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By S Larbi-Bram, F Shi, E Manlapig

Mining companies have recognised that characterisation of particle breakage plays an essential role in the design and optimisation of comminution circuits. Recently the JKMRC comminution research team has developed a new breakage model incorporating the effect of particle size, and a new breakage characterisation testing device, called the JK Rotary Breakage Tester (JKRBT), which allows rapid testing of particle breakage under high energy single impact and low energy repetitive impact conditions. The latter is believed to be the dominant breakage mechanism in AG/SAG mills. Existing devices, such as the JKMRC Drop Weight Tester, are not suitable for performing repetitive impacts since they are too time consuming. Positive feedback received from mining company sponsors to the new technology has prompted the JKMRC to further validate the device and the model through a formalised experimental test program on professionally designed and manufactured JKRBT machines. The first JKRBT was installed at the Anglo Research laboratory in Johannesburg in March 2007 and four more major mining companies will participate in the project in 2008, with commercial release expected in early 2009. The JKRBT has the potential to revolutionise ore testing, with applications in laboratory impact breakage characterisation of rock samples, drill cores, coal and other materials. It also stands poised to significantly advance the process control of comminution circuits since it is readily adaptable to on-line ore hardness measurement. Can any mine afford to miss out on this technology?

Jan 1, 2008

By C Robertson, J Campos

The South African mining industry first experienced en-masse use of electronic detonators in the Narrow Reef environment using AELÆs ElectrodetÖ pre-set delay system. In recent years, programmable systems such as AELÆs SmartdetÖ have also established their position, and within both AEL and the mines there has been important learning around the strengths and weaknesses of these systems. In general, the fixed delay systems tend to be more easily appreciated by less-skilled work teams, and are very well suited to simple layouts, especially long, narrow blasts. However, development of programmable row controllers and series delay inserts has greatly expanded the field of usefulness of these systems while retaining most of the simplicity of use. The programmable systems are immensely flexible and therefore able to function under any condition, but require a higher level of discipline and knowledge. Much has been done to address this issue and make the systems user friendly, so the systems have converged to some extent. These systems are both valuable tools for achieving control over blasting in underground and surface applications. The choice of system is very dependent on the prevailing conditions. Accurate timing with electronic enhancements continues to show an increasing range of benefits to mining operations. There is a strong parallel with non electronic initiation systems which helps to understand the appropriate use of the systems.

Jan 1, 2001

By J J. Jiang, B G. Bow

Atlas Iron Limited’s (Atlas) Abydos Mine has developed its Scarborough open pit proximal to a rock shelter that has been assessed as a significant Aboriginal heritage site by the Traditional Owners of the land. The rock shelter, named Yurlu Kankala, is located to the north-west of the pit with a stand-off distance of 35 m. Within Atlas’ Native Title Agreement with the Traditional Owners, and approvals from the Western Australian Department of Aboriginal Affairs, commitments have been made to conduct mining in a way that avoids or at least minimises disturbance and damage to the rock shelter. This complies with the Aboriginal Heritage Act 1972 (WA) and respects the heritage and culture of the Traditional Owners.CITATION:Bow, B G and Jiang, J J, 2018. Iron ore mining in proximity to a significant Aboriginal heritage rock shelter, Pilbara Region, Western Australia, in Proceedings Life-of-Mine 2018, pp 2–5 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 25, 2018

The Australian Mineral Industry's growth in the last two decades is directly related to the skill and experience of its consultants in mining, metallurgy, geology, finance, management, marketing, and engineering. The role of mining consultants needs to be re-examined, so that the quality of the service they deliver will continue to be adequate for the 1990's. One means of this evaluation is by examining Case Studies in the strategies and difficulties of developing contract and entrepreneurial research.

Jan 1, 1986

By A Grice

AMC has completed a number of backfill options studies, including several in recent years for large, three-dimensional orebodies involving total extraction by longhole open stoping with backfill. This has led to the development of a thorough review methodology that assists in the selection of the most appropriate backfill system and the most economic mixes to achieve the required performance. A recently developed design tool has simplified the calculation of backfill strengths for various exposure dimensions and automatically determines strengths incrementally over the height of a stope. Using a generic orebody with a plan dimension of 120 m wide by 360 m long, several different stoping layouts have been analysed to determine the effect of stope dimensions and sequencing on backfill strength requirements. This has been done for stope heights from 50 m to 300 m, in 50 m increments. The required strengths have been calculated in slices and summarised for each stope in four equal layers. The average strength requirement for each layout at each stope height has been compared graphically. For all stope heights, a panel stope layout that minimises the proportion of primary stopes results in a lower average strength requirement than grid layouts on a checkerboard pattern. However, for very high stopes, smaller plan dimensions become more economic. The increase in required strength with stope height is non-linear, making taller stopes potentially more attractive. The main cost factor in most backfills is the rate of binder addition, which is closely related to the strength required. By choosing a layout that minimises the backfill strength requirement, significant savings in binder addition rates and overall costs can be achieved. These must, of course, be weighed against other factors to determine the optimum stoping layout and backfill system.

Jan 1, 2000

 Increasing concern about the impact of alluvial mining discharges on the water quality of some West Coast rivers lead to a joint West Coast Gold Miners Associate, Trade and Industry funded study by Water Technology (NZ) Ltd. The objective of the study was to assess the treatability of West Coast alluvial gold mining discharges and to develop simple treatment systems which could be effectively adapted to a variety of sites in the region.   The approach was to apply standard water treatment techniques to field situations using low cost technology. Initially the various types of alluvial gold mining operations were identified then after preliminary site investigations and laboratory studies were carried out, site pilot plants were set up. The results of the trials particularly those using chemical aids were encouraging and it was found that chemical aid performance was largely dependent on the degree of mixing at and downstream of the chemical addition point. Design alterations to settling pond configurations in conjunction with optimised chemical addition yielded dramatic results in the form of reduced effluent turbidities.   A generalised approach to effluent treatment was developed and some of the specific 'mix and match' requirements were identified for different types of sites. The general conclusion is that improved physical treatment combined with good plant management and operation and (where necessary) chemical treatment, will produce water of acceptable discharge quality.

Jan 1, 1989

By X Yang, T Zhang, Z Li, Z Yan, M A. Williams, S Qin, P Wilson

Continuous development of complex new steel grades to meet the ever-increasing demand of high performance causes recurrent issues in steel continuous casting such as surface quality defects (eg cracks, depressions, deep oscillation marks) and productivity challenges (eg faster casting, near-net shape casting). Continuous casting of steel is a highly successful metallurgical process. Much of this success can be attributed to the performance of the casting powder that is added to the top of the mould, creates a liquid slag pool as it is heated, and forms a slag film between the watercooled copper mould and steel shell during its passage down the mould. Mould powder selection is a compromise between the conflicting requirements of heat transfer and lubrication. In an EU RFCS (Research Fund for Coal and Steel)-funded project, various techniques are developed to offer the opportunity to adapt the slag film to meet the conflicting needs in different parts of the mould such that mild cooling can be generated in the meniscus, mid-broad face or corner areas whilst maintaining lubrication and offering higher cooling rates in other areas of mould. This has significant potential to address the industrial issues in product quality and productivity of continuous casting. This paper reports, as part of the EU RFCS project, the determination of crystallinity and porosity in slag films for casting challenging and innovative steel grades using new methods. In comparison with the methods such as X-ray powder diffraction (XRD) analysis and optical microscopy / scanning electron microscopy (OM/SEM) analysis that are currently adopted by the industries, EBSD (electron backscatter diffraction) has been employed to determine the crystallinity of the slag films taken from industry casters. X-ray computed tomography (XCT) plus 3D image reconstruction has been used to determine the slag film % porosity with pore volume, pore size distribution, and pore location, which can be linked with the performance of the slag films during casting different steel grades.

Jun 19, 2024

By M Yadav, K Clode, S Daykin

The mining industry faces numerous challenges related to sustainability and circular economy principles, necessitating strategic approaches to innovation and resource management. As demands for mineral resources continue to rise, mining companies are under increasing pressure to address environmental impacts, minimise waste generation, and optimise resource utilisation. These challenges underscore the importance of Research and Development (R&D) roadmaps as strategic tools for guiding innovation and sustainability efforts within the sector (Jochen Berbner, 2022). A design-led methodology offers a structured approach to R&D roadmap development, emphasising stakeholder engagement, collaboration, and alignment with industry objectives. By leveraging design principles, mining companies can ensure that their R&D initiatives are responsive to evolving challenges and opportunities, fostering a culture of innovation and continuous improvement. Against this backdrop, the project aims to address the pressing challenges associated with sustainability and circular economy in the mining industry. Through the development of R&D roadmaps and the application of a design-led methodology, the project seeks to identify innovative solutions for enhancing resource efficiency, minimising environmental impacts, and promoting sustainable practices within mining operations. This paper highlights the collaborative efforts among Isle, the mining industry, and water utilities, which have yielded tangible benefits. The study demonstrates how the outcomes from the roadmaps outlined below effectively align research with strategic objectives, fostering innovation to address pressing challenges.

Sep 1, 2024

By E Forbes, G V. Franks

"This study investigates the dual function of a temperature responsive anionic co-polymer of poly (N-isopropyl acrylamide) (PNIPAM) as a selective flocculant/flotation collector. PNIPAM is used for separating hematite from 50:50 mixtures of hematite and quartz, at a variety of particle sizes. The performance of PNIPAM in this system is compared to that of conventional flotation collectors: sodium oleate and sodium dodecyl sulfate. The results of the study demonstrate that anionic PNIPAM used at 50¦C (above the lower critical solution temperature (LCST)) is the most effective flotation collector for hematite particles in the size range between 10 and 20 ¦m. This is attributed to the increased probability of both particle/bubble collision and particle/bubble attachment through the formation of hydrophobic hematite aggregates. Anionic PNIPAM used at 50¦C also produced the highest hematite recoveries for very fine hematite particles (circa 1 ¦m). However this recovery was completely unselective. This lack of selectivity is partially attributed to the activation of quartz particles by PNIPAM, but is thought to mainly occur as a result of entrapment of quartz particles within the matrix of hematite aggregates.CITATION:Forbes, E and Franks, G V, 2013. Selective separation of hematite from quartz by flotation using a temperature responsive polymer, in Proceedings Iron Ore 2013, pp 381-390 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Aug 12, 2013

By L B. Sukla, V N. Misra

Microbial desulfurisation of coal has significant advantages over physicochemical desulfurisation processes since the former process selectively removes the inorganic sulfur compounds and heavy metals without significant carbon loss. The purpose of this study was to improve the desulfurisation yield of a coal sample from northeastern coalfields, Assam, India using microbial technique. The coal sample contained 2.13 per cent of total sulfur and 2.59 per cent of ash. Stirred tank reactors of 40 L capacity were operated in batch mode. Initially, the reactor was fed with 40 L of slurry containing ten per cent (w/v) coal, ten per cent (v/v) inoculum of mixed culture of mesophilic acidophiles, native to coal itself and the requisite amounts of constituents for 9K medium without added ferrous sulfate. The percolate of the reactor was then used to seed the medium for the next experiment. The purpose was to obtain a better adapted and more active biomass which would give a better desulfurisation yield for coal. Further studies were conducted in the bioreactor, fed with 40 L of slurry containing ten per cent (w/v) pulp density of coal, ten per cent inoculum (derived from previous studies) and the medium, supplemented with ferrous sulfate. Results showed an increased total desulfurisation yield of 43 per cent in the latter treatment in comparison to the previous one, where the desulfurisation yield was only 23 per cent. The findings also demonstrated the convenience of using inocula derived from coal, where 50 - 60 per cent of pyritic sulfur was removed, while chemical desulfurisation is of little significance with the majority of coal types. The ash content was also reduced to 1.74 per cent as the low pH of the process caused dissolution of a number of common minerals present in the coal.

Jan 1, 2004

By T Raynlyn, A Edenton, M Adam, R J. Holmes, J R. Manuel, N Ware, R Smyth

Due to ongoing demand and increasing depletion of high-grade iron ore resources from large deposits, Australian iron ore producers are developing smaller size deposits to maintain current export levels. The iron grade, mineralogy, chemical and physical characteristics of iron ore fines being mined from different deposits vary considerably. It is therefore imperative to develop long-term strategies to maintain the quality and consistency of iron ore fines while moving to a larger diversity of smaller deposits. Blending is a common practice in sinter plants as it is almost impossible to produce a high performance sinter mixture displaying the required characteristics from one single ore. Blending is also one of the most effective options being used by iron ore producers to ensure the long-term stability of their products while increasing production. When designing a blend, the blend components are selected to support each other to achieve the required overall balanced metallurgical performance of the final product at a relatively low cost. To do so, a fundamental understanding of the key characteristics of iron ore fines and their potential impacts on the iron ore sintering process and sinter quality are required. In this paper, the sintering process and sinter structure have been analysed and the key factors affecting the sintering performance of iron ore fines, including productivity and quality, identified. Under fixed sintering conditions, the granulation efficiency, nuclei stability and the volume and properties of the primary sinter melt are believed to have important impacts on both sintering productivity and sinter quality. Discussion is then focused on the effects of ore chemical, physical and mineralogical characteristics on the key factors identified and in turn the consequences for sintering productivity and sinter quality.

Jan 1, 2009

Commissioning is one of the many phases of a project, it has inter-dependencies with the other phases, as they have amongst themselves, and has its own terminology and distinctive features. Commissioning time and cost can severely affect project economics, especially through unrealistic estimating, and requires a separate management team to ensure full control is. maintained. Targets to be achieved in commissioning are identified, together with the necessary policies to achieve them. Factors which have to be taken into account in applying these policies are Discussed.

Jan 1, 1986

By I R. F MacCulloch, K Jones

Pintail Systems, Inc, a Colorado USA based company has developed and commercially applied bioremediation processes for biological detoxification of cyanide compounds in mine waste. Site-specific microorganisms are isolated from spent ore, tailings or process solutions and augmented in the laboratory for cyanide oxidation, denitrification and metal biomineralisation. Biological processes typically treat complex contaminants (cyanide compounds, soluble metals and nitrates) in a fraction of the time of conventional remediation processes. Cyanide is used in microbial metabolic processes as a carbon or a nitrogen source. Biological detoxification processes applied at the end of mine life can end long-term liability and perpetual monitoring and containment. Case studies from commercial application and demonstration programs for the US Environmental Protection Agency will be presented in this paper.

Jan 1, 2004

By T R. Stacey

South Africa has a long history of rockbursts, some 100 years. During this time much research and many developments have taken place in the country to limit the occurrence of rockbursts, and to mitigate their effects. In this paper I shall present a personal view of what I consider to be important achievements, and contributions made. Some of these are: planning of stope layouts, and the use of strike barrier pillars; recognition of energy as a key factor, the use of the energy release rate ERR as a layout planning criterion, and development of MINSIM for calculation of ERR and stope planning; sequential grid stope layouts; use of backfill for stope support; and, development yielding support elements, and dynamic testing of stope and tunnel supports. The record shows the establishment of a rock engineering research powerhouse over a 40 to 50 year period and, unfortunately, the complete breakdown of this capability in the subsequent 10 years. CITATION:Stacey, T R, 2018. A personal review of South African rockburst research, experience and lessons learnt, in Proceedings The Fourth Australasian Ground Control in Mining Conference (AusRock), pp 5–16 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 30, 2018

By J Meinhart, J Rodler, I Katolicky

The ever increasing number of vehicles is leading to slow-moving and even stationary traffic sitting longer in traffic jams over extensive city areas. This traffic situation causes a sharp increase in pollutant emissions from vehicles, and high levels of pollution usually result throughout the built-up area. Reducing the pollution level by using traffic routing measures to speed up the flow of traffic in the existing street network is only possible in exceptional cases.In many cases the only option for achieving a significant improvement in traffic conditions is to shift the traffic underground using a road tunnel or underpass. Such tunnel routes suck off the traffic from large sections of the city, thereby easing the overall traffic flow. Thus on the one hand it produces a sharp reduction in pollution levels in the area of the tunnel route, but on the other hand it can result in locally increased exhaust pollution levels from longer tunnel systems that require mechanical ventilation. The air extracted by the ventilation system is blown out into the atmosphere either directly through the tunnel portal, or via a venting tower. Pollution can therefore occur in the area surrounding such exhaust air outlets.Thus if a tunnel is planned in a city, then closer investigation is required of both aspects: the reduction in pollution in the area of the tunnel route thanks to relocating the traffic and easing congestion, and the increased short-range pollution around the tunnel portals (shafts).

Jan 1, 1999

By D Cliff

Despite advances in technology, the Australian underground coal mining industry continues to have incidents involving spontaneous combustion. Managing these incidents relies heavily on understanding the state of the event as it develops and controls are applied. Gas analysis plays a major role in aiding this interpretation. This interpretation is based upon laboratory testing of coal samples under conditions very different to those found in an underground coal mine. This paper will explore the links between laboratory data and actual events. It will highlight the difficulties of using laboratory data. It will outline the relevance of laboratory data and how it can be usefully applied to manage spontaneous combustion events as well as in establishing relevant trigger action response plans to facilitate early detection and control of such events. The paper will identify some of the factors that need to be applied when adapting laboratory data to apply to the underground coal mine. It will outline the need for comprehensive knowledge of the local conditions and gas concentrations to be expected at all locations in an underground coal mine. Further, it will demonstrate the need for mine environment monitoring to go beyond simply measuring gas concentrations but also to include reliable atmospheric pressure, temperature and air velocity monitoring.CITATION:Cliff, D, 2013. Gas analysis - Linking the laboratory with reality, in Proceedings The Australian Mine Ventilation Conference , pp 277-282 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 1, 2013

Following the Moura No 2 Wardens Court of Inquiry and subsequent changes to the Queensland Mining Legislation there is a requirement in Queensland coal mines for: a person with the recognised competencies to be appointed at each underground coal mine to the position Ventilation Officer; and the person is directly responsible for the implementation of the mine ventilation system and for the establishment of effective standards of ventilation for the mine. The Regulations require that an underground mine must have principal hazard management plans that provide for at the least the following: emergency response, gas management, methane drainage, mine ventilation, spontaneous combustion, and strata control. Other than strata control all the plans require the ventilation officer to have roles and responsibilities to develop, control, monitor and undertake actions in relation to these plans.There are also another 34 Regulations that either directly or indirectly requires the Ventilation Officer to take actions.The purpose of this paper is to outline the information that the regulators look for in sealing plans and the actions the regulators will take if the sealing does not go to plan (TARPs being exceeded).

Jan 1, 2005

By G D. Matthews, M E. Haylett, S Khosrowshahi, A Weeks

Effective domaining is fundamental to geostatistical modelling for grade control. Through analysis of lithological, structural and alteration logging data, effective groupings (domains) can be identified and employed for estimation or simulation purposes.The poor definition of domains can adversely affect the grade control model resulting in a misinterpretation of the optimal ore-waste boundary and ultimately reduces the quality of recovered ore. The implementation of an appropriate domaining strategy is therefore expected to improve recovery and reconciliation.A thorough understanding of the geology of the deposit and adequate sample data is required for selecting domains. For new deposits, a resource drill database and resource model may be the only information available. Where extension to a previous operation is taking place, historic grade control, mapping and exposed geology may be used to improve domain selection. Preconceptions about domains, should they exist, need to be re-evaluated and tested to ensure they are fit for the purposes of grade control.While mining progresses, the domain model is re-evaluated to ensure that the previous interpretation is still suitable for the present configuration and geology. The grade control process, being iterative, lends itself to regular review and continuous improvement as further data is collected during the grade control cycle. Regular updates to the geology model, mapping, geostatistical data analysis and review of variography will provide indications of a changing domaining environment.Narrow vein gold deposits, which may have several factors influencing mineralisation, present considerable domaining challenges. By scrutinising the data, sample populations can be grouped into domains, which not only improve ore recovery, but help assist in the development of a mine geology model.CITATION:Matthews, G D, Haylett, M E, Weeks, A and Khosrowshahi, S, 2014. Effective domain selection for grade control in narrow vein gold deposits, in Proceedings Ninth International Mining Geology Conference 2014 , pp 191–196 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 18, 2014

Pisolitic iron ores (also known as channel iron deposits) are an important resource of medium-grade iron ore in the Hamersley Province of Western Australia. They are a special case of transported pisolitic ferricrust, differing from normal transported ferricrust only in the exceptionally high iron and low alumina content. The pisoids typically range up to 5 mm in diameter with abundant particles of ferruginised fossil wood up to 15 mm in maximum diameter preserved in the sediment. Field observations indicate that pisoliths are commonly initiated by the action of raindrops on iron-rich soil. Pisolites form by the impact of raindrops forming coated beads of ferruginous soil, which after dehydration obtain additional coatings during successive showers. Thick deposits of pisolite that are transported and deposited primarily by sheetwash form in the distal regions of the pediment. A size range limited to particles that may be transported by extremely shallow water characterises the abundant fossil wood fragments. The absence of fine sedimentary layering in pisolitic iron ores is explained by the action of soil-forming processes after deposition, while the major coarse bedding features derive from successive erosional and depositional events in the evolution of the pediment. They are not deposited in channels by rivers which, in arid to semi-arid conditions, typically deposit quartz sands and gravels with characteristic point bars and current bedding, abundant ferruginous granules, but rarely pisoids. However, they may fill abandoned river channels.

Jan 1, 2007

By R A. Pax

Operational grinding mills emit significant acoustic emissions which are a consequence of the dynamic environment prevailing inside them. From a technical perspective, the noise presents an opportunity to determine some details of the processes occurring inside the mills. The noise generated is not random and can be attributed to a range of events that occur inside these mills, consequently non-contact acoustic determinations of in-mill behaviour provide powerful insights into the operation of primary comminution tumbling mills. To enable a logically coherent picture to be formed of the processes inside a mill, arrays of microphones have been used. This approach allows a clearer picture of the in-mill behaviour of the charge to be accessed. In contrast to single microphone approaches, usually located near the expected charge toe position, an array of microphones allows much more useful information to be obtained from grinding mill noise.This paper will discuss and present data obtained from microphone arrays positioned at the toe and shoulder locations of a mill, and how this information can then be used for the optimisation of grinding mills in real-time.CITATION:Pax, R A, 2012. Determining mill operational efficiencies using non-contact acoustic emissions from microphone arrays, in Proceedings 11th AusIMM Mill OperatorsÆ Conference, pp 119-126 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Oct 29, 2012