80 km southwest of the town of Mwanza in the north-west of Tanzania and is 100 per cent owned by AngloGold Ashanti Limited. Open pit mining commenced at Geita in 2000. In 2011, the operation produced 494 000 oz at a cash cost of US$536/oz. This is a significant improvement from 2008, when 264 000 oz were produced at a cash cost of US$742/oz.A period of relatively poor operating performance at Geita was recorded over the period from 2006 to 2009. A period known at Geita as æthe turnaroundÆ commenced in 2009, and has been remarkable to say the least. Over the last couple of years the mine has embarked on a journey, which saw various interventions and initiatives. Among the key initiatives were Project ONE (which focuses on business process framework, systems for people and safety transformation), asset integrity, fatigue management and contract mining of satellite pits.Since the commencement of the turnaround at Geita, gold production has matched market guidance. The mine has returned to positive cash flow on the basis of strong performance on cash management, improved production and increased gold price.This paper explains some of the details of the mine operationsÆ improvements, how they were implemented, their relative contributions to improved mining performance and the path ahead to best practice. Observations will be made about some improvement rules that can be applied generally in open pit mining.CITATION:Gregory, B S and Monaghan, M, 2012. The path to best practice at Geita Gold Mine, in Proceedings Eighth Open Pit OperatorsÆ Conference , pp 41-48 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 18, 2012

By D Thornton, R Hodson, D Sprott

Blast fragmentation size distribution and thus blast design have been found to have a direct impact on the load and haul cycle through excavator dig time and bucket payload. Previous studies have demonstrated that by reducing the excavator dig time and increasing bucket payload, significant improvements can be made in both productivity and unit cost. Simulation work reported in the literature indicates that a 20 per cent improvement in dig time may result in only a three per cent improvement in load and haul productivity and unit cost. At the same time, a ten per cent improvement in bucket payload will directly translate to a ten per cent improvement in load and haul productivity and unit cost. Based upon these findings, extensive laboratory and field work have been undertaken in the past to correlate blast fragmentation distribution to bucket payload. In contrast, the literature reports limited studies quantifying the impact of blast fragmentation on excavator dig time. Field work was conducted at Placer Dome Asia PacificÆs Granny Smith Mine (Wallaby Pit) in Western Australia, concentrating on quantifying the impact of blast fragmentation on the dig time of a Liebherr 994 hydraulic excavator (shovel attachment with 14 m3 bucket). Fragmentation was assessed for each truck load of material using the Split Desktop system, while the excavator cycle analysis was conducted manually. Measured fragmentation P80 (fragment size at which 80 per cent of material passes) values ranged from 200 mm to 1200 mm. The field study investigated the impact of various fragmentation parameters (P20, P50, P80, cumulative per cent passing 250 mm size fraction, and uniformity index) on the average and total dig times. The results indicate that the fragmentation P80 provides the best correlation to average dig time (total dig time divided by the number of bucket passes to load a truck). The total dig time was found to be dependant upon the fragmentation P80 and the number of bucket passes to fill a truck. Monte Carlo simulation results, based upon these relationships, indicate a 26 per cent improvement in average dig time and a 12 per cent to 46 per cent improvement in total dig time (bucket passes ranging from 4 to 8), with a change in fragmentation P80 from 600 mm to 200 mm.

Jan 1, 2003

By D Pienaar, B McFadzean, C T. O’Connor

Collector and frother molecules in sulfide mineral flotation are thought to have separate roles in the flotation process, where the collector selectively hydrophobizes the mineral surface and the frother adsorbs onto the bubble surface, inhibiting bubble coalescence. Molecular interactions have been observed between these molecules which allow them to co-adsorb at each of the respective interfaces, improving pulp phase recovery. This study investigated the molecular interactions between sodium diethyl dithiophosphate (SDEDTP) and hexanol, and the mechanism by which these interactions improve the recovery of galena. In this study each of the respective interfaces were investigated for the adsorption of SDEDTP. The adsorption of SDEDTP on galena was measured by UV-Vis spectrophotometry and isothermal titration calorimetry. At the air-water interface foam stability and pulp bubble coalescence was used to quantitatively discern if there are interactions between SDEDTP and hexanol. Microflotation and induction time experiments were performed to determine the effect of SDEDTP, hexanol and their mixtures on mineral recovery and bubble-particle attachment. The results of all these tests were collated to determine if SDEDTP-hexanol mixtures synergistically improve sulfide mineral recovery. It was found that SDEDTP reduced bubble coalescence in the pulp demonstrating activity at the airwater interface. Together SDEDTP and hexanol synergistically enhanced foam stability. This indicated that there are attractive molecular interactions between these reagents. Even though DTP did not adsorb onto galena, DTP-frother mixtures synergistically improved the recovery and attachment probability of this mineral. Adsorption studies with aeration showed that DTP in the presence of a frother transfers from the air-water interface to the galena mineral-water interface during bubble-particle collision. It was proposed that the transfer of hexanol through the thin film enhanced the kinetics of film thinning between the bubble and the particle by destabilising the thin film thus improving pulp phase mineral recovery.

Aug 24, 2022

By Andrews B. S

The sinter plant at the Sulphide Corporation's Cockle Creek works produces a feed for the company's Imperial Smelting Furnace. The feed contains lead and zinc oxides and all the fluxes necessary for furnace operation. The quality of this feed is a major factor in furnace performance and the considerable flexibility of operation possible at the sinter plant has been used in efforts to achieve optimum operating conditions.Operating data is processed daily and information gathered from this source has led to three of the four improvements described.These improvements have resulted from elimination of gas recirculation, reduction of sinter returns sizing and alteration of ignition conditions and main layer fuel loading.

Jan 1, 1964

It is a facet of modern-day life that change, even of a revolu- tionary nature, normally passes without comment. People have become so conditioned to continuous improve- ments in every aspect of their lives that they would be surprised only if there were to be no change. This paper seeks to demonstrate the extent of technical change, and to indicate the need for a fuller advantage to be taken of the technologies available, or potentially available, to the profes- sion. It contends that the mineral industry has been particularly slow to embrace technical change, and has good reason to con- sider an improved attitude for both prosperity and survival.

Jan 1, 1988

By Molloy GR, Eaton RA

The crusher development programme for 7ft Super Extra Heavy Duty (SXHD) Symons cone crushers commenced in 1984. The main objective of the programme was to run the crushers at maxi- mum power for the full life of the liners. This would give a finer product sizing enabling grinding and flotation plant throughput to be maximised. The study was conducted along two basic lines of attack, the first main- taining an effective profile through the life of the liners, the second improv- ing the properties of the liners. It has been found that crusher liner life can be extended and crushing efficiency improved by modification of liner composition and profile.

Jan 1, 1988

By M Denton, M Rheinlander, S Mundell, M Broadgate

The manufacturing industry reinvented its approach to the manufacturing process by managing and measuring it end-to-end. This improved returns on production assets, improved information quality and reduced delivery time, resulting in larger net profits through cost reduction and improved cash flow. Today this approach is standard in the manufacturing industry. Resource development has many requirements in common with the manufacturing production line. These include: control of the various steps, transparency of the state of the process to various levels of the organisation and the overall efficiency with which the process is executed. The authors argue that the introduction of manufacturing execution systems (MES) concepts and technologies to resource development processes will lead to similar improvements in control, transparency and efficiency and could improve profitability and enable staff to work more effectively and make better decisions.

Jan 1, 2009

Copper-Cobalt hydrometallurgy has seen a resurgence in recent years with the development of projects in Zambia and the DRC. Many of the flow sheets are unique in their use of hydrometallurgical techniques to improve performance compared to the older types in current use. The emphasis has moved from direct copper electrowinning/stripping, with multiple stages of precipitation for removal of impurities and concentration of cobalt, to innovative use of solvent extraction and ion exchange with higher cobalt recoveries to final product. The poor quality direct electro-won copper has been supplanted with solvent extraction-electrowinning; with consequent production of LME 'A' quality metal. Many of the precipitation steps in cobalt recovery and concentration, have been replaced with solvent extraction; while the remaining precipitation stages have been enhanced with use of oxidants to improve impurity removal. Operating experience from two of these circuits has shown the benefits of the new technologies and the improved overall recovery of both copper and cobalt into higher quality products.

Jan 1, 2008

By C Sylvestre

Leaders have invested heavily in traditional safety management to improve safety performance over the years. This primarily involved: • fixing the environment (eliminating the hazard) • improving the system (more/less rules, procedures etc) • making safety more conscious (more/better interactions about the importance of safety). These approaches have helped improve safety performance significantly during the last 50 years and will continue to play a role in the future. Although these approaches may be part of an overall solution, they are not enough to prevent many incidents. Today, these three approaches are used more than before, and are used better than ever before. Yet, workplace fatalities in Australia have stagnated from 2013 to 2019, as have the number of incidents, even serious ones. In the USA, workplace fatalities have increased by 15 per cent in the same period.

May 5, 2022

By L Y. Yang, Z Wang

This work presents the fundamental properties of CITIC magnetite concentrate and its performance in pelletising and sintering. CITIC concentrate has been widely used in pelletising to produce pellets for blast furnaces. It is also used in sintering to benefit from its sintering performance. CITIC concentrate has excellent balling properties owing to its size distribution, particle surface properties, large specific surface area and balling index, leading to strong green pellets and product pellets. When used in sintering at appropriate levels, sinter bed permeability improves, productivity is increased while coke consumption reduces, and sinter strength improves.

Nov 8, 2021

By C Jenkins, J Jasper, Y Suryaputradinata, S Lozyk, M J. Hartmann

The primary objective of mining companies is to function as a profitable business by delivering products that fit customer requirements in a safe and sustainable manner. Optimum resource utilisation is a critical focus area to achieve this objective, and the long-term sustainable business performance of a mining company is determined by the extent to which this is achieved. Technology improvements and/or new technology development could improve resource utilisation. However, adding new projects to a Brownfield operation carries risk. Overall project schedules, tie-in schedules and safety risks normally receive adequate attention, but the introduction and integration of new technology to a Brownfield site also carries the significant risk of failure to achieve design performance (quality or throughput). This risk must be addressed via rigorous design phase risk assessments and piloting. Post commissioning, the effective metallurgical integration of any new technology/circuit/process plant into an existing process plant calls for critical assessment, through circuit performance testing, and optimisation to ensure alignment with design criteria. In addition, this approach provides clear focus areas for further optimisation of the new plant and additional opportunity for overall plant optimisation. Roy Hill recently navigated this process successfully, and this paper provides feedback on the journey that led to improved resource utilisation.

Nov 8, 2021

Development of aggregate resources for use in structural concrete has been encouraged in Japan to support infrastructure improvement and national land conservation. Natural aggregate is a valuable resource necessary for sound economic development, and its importance is growing. After completion of aggregate mining projects, planting and afforestation are implemented. But sandy soil in excavation sites is not optimum for the growth of vegetation, and many years are needed before forests are restored. Planting techniques should be improved to support efficient reforestation in a shorter period of time. For this purpose, problems hampering growth of vegetation must to be solved through application of physical and physicochemical techniques to ensure that the environment and the ecosystem will be conserved in project sites.

Dec 6, 2010

By Williams P, Hender A

The 1980s witnessed a major revolution in the application of airborne geophysics to mineral exploration. The now commonplace term `high resolution aeromagnetics' (HRA) evolved from advances in survey specifications, instrumentation, data processing and imaging techniques which greatly improved the quality and geological information content of the final maps. Although initially HRA was successfully applied in `hard rock' basement terrains, eg the Archaean Yilgarn Craton of Western Australia, the technique along with the radiometric and electromagnetic techniques is now gaining wide acceptance in all geological terrains including inaccessible sedimentary rock dominated mountain belts such as New Guinea for mineral and petroleum exploration. It is also being used in more and more diverse roles away from exploration, such as environmental monitoring. The main reason for this acceptance is of course the very cost-effective surface and sub-surface mapping capabilities of the various airborne techniques. Although the three main techniques (magnetic, radiometric and electromagnetic) have been in use for some time, they are continuously being improved. Recent developments include: ò better navigational positioning using real-time GPS systems (Geographic Positioning Systems) such as Picodas Navigation Systen (PNAV); ò the use of magnetic gradiometer systems; ò improved sensitivity and sampling rate of magnetometers; ò increased use of ultra detailed low level (

Jan 1, 1996

Secondary steelmaking (or ladle metallurgy) has been developed as a post- steelmaking ladle treatment to produce steel of superior quality. Its rapid growth has resulted from quality improvements, productivity increase, operational flexibility and process route economics. Advances in secondary steelmaking are very impressive during the past decade, and many commercial systems have been developed for performing one or more of the following unit operations: degassing, atmosphere regulation, reheating, refining with synthetic slag, rinsing gas treatment, injection of solid materials and alloying. The metallurgical requirements imposed by the current competitive steel market include more precise analysis tolerances, minimum level of detrimental elements, improved cleanness, demanding service performance and better processability. In most cases, these requirements could only be realized by the application of appropriate secondary refining facilities. Continuing developments in simplicity of design, cost advantage, quick cycle time, improvements in peripheral services such as refractories, instrumentation and in-situ analysis, extensive exploration of new applications, and the use of computer, can be expected. An exciting future is predicted for the widespread adoption of secondary steelmaking to perform most of the major refining functions over a variety of steel quality. It will also become a vital link in the total steelmaking process for production of tonnage steel at the large integrated steelworks and the mini-steelmills.

Jan 1, 1986

Competitive commercial circumstances internationally provide a prime impetus for miners to seek new technologies as a means to profitability and survival. Engineering and project management activities play a vital role in establishing, operating and developing the capital facilities used by miners. Computer based technologies are the single most important technology for maintain- ing competitiveness in engineering and project management into the future. Current applications of computers in engineering design and drafting are finding economic applications, computer-aids are more readily introduced, accepted and profitable. Computing technology is advancing very rapidly and on a broad front in hardware, software and communications. This technology advance is improving the ability of engineers and project managers to provide a high quality, responsive and low cost service which will improve in parallel with computer technology. As this technology advances, a key challenge is created for managers in selecting hardware and software, in developing people and organisations and in marketing the technology to advantage. While the future holds many exciting developments, people will still hold the key roles. While the nature of their roles may change, the final acceptance or rejection of technology will be by people, whether as users or owners, who will judge on the basis of whether their stake is improved or not.

Jan 1, 1986

Within the Business Process Improvement Program initiated at Placer Dome during 2003 was the Business Performance Management Project (BPM).BPMÆ s aim has been to extract productivity improvements from individual business units by providing a model for implementing leading practice based management process within the Placer Dome Group, sharing management best practice, injecting new management techniques and instilling a continuous improvement culture. The installation of an underground dispatch system has been a key component of the BPM project at Osborne Mine.Information capture and analysis allows for corrective action to be planned and executed before there is a material impact on the performance of a business unit. This paper briefly describes the principles and practices of effective business performance management, the four processes of a management operating system namely; strategic and tactical planning, implementation and reporting. The identification of business drivers, their measures and associated key performance indicators is discussed. The benefits of an underground dispatch system at Osborne with respect to safety, production and maintenance is described along with the installation process within the mining department that included its configuration, resourcing and roll out.

Jan 1, 2005

By T Haskell, Y Joe, S Dickie

A current trend amongst producers is the increase in dewatering of iron ore fines (<0.5 mm), due to an increase in wet beneficiation processes used to upgrade lower quality ore deposits, increased water content in orebodies located below the water table, and increasing focus on transportable moisture limits (TML). Vacuum filtration is commonly used for dewatering of iron ore fines, and as with all filtration processes performance decreases with particle size. Significant improvements are possible with the use of filter aids, usually anionic surfactants and flocculants. Anionic surfactants reduce the surface tension of the associated water, which is then removed more readily leading to improved filtercake moistures. Anionic flocculants used correctly can improve cake permeability, in turn, decreasing cake formation times and increasing filtration rates. In addition to increased throughput, savings and benefits for producers can include: moisture limit penalties, improved handleability, along with energy and water savings.The effect of filter aids on two iron ore fines samples from the Pilbara region were evaluated using a lab scale vacuum filtration unit. The first sample showed a reduction in the filtercake moisture content by 2.3 per cent weight/weight (w/w) with the use of BASF’s Drimax® 1234. For the second sample a reduction in the filtercake moisture of 3.4 per cent w/w along with an increase in filtration rate of 20 per cent was achieved by using a combination of Magnafloc® 5250 and Drimax® 1239 NF, as both filter throughput and cake moisture were considered important by site.CITATION:Haskell, T, Dickie, S and Joe, Y, 2017. The use of filter aids on iron ore fines, in Proceedings Iron Ore 2017, pp 183–186 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 24, 2017

By Johnson G. D

The typical management systems used to address the issue of operating risk centre around technologies that identify, analyse and evaluate the risk factors. These logical systems such as HAZOPs, Fault Tree Analyses, etc rely heavily on technical considerations and process flow analysis. However, several research projects, across industries and countries have clearly shown that up to 80 per cent `operating risk' is determined by the actions of workers, supervisors and managers. Yet, most of the focus of risk management is on technical and procedural issues. This suggests that a significant imbalance exists in our management systems and that industries are unlikely to show significant improvement on current levels of safety performance. Effective risk management must include the intangible element of the organisation psychology towards risk. A practical and theoretically sound approach had been researched and developed in and for the mining industry. This paper describes the approach and methodologies applied at the Cosmo Howley Gold Mine in the Northern Territory, where an inclusive approach to managing financial and operating risk was followed. The Cosmo Howley Mine showed a dramatic reduction in lost time injuries and improvements in financial indices - providing conclusive evidence of the link between management effectiveness, safety and productivity. This `triangle' has often been the subject of speculation and theory. It is demonstrated in this paper how the management team of Cosmo Howley focused their practices and systems on the improvement of organisational dynamics, ensured tangible and clear focus on parameters of costs and safety and how the improvement process was managed. It is concluded that the improvement process did not require a `major re-engineering' of the organisation. The organisation culture changes that occurred were incremental, planned and effective. It entailed the implementation of sound risk management methodologies, and ensured that a significant emphasis was placed on an aspect that is defined as `organisational dynamics'.

Jan 1, 1994

By K C. Williams, A W. Roberts, J D. Prigge

For stockpile design, the flowability and structural interfaces are critically dependant on the stress conditions throughout the pile. Historically, the predictive methodologies for stress determination have been too conservative, which adds inefficiency to the stockpile reclaim interface selections, especially for live reclaim stockpile systems. In addition, accurate pressure profiling throughout stockpile is essential to correctly design the stockpile support structures, which are buried within the stockpile. Such buried structures include trestle legs or columns to support load-out conveyors or the roof of bulk storage sheds. Improved methodologies with respect to the development of the hoop stress condition which exists in material ædrawn-downÆ within the stockpile has been developed. This hoop stress approach has significantly improved the live capacity prediction to over 90 per cent accuracy and improved rathole structure prediction within live reclaim stockpiles. Additionally the methodologies in estimating the vertical and circumferential stress variation acting on buried stockpile structures have been significantly progressed, with experimental testing shown good agreement with the theory.CITATION:Williams, K C, Roberts, A W and Prigge, J D, 2013. Recent developments in stress analysis and live reclaim prediction within iron ore stockpiles, in Proceedings Iron Ore 2013 , pp 501-510 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 12, 2013