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By M J. Davies, R S. Davies

Despite increased expenditure, the global discovery rate of world-class ore deposits has been in decline for over a decade (Schodde, 2017). Mineral exploration has traditionally followed an empirical approach, searching for evidence of mineralisation upon the surface of the planet, then drilling to define the extent of an ore body beneath the surface. As outcropping deposits in well-defined areas are depleted, there is a need for exploration to extend to less well-explored search spaces. One popular new frontier is exploration at greater depths beneath the Earth's surface. However, exploring for deep deposits with limited surficial evidence requires the implementation of predictive targeting methodologies (Hronsky, 2011; McCuaig & Hronsky, 2014). The Mineral Systems Concept (Hronsky & Groves, 2008; McCuaig et al., 2010) provides a framework for predictive exploration targeting. Ore deposit formation is recognised to be a focused mineralising event. These events represent self-organising critical systems and are underpinned by the interaction of complex, non-linear processes. Through the collection and analysis of datasets that map mineralising processes, it may be possible to predict the size and location of resultant ore bodies. CITATION: Davies, M J and Davies, R S, 2018. Beyond below-ground geological complexity: Developing adaptive expertise in exploration decision-making, in Proceedings Complex Orebodies Conference 2018, pp 95–98 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 21, 2018

By L Blackwell

Strategic mine scheduling is an industry best practice for increasing the long-term value of mining operations and supply chains. The application of optimisation technology such as mixed integer linear programming (MILP) is able to achieve a mathematically optimal result for a given scheduling model. Such a model will typically define the available source material, processing options and desired constraints for accessing and processing the material. Most strategic scheduling models, however, do not include a sufficiently detailed model of capital expenditure options related to capacity expansion.Typical strategic schedule models do not include important capital expenditure features such as capacity decay or expiration (limited lifespan of trucks), precedence relationships over time (rail construction before a new plant or non-linear expansions due to economies of scale) or mutually exclusive option sets (choices of plant size). By not including these features, a strategic mine scheduling model for a capital-sensitive operation is unable to be optimised to deliver maximum value or profitability.This paper presents several results of MILP optimisation using advanced capital expenditure modelling for mining operations and supply chains. Results of the study demonstrate that optimising capital expenditure at the same time as optimising the mining schedule allows for minimisation of capital purchasing, optimal timing for those purchases and optimal scheduling around them. Overall, this results in an increase in net present value.CITATION:Blackwell, L, 2014. Capital expenditure modelling for strategic mine scheduling, in Proceedings Orebody Modelling and Strategic Mine Planning Symposium 2014 , pp 315–322 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 24, 2014

The optimisation and validation of shearer cutting methods is a time consuming engineering task. Many different parameters, of which not all can be controlled, can vary. The easiest solution, to increase the installed power and the longwall length, is not always the best. A different cutting method can increase the capacity without the need of new machines. The Department for Mining and Metallurgy Machinery at RWTH Aachen University therefore developed ProSL, the simulation tool for shearer and longwall operations. ProSL enables the engineer to create his own cutting methods and compare it with other methods. Machine-data can easily be varied to see the impact on the method. The research shows that sophisticated longwall methods increase the productivity of the system. The paper presents the results of the calculation with ProSL and shows how higher efficiency and lower costs can be achieved.

Dec 6, 2010

By D P. Murphy, R F. Dewhirst

Traditionally closure has been seen by the Resource sector solely as a green or an environmental issue, focused primarily on the requirement to rehabilitate the site following cessation of production activities. In addition to operational, maintenance and production aspects of processing plant design, future design teams will need to take a more holistic view and consider an increasing number of sustainability issues including safety in design and cleaner production as well as closure itself. Sustainability principles being adopted by industry such as the Minerals Council of AustraliaÆs Enduring Value Framework are now broadening our understanding of closure. While issues around the closure of tailings dams and associated infrastructure have been widely studied, few investigations have looked closely at the implications of closure on the design of minerals processing plants. It is likely that design teams may be able to make a significant contribution to meeting industry objectives by adopting innovative designs which, in addition to meeting production objectives, deliver sustainable and cost effective plant closure outcomes. This presentation explores the opportunity for innovative design of mineral processing plants through the assessment of alternative closure objectives. This assessment specifically looks at current industry standards and statutory requirements, as well as potential risks and opportunities associated with each objective. Alternative design strategies to meet these objectives are discussed.

Jan 1, 2006

By L Mariano

Three selected iron ore samples from the major bedded and channel iron deposits of Western Australia were analysed using a scratch test commonly used in the oil and gas industry. The portable commercial equipment dubbed Wombat cuts a groove on the surface of the sample with a cutter under imposed depth of cut and cutting velocity. The normal and tangential components of the force acting on the cutter are recorded with a high degree of precision (about 1N) at fine spatial resolution of about 20 measurements per millimeter.The intrinsic specific energy inferred from the scratch test measurements is found very well correlated with a classical measure of strength such as the uniaxial compressive strength, for over 300 sedimentary rock samples.The results obtained on the iron ore samples are comparable to those obtained on oil and gas sedimentary rocks. This method could provide an objective and semi-automated measurement of material strength and brittleness in iron ores that can possibly be correlated to the lump to fines ratio.

Jul 11, 2011

By S Ravn

Under platform exhaust (UPE) systems are often designed into metro stations as a means of removing heat generated by trains as they come to a halt in the platform. These systems are designed to extract heat from the brakes and brake resistors directly at the source in order to capture as much heat as possible before it can enter the public areas of the station, or contribute to the temperature build-up in the tunnels. Due to space requirements for the associated duct and air handling units, the UPE plays a significant role in the geometric design of the platform and station as a whole.In recent years questions have arisen as to the effectiveness of UPE systems. However, very little data is available for designers to use when making important decisions on the station designs for new metro systems. This is important as significant savings could be achieved by omitting or re-designing these systems for new build stations; not only due to the capital costs of space provision for the duct itself but also due to the associated operation and maintenance cost of the UPE system.This paper will present recent measurements of the UPE system of the Copenhagen metro together with one-dimensional (1D) simulations, looking at typical dispersion of heat into the station plenum box and air exchange through draught relief shafts as the train enters the station in order to evaluate the effectiveness of the UPE system. The aim of this paper is to disseminate the results of measurements and analysis to increase awareness of the issue and to provide discussion relevant to designers in their evaluation of heat removal systems in new build station designs.

Mar 8, 2011

Alfred Nobel first invented a practical detonator in 1863 and then the blasting cap in 1865. At that time the detonator was used on the end of a length of safety fuse to initiate nitroglycerine-based explosives. Since then the detonator has gone through a number of changes. The instantaneous electric detonator was the first to allow remote firing. The electric delay detonator followed and allowed for timing between holes. In the mid 1970s the NONEL« Tube was invented. This tube combined with NONEL« detonators meant that many of the safety issues, such as stray current and radio frequency, associated with electric delay detonators were eliminated. This system gave the mining industry a reliable and fairly accurate system with which to detonate shots of any size. Since the early 1980s a large amount of research and development work has been done around the world to create a more accurate detonator for the mining and quarrying industry. After years of research, electronic detonators have emerged as the most accurate and precise initiation system available to the mining and quarry industry today. Electronics provide the user with millisecond timing accuracy. The improved level of timing control allows operations to improve fragmentation, throw and reduce vibration levels. There are now a number of different electronic detonator suppliers on the market today. In 2004 Dyno Nobel formed a joint venture called DetNet with AECI. DetNet has a suite of electronic detonators: DigiDet«, HotShot« and QuickShot«. This paper will focus on the HotShot« system, the first of the three new initiation systems to be released to the market in Australia by Dyno Nobel.

Jan 1, 2005

TSL Concepts and Practical Examples of the Non-Reactive System - Meyco TSL 865 Thin Spray-on Liners (TSLs) have been intensively investigated by mining and chemical industries within the last decade. Apart from the basic concept of spraying thin liners, expectations of the product's performance vary, eg immediate active strata support is seen as a key to control the ground permanently. For many coal mines this is an important factor to reduce maintenance in their roadways and enable permanent production from the long wall. In opposition to a passive mesh system this technology offers immediate active support to the strata. But not only coal mines are interested in TSL technology, there are potential applications in hard rock mines, during shaft sinking, pillar support and as an anti-weathering sealant. This paper will explain the advantages and disadvantages of TSL concepts; it will give examples of successfully applied TSLs with a main focus on the non-reactive and flexible system MEYCO TSL 865 by BASF. Furthermore, it will indicate the limitations and discuss briefly the bearing capacity and reasonable lab testing of such systems.

Nov 25, 2010

Gravity gold recovery has been practiced for thousands of years, making it one of the oldest forms of mineral processing. Gold is 19 times heavier than water although the barren rock is generally only 2.7 times heavier. Any potential gold ore needs to be characterised to assess its amenability to a gravity recoverable gold (GRG) process based on well planned and executed test work. Scale up considerations need to be considered in designing a gravity circuit. The economic impact of a gravity circuit should be justified based on the installed cost and likely benefits. Maximising gravity gold recovery results in a faster cash flow, lower operating cost per ounce and higher overall gold recoveries compared to the several weeks required to recover gold adsorbed onto carbon. The advent of centrifugal concentrators such as the Knelson and Falcon, coupled with intensive leaching of concentrates (ILR), has revolutionised gravity gold circuit designs. Considerations associated with the sizing of the centrifugal machines and the percentage of the circulating load (bleed) that should be processed is discussed in this paper. The trends with gravity circuit layout, engineering, as well as optimum dumping cycles, are important areas which require close consideration. Key aspects of these are presented in this paper. There are a number of circuit configurations to be considered, including the integration of different gravity concentrators. Other gravity process design considerations such as fewer modules, the effect of equipment size and enhancement of process efficiency using preconcentration, together with factors that affect OPEX and CAPEX are addressed. Practical considerations of maintenance, security from theft, minimisation of risk and water balance considerations are discussed using different equipment and circuit configurations. The trend towards using gravity recovery in flotation plants is also reviewed. A number of examples are cited and good design aspects highlighted.

Aug 1, 2010

By M Medina, J Alexander, R J. Longey

Capricorn Copper Pty Ltd (CCPL) are operating the Capricorn Copper Mine located at Gunpowder, Queensland. As current holder of the environmental authority for the site, CCPL have obligations to rehabilitate areas of the mine that are no longer operational and have the potential to cause/contribute to environmental harm. CCPL sought a voluntary Transitional Environmental Program (TEP) to provide an agreed program of works to cap and rehabilitate the former Mammoth Tailings Storage Facility. The voluntary TEP contained conditions that were required to be met, to reduce the potential for environmental harm from the facility. The former Mammoth Tailings Storage Facility commenced use in the early 1970’s, and is an unlined valley in-fill structure, contemporary in design compared with other such approved structures of the era. The decommissioned Mammoth Tailings Storage Facility, now known as the Old Tailings Storage Facility (Old TSF), has been a legacy source of contamination due to the existing capping not meeting modern cover criterion, and allowing oxidisation and infiltration to the underlying acid forming tailings resulting in Acid and Metalliferous Drainage (AMD) from the facility. A cover design for the Old TSF, and other mine waste storages onsite that required clay capping, had been proposed by previous operators. Under the TEP cover design phase, it was identified that a key constraint was the lack of significant quantities of low permeability clay onsite. The lack of available clay prompted the consideration of alternate lining materials for the Old TSF, with a Bituminous Geomembrane Liner (BGM) being adopted as the preferred alternative. The BGM compared favourably with clay-based materials on seepage analysis, and led to other benefits by eliminating the need for borrowing clay off site, reducing the site’s environmental footprint, and reducing construction time. The BGM cover system on the Old TSF is being monitored with the intent to use this as a case study to confirm expected performance, enabling the cover design to potentially be adopted on the remainder of the site’s mine waste storages that require capping.

Jul 1, 2021

By S Marshall, A Fowler

The Augusta underground mine at Costerfield in Central Victoria has been in operation since mid 2006; however, AGD Operations Pty Ltd have explored and undertaken open pit operations in the area for over 20 years. The high-grade, narrow gold-antimony orebody is being mined using both mechanised and hand-held methods, to produce up to 70 000 tonnes per annum at ten grams per tonne gold and six per cent stibnite. AGD Operations Pty Ltd processes the ore on site using gravity and flotation to produce two products; a concentrate which is sold to Chinese smelters and a gravity concentrate which is refined off-site. The circuit achieves up to 30 per cent recovery of gold from gravity methods. There are many challenges in the underground mine, including an orebody with an average width of 300 mm, very poor rock mass conditions in the host rock and variable dips in the ore along strike, between 45¦ and 90¦. The upper levels of the mine have been developed ready for stoping; however, their depths range from 20 m to 70 m below surface in both oxide and transitional material. A major fault structure consisting of mud has been encountered underground and is associated with the orebody causing very poor ground conditions, water inflow and requiring additional reinforcement. The northern limit of the mine is defined by the proximity of historical workings in the South Costerfield mine, which is being continuously dewatered.

Jan 1, 2008

By D Kilkenny

This paper discusses the use of a mechanised shaft sinking machine Herrenknecht Vertical Shaft Sinking Machine (VSM) – to conduct the 93 m presink for the Wira Hoisting Shaft at the Prominent Hill Mine in South Australia. This technology has been widely used in the global construction industry, however, this was the first time it had been used in Australia and the second time in a mining application. The non-entry shaft sinking system eliminates risks associated with a traditional manual method and allows all shaft construction operation to take place from surface. The geology in the upper 100 m at the Prominent Hill mine is conducive to mechanical excavation, with expected rock strengths below 130 MPa. This enabled an alternative shaft construction methodology to be considered. The Herrenknecht VSM system was selected due to its extensive work history and demonstrated performance in similar ground conditions. In collaboration with the operations and design team, the shaft collar and surface configuration were modified to suit the requirements of the VSM, additional equipment, and loading jacks that support the pre-cast lining. Dedicated concrete moulds were designed in Germany and built in Italy. The concrete segments were cast in Adelaide and road freighted to site. This paper outlines each stage of the presink – refurbishment, transportation, logistics, establishment, operation and demobilisation. Selecting this shaft presink excavation methodology, delivered through positive collaboration and communication despite some challenges, shows the benefit to the mining industry of applying new technology and innovation to improve safety and productivity.

Mar 29, 2023

By M Zoorabadi, Y Zhang, D Bringemeier, S Nicoll, N Kerr

Lihir operations of Newcrest Mining Limited (NML) are on Lihir Island (PNG) which is located approximately 900 km north-north-east of the national capital Port Moresby. The mine is located within the Luise Caldera of the Luise Volcano which is located on the east coast of the island. The caldera is an extinct volcanic crater that is geothermally active. Volcanic activity on Lihir Island is limited to remnant hydrothermal venting in the Luise Caldera in the form of hot springs and fumaroles. Steam and gas (including H2S) naturally discharge within the pit area and along the Kapit beach and near shore region. The hydrothermal reservoir temperatures can reach 100°C at the water table and exceed 200°C at depth. Newcrest maintains a Geo-hazard Management Plan to identify and manage the various geotechnical and geothermal hazards on-site. The major geothermal hazard to mining at Lihir is the occurrence of geothermal outbursts, which have occurred in the past with varying intensities and caused two ‘near misses’, production delays and material losses.

Nov 29, 2022

By S Grant, S Emeric, P Baker, E Jones, D Clark

As we strive for a sustainable and resilient future, repurposing assets has become a top priority. In Australia alone, we have a significant number of mineral projects in the pipeline, extensive existing operations, and over 50 000 legacy sites. Collectively, this presents a unique opportunity to be a world leader in mine rehabilitation. Complex stakeholder landscapes, inflexible policies, aged regulatory frameworks, technical uncertainties and increasing liabilities are all barriers hindering effective transition of legacy assets. The impetus for change is further catalysed by shifting consumer preferences, workforces in flux and regional Australians questioning what the transition means for their local community. We need innovative approaches to take a leading role in the industry and support global efforts more broadly. Co-designing an ambitious, shared vision spanning projects, operations and legacy assets with all key parties is a fundamental step to unlock and realise maximum societal, environmental, economic and reputational value. Serious play and gamification can further enhance this visioning process.

Aug 2, 2023

By A Wanninayake, E Novello, I Gillani

A residue storage facility (RSF) was designed to cater for Davidson Creek Area and Robertson Range Area operations under the FerrAus Pilbara iron ore development project in the Pilbara Region, Western Australia. Annual ore production was about 15 million tonnes over a period of up to 15 years. The RSF was designed to handle a tailings production rate of 2.2 Mt/a over the project life with ability to be expanded at a later date. The composition of tailings was predominantly -45 ¦ material with some spiral reject material. The fraction of solids was expected to be between 40 per cent and 50 per cent solids by weight.The RSF was designed as an above ground storage facility, integrating with a mine waste dump planned close to the selected RSF site. This integration helped to increase the stability of the RSF embankment and to reduce the construction cost. The main source of construction material for the remaining part of the RSF embankment was selected to be mine waste. The RSF was designed to be constructed in stages by considering the availability of mine waste according to the mining schedule. The use of mine waste for construction of RSF embankments has several benefits over use of borrowed material. These include less construction costs and less disturbances to the environment, by minimising borrowed areas and waste dump footprints.CITATION:Wanninayake, A, Novello, E and Gillani, I, 2013. Effective use of mine waste in the design of a residue storage facility, Pilbara region, Western Australia, in Proceedings Iron Ore 2013 , pp 39-44 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 12, 2013

By X Z. Sun, N Jiang, J H. Zhao, C X. Wang, L Y. Bai

In backfill grouting for underground coalmines, the filling materials strengthen the caving rock and support the overlying strata to reduce surface subsidence. The broken roof strata fail and collapse during mining operations without appropriate supporting measures being taken. It is difficult to perform continuous backfill mining on the working face of such roofs using the existing mining technology. Therefore, in order to solve the above problems, fly ash and mine water are considered as filling materials, and flow characteristics of fly-ash slurry are investigated through laboratory experiments and theoretical analyses. Laws governing the diffusion of fly-ash slurry in the void of caving rock masses and in the void between a caving rock mass and a basic roof are obtained and verified. Based on the results obtained from the above analyses and field conditions at the Zhaoguan coalmine, Shandong Province, China, a cave backfill grouting system of the hauling pipeline is developed and successfully tested at the 1703 working face. The results demonstrate that a filling rate of 43.46 per cent is achieved, and the surface subsidence coefficient of the grouting process is found to be 0.475. Compared to the total caving method, the proposed system is found to achieve a reduction rate of 40.63 per cent. This effectively helps in lowering the value of the surface subsidence coefficient. Fly ash and mine water, considered as primary materials in this study, also play a significant role in improving the air quality and water environment.

Nov 29, 2022

By A G. Guinea

Every person in an organisation has what could be called ‘a different take’ on what it means to be a safety leader. The directors will tell you they are ultimately responsible for everyone’s safety and that they can be imprisoned as a consequence of a workplace fatality. Managers, take more of a focused approach and would explain that they are totally responsible for the safety of their teams. And then there are front-line leaders. Those that not only have the responsibility (like directors and managers) but they also have the accountability, and the ability, to influence how safely their teams work. But it is not just physical safety that leaders should be concerned with.

May 5, 2022

By S Benson

Staurolite is one of the major contaminant minerals contained in the Tiwest Cooljarloo orebodies. Approximately 80 per cent of staurolite in mined ore, reports to the heavy mineral concentrate that is supplied to the Dry Mill. Staurolite in heavy mineral concentrate is typically five per cent by weight and has no significant effect in the Dry Mill other than to occupy equipment space, reporting as a tailing, that requires transportation and disposal back to the mine site. Staurolite is an aluminosilicate with a MohÆs hardness of 7.5. It is known to have potential as an abrasive blast agent and it is produced in substantial quantities in the USA for that purpose. Research indicated that there was potentially a market for staurolite within Australia, as a replacement for some of the lower grade abrasives as well as a material of choice. A small tonnage of staurolite product was manufactured through a simple circuit within the Dry Mill in December 1998. This was subjected to industrial scale tests by external companies specialising in sand blasting. The most significant batch of tests were conducted at the Tiwest Chandala site on plant and equipment undergoing corrosion repairs. Staurolite was tested against three other commercially available abrasives and compared very well with respect to surface profile, surface texture, coating adhesive strength and dust generation. As part of a due diligence study, free silica, radiation and heavy metals contents of spent abrasive and dust was investigated. This information was needed to seek approval from the appropriate Western Australian statutory authorities to sell staurolite as a product. Approval was received in November 1999. Tiwest has since installed a production circuit in the Dry Mill capable of producing 20 000 tpa of Staurolite.

Jan 1, 2001

This address is set deliberately in the broadest possible terms. A review of the place of mining in Australian life today will serve to point up the changes that we can see in the life of people in the industry. Some of the influences on the future welfare of mining people bear also on the progress of this Institute, now approaching its 90th year. As mining becomes more and more dependent on higher technology and therefore, on the higher skills of the people in the industry, the role of The Institute, I suggest, becomes more and more significant.With investment per employee in mining generally continuing to rise, our ability to handle problems of manpower and human relations becomes a matter of greater importance.Questions that flow from these general thoughts form the substance of what I have to say.

Jan 1, 1982

By S J. Loach

F-Series reconciliations are formal comparisons of estimates and measurements of ore quantity and quality made at pre-determined points along the mining value chain. F1 is the ratio of ‘Depleted Grade Control Ore/Depleted Long-term Model Ore’ and validates the models upon which Resource and Reserve statements are based. F2 is the ratio of ‘Produced Tonnes and Grade/Depleted Grade Control Ore (-) Changes in Pre-Crusher Stockpiles’ and validates that the ore tonnes and grade delineated in the pit are being accurately extracted and correctly delivered to the processing plant. These factors provide important corporate assurance for a mining company by providing quantitative feedback on model-predicted tonnes and block grade estimates. Since 2009, BHPs Western Australian Iron Ore F-Series reconciliations have been calculated in a single, centralised sequel-server database. This software routinely collates data regarding mineral resource block model depletions, grade control model depletions, pre-crusher stockpile inventories and production tonnes and grade measurements and then calculates F-Series factors for both tonnes and product quality. This paper will present case studies where reconciliation factors were used to identify improvement opportunities leading to projects that improved our models and subsequent forecasts of production tonnes and quality. In addition, it will show how reconciliation factors are tools that monitor control during periods of rapid change and provide feedback on the effectiveness of improvement projects.

Sep 18, 2023