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By Benkendorff P. N

Cement production in Australia approximates 6.5 million tonnes per year. Cement clinker is sourced from 15 plants which operate 28 kilns. Cement grinding is conducted at 14 of the clinker plants plus 7 grinding plants. Average annual capacity per kiln or plant is lower than in many overseas countries, but kilns introduced since 1970's have been of larger size more in keeping with size trends overseas, although still smaller than the large units overseas. Substantial economies in capital and labour costs can be achieved in large production units, particularly with dry process kilns using precalcination techniques in which part of the fuel is introduced in the static preheater section ahead of the kiln while the balance is added to the kiln in a conventional manner. Precalcination techniques have been introduced to the Australian cement industry but as cement transport costs form a major part of supplying diverse market areas, the size of kilns is likely to remain less than maximum owing to balance with distribution costs. The cement industry uses significant amounts of thermal and electrical energy which can be minimised by proper selection of equipment and technology. Labour costs are also significant and can be contained by automation and computer control of the process.

Jan 1, 1989

This paper briefly reviews the demise of professional mining education and training in NZ over the past ten years; compares it with the Australian experience; and discusses the immense success experienced by EXITO and the upsurge of competency based education and training we are currently experiencing in the mineral extraction and associated industries. It also looks to the development of a Bachelor in Mining Technology.

Jan 1, 2001

By T Ross, S Cameron

The requirement to use explosives in ground temperatures exceeding 50¦C is becoming more common as mines work to maximise the recovery of their resources. Orica Explosives was requested to assist in the development and implementation of æhot blastingÆ safe working procedures at Liddell Coal Open Cut in the Hunter Valley. The mine operator, Hunter Valley Earthmoving (HVE), had to contend not only with elevated temperatures in their overburden resulting from burning coal beneath, but also old underground workings which tended to exacerbate the problem. The paper discusses the following issues:the consultative process that was used to develop the procedures employed to ensure the process could be carried out safely; the technical issues surrounding blasting in hot ground, including temperature monitoring, product selection, application and design to ensure safety and performance were maintained; the need for confidence and trust in the team that was working together in a potentially hazardous environment, the emotive issues that were encountered and how they were addressed; the value of a regular review process combined with open and honest communication to ensure the procedures represented best practice and that all stakeholders understood the process; and the value delivered to Liddell Coal when sterilised areas of coal became accessible with little disruption to the mining process. The paper also discusses the challenges that were encountered in the Reservoir Block where proximity to major power lines and rail infrastructure meant that hot blasting procedures had to also consider vibration limits and the need for Energy Australia to disconnect the power.

Jan 1, 2001

By J K. Claflin, S R. La Brooy, A M. Claflin

Rotary kilns have been in service in the gold industry to regenerate carbon for 65 years. At the time oxide ores with gold head grades of 8 to 10 g/t were being treated. Carbon could be regenerated adequately at 650°C and solution losses were less than 1%. Forty years ago, research indicated that heavily fouled carbon from flotation circuits had to be held at 750 to 850°C for ten to twenty minutes for full reactivation (Avraamides and La Brooy, 1987), gold head grades were typically 5 g/t and solution losses typically 0.02 ppm – still less than 1%. In 2017 it was determined (Claflin et al., 2017) that a residence time of less than 1 minute at 750°C can be adequate to reactivate carbon fouled with organics sufficiently to achieve 0.005 ppm solution losses in a flotation tailings leach plant.With the potential for discovery head grades to drop below 0.6 g/t, solution losses of 0.02 ppm represent over 3% loss. Tight operation of the whole carbon circuit is required to keep gold solution losses below 1% going forward.There are alternatives to a rotary carbon kiln, e.g. vertical kilns of which the Minfurn, Rintoul and Combustion Air kilns are examples. The alternative kilns can be heated using electrical heating elements, induction, and microwave. These kilns can operate successfully under the right conditions, however, they are almost exclusively for small carbon throughputs and are not suitable for the large carbon advance rates that are required to process low head grade ore deposits. Large throughput carbon kilns are are almost exclusively fossil fuel fired rotary kilns and the subject of this paper. In the view of the principal author, a fossil fuel fired vertical carbon kiln is preferred to a rotary kiln, however, it is not currently used in the industry.Thermal regeneration of activated carbon has a major impact on gold recovery in the carbon circuit. The carbon kiln and associated equipment constitute 3 to 5% of the capital cost for an oxide processing plant and up to 10% of the capital cost if flotation tails are leached. Despite the capital cost and impact on recovery, the carbon kiln is often poorly selected, operated and maintained.Six years ago Ausenco embarked on the Carbon Kiln Initiative to reduce solution gold losses. This body of knowledge has been published in a series of papers culminating in this paper on how to:1. Select a kiln appropriate for the flowsheet;2. Maintain the kiln to achieve design operation; and3. Operate the kiln to minimise costs and maximise reactivation.CITATION:Claflin, J K, La Brooy, S R and Claflin, A M, 2018. Carbon kiln selection, operation and maintenance, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 251–274 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

By A T. Job, P R. McAree

There is significant value at stake in the mining industry from the implementation of new technologies that support the enhanced profitability and sustainability of mines. However, in order to realise this value, new technology must be implemented in a way that is both effective and sustainable. The industry has a mixed history for technology implementation that provides fertile ground for understanding what is necessary for innovation to deliver value. This paper describes early stage research investigating why this is so, with the aim of improving how to deliver value. Several case studies are provided covering both successful and unsuccessful technology interventions. The paper identifies the common factors that emerge from the case studies, and offers a path forward for further research in this area.CITATION:Job, A T and McAree, P R, 2017. Three case studies on the implementation of new technology in the mining industry, in Proceedings Iron Ore 2017, pp 407–414 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 24, 2017

I have chosen this subject in view of the fact that, while there are many and ample opportuuities of getting reliable assays made, there are but few who are in a position to obtain reliable data on the sampling of minerals and metals my long experience at Port Pirie, where, for five years, I had charge of the Refining and Sampling Mill, showed me how important it was that a correct sample should be taken.Weighing; This, to the ordinary layman, seems so simple that no expert knowledge is needed, but in actual practice there are hundreds of pounds to be lost by the lack of knowledge in this department.(1.) There is the matter of weighing in large or small quantities.(2.) The class of weighing machine used.(3.) The accuracy of weights used.We all know that, say, 1000 tons of ore cannot be weighed in one parcel; but the fewer the weighings the less loss to the seller (and usually wishes it weighed in small lots carefully) for it is a well known fact that the most sensitive scales take a certain weight to show distinctly the indication of the balance, or, in other words, what is known as "the pull of the scales." As for instance, 1000 tons weighed in lots of 1 c. each, taking the pull of the scale as being equal to 1 lb., would give a result of 9 tons loss to tbe seller, and as most of the ore sent to Customs works is worth 5. -£20 per ton-this would mean £180 loss to the careful man.

Jan 1, 1901

In dealing with the pulverization and treatment of auriferous ores, it may be stated that there is not one system of treatment applicable to all classes. In the southern portion of New Zealand the ores generally contain free gold, with scarcely any impurity that is, it is found in an almost pure state, without any alloy, and its dissemination amongst the matrix is generally in tolerably coarse particles. The only difficulties the mill man has to contend with, are the economical concentration of pyrites, which in some of the lodes are rich in gold, and the extraction of the gold the pyrites contain. In some of the lodes there is what may be termed float gold, that is, the particles of the precious metal are so finely divided that it passes over the quicksilver tables, and, unless there are other appliances for saving it, this class of gold is entirely lost.Indeed it is only within the last five years that any attention has been given, in the southern portion of the colony, to saving the fine gold that has passed the amalgamating tables. In the North Island the ores are very complex there are scarcely two mines, although they may be adjoining each other, where the bullion is of the same character. On every field the gold is alloyed with silver', and in combination with other metals and mineral substances, such as copper, zinc, antimony, galenfl, iron, sulphur, arsenic, etc., and, in some instaaces, cinnabar, as in the case of the Champion lode at Tui Creek, Te Aroha. Ores of this class are extremly difficult to treat satisfactorily.

Jan 1, 1903

Regions with extensive reserves of brown coal but with inadequate deposits of hard coal provide a particularly suitable field for the application of brown coal petrology.In fact, this discipline is indispensable where brown coal is to form the basis for high-quality products of upgrading. Both chemical and physical analyses are required in addition to the techniques employed in coal petrology, but it is the macropetrographic and the microscopic investigations that are of decisive and specific importance.Foremost among the methods of upgrading brown coal is briquetting. From the raw materials aspect the biochemical rank of coal (i.e. the type of deposit) and the coal variety (i.e. the lithotype) exert a marked influence on briquette strength. These are also the significant factors in the suitability of a brown coal for high temperature carbonization; here the demands on coal quality are even more exacting if adequately sintered and therefore high-strength lump chars are to be obtained. The principle applies also to the char from low temperature carbonization. There are close relationships between the tar yield and the remission of the coal.The reflectivity measurement therefore provides a rapid method for evaluating the suitability of a brown coal for low temperature carbonization. Similar correlations have been established between the content of extraction bitumen (raw montan wax) and the remission. Petrological investigations show that the quality of the coal bitumen is a function of the type of deposit and of the lithotype.

Jan 1, 1968

By B Yeganeh, A Sam, A Kohsari

The base of separation at Gol-e-Gohar iron ore plant (Sirjan in the south of Iran) is magnetic separation after milling. Magnetic separation in the plant is divided into two parts: dry magnetic separation and wet magnetic separation. Sixty-five per cent of the plant production belongs to the dry magnetic separator section. Therefore, investigation of this part of the plant is necessary. Prediction of plant production is one of the most important subjects in mineral processing plants. That means, before feed enters the plant, specification of production has been calculated with laboratory methods. The purpose of this paper is the prediction concentrate quality has achieved from the dry magnetic separator. The content of iron in the final dry concentrate will be predicted, with laboratory, pilot and modelling methods, before feed enters the plant. Different variables are used in this approach, which consist of: speed of the first dry magnetic separator (rougher), speed of the third dry magnetic separator (cleaner), iron content in plant feed, size of 80 per cent passing of feed, size of 20 per cent passing of feed and iron content in pilot dry magnetic separation concentrate that performs in a standard manner. The artificial neural network is used for modelling and one of its branches is the radial basis network (RBN). Iron content in magnetic separating concentrate in plant will be introduced as the target and will be calculated with the RBN method. In the RBN method, a set of data enters to neural network and they will be trained and simulated. Finally, the target will be predicted. Ultimately, the original target (actual iron content) and the predicted target (predicted iron content) compare and error of them will be calculated. The obtained result is acceptable and satisfactory.

Jan 1, 2007

By D Cliff

"Recent underground coal mine incidents have again raised the issue of: under what circumstanceis it safe for personnel to re-enter the mine? Mine rescue guidelines make recommendations aboutthe limits in terms of the circumstances, lives at risk, no lives at risk and training exercises. Theseare based upon percentages of the upper and lower explosive limits. Many factors infl uencesett ing limits for safe re-entry. These include: the representativeness of the sampling location(s),the rapidity of gett ing an underground sample analysed and the rate of change of the atmospherebeing monitored. Value judgements based upon these parameters will then infl uence the sett ing ofa trigger point based upon per cent explosibility. This raises the question of how the percentage ofthe lower or upper explosive limit is established. It is easy to defi ne this when the sampling pointdata sit on the fresh air limit line. However - what value is used when the sample sits somewherein the body of an explosibility diagram? This paper explores the various options and illustratesvarious pitfalls and problems that are faced in making such a determination. These include howthe data are represented and the assumed knowledge of those doing the interpretation."

Jun 1, 2012

By R B. Stewart

Where pasture production is the intended land use of the areas to be reclaimed, the creation of a suitable growing +medium is a major objective. To achieve this land reclaimers require a sound understanding of the proposed mining plan and a knowledge of the physical, biological and chemical properties of materials intended for resurfacing disturbed areas. Where the original soil is not being replaced in its natural state, research is usually required to determine an alternative growing medium. Results from field research conducted on waste material from the Waihi Gold mine are reported with emphasis on the significance of soil depth in relation to pasture production in this environment.  Problems in extrapolating field research to large scale operations are also considered.   Essentially the requirements for successful pasture production, on surrogate growing medium, are akin to conventional approaches used in New Zealand in the development of unimproved agricultural land. High inputs of fertiliser are initially needed, especially where volcanic soil is used, and careful management of pastures and soils is required to minimise soil erosion and create a sustainable system. In the first three to five years of pasture production, grazing use of the land requires to be dictated by pasture availability and soil conditions and not by animal feed requirements. The use of light stock (young dairy or sheep) is recommended.   Successful land restoration requires a team approach by a range of cooperative specialists including engineers, soil scientists, farm managers, agricultural contractors, landscape architects and environmental officers.

Jan 1, 1991

A quantitative chemical model of the rocks of the Broken Hill lode environment is presented to illustrate a stratiform orebody in a meaningful form to scientists interested in environmental control on the chemicalcomposition of sediments.Even though this study was restricted by the narrow range of rock analyses available it is obvious that significant chemical differences exist between the various rock units and also that some association of metallic sulphides with Ca, Mn, Fe, and P is indicated.Correlation of this evidence with that from other mining fields may point out more definite chemical relationships and elucidate the puzzle of the mode of formation of many stratiform orebodies.

Jan 1, 1968

Recent developments in diamond drilling practice have been chiefly 'concerned with modifications in drill design and 'operating technique whereby an increase in daily footage rates and reduced footage costs have been achieved without any marked improvements in the recovery of core. This trend is perhaps due to the general acceptance by the mining and drilling engineer alike of the belief that diamond drilling has definite limitations in exploratory work on mineral deposits characterized by irregularities in continuity and grade, such a belief arising from the fact that drilling technique has not yet evolved coring devices to ensure the full recovery of the rock and mineral formations penetrated.Current diamond drilling operations at Moonta and Wallaroo Mines, carried out by the South Australian Department of Mines, have attained remarkable results in completely eliminating core-loss by the use of a special double-tube core barreI.It is considered that assays of borehole samples taken with this special barrel have a reliability comparable, if not superior to that of similarly situated mine samples and, provided they are spaced satisfactorily, can be used as, a basis for calculating tonnage and grade. Formerly, with only partial core-recoveries, positive borehole results on narrow irregular lodes, such as those in the Moonta and Wallaroo Mines, could be accepted mainly as indications of the presence of mineralization, and could have only a limited bearing on estimates of ore reserves.The value of this special double-tube core-barrel lies In the fact that it guarantees good core recovery and, therefore, good samples, and eliminates the need for sludge-sampling, which is prone to give unreliable assay results from several causes, such as gravity concentration in the bottom of the hole and return water losses which cannot be overcome.In view of the increasing demand for minerals and the probability that the search for them will be carried on largely by boring, it is felt that it would be of interest and value to direct the attention of mining engineers to core-recovery results obtained by diamond drilling plants in South Australia and the features of the special core-barrel, designed by the writer, which has made this possible. Also, the writer is desirous of placing on record two other core-recovery devices designed to extract accurate samples in relatively soft or unconsolidated formations. The latter are used with percussion and calyx plants, respectively and their value has been proven on phosphate rock and coal deposits in South Australia.

Jan 1, 1943

By A G. L Pratt

The record for autonomous haulage systems in underground mining over the past 15 years is patchy, marked by many trials and attempts, with few examples of sustained operation until relatively recently. The drivers for the introduction of this technology are variously listed as the occupational health and safety of people working in underground mines, reductions in direct operating costs and increases in productivity.This paper reviews the trends for operation of semi-autonomous and autonomous haulage achieved by underground mines and the defining features of the technology currently available. The inclusion of autonomous haulage as part of mining studies and the fundamental conditions for its successful application is discussed in the paper. The components required for an autonomous underground haulage system are outlined and the key aspects that need to support its effective implementation are examined together with their associated opportunities and risks. Special note is made of the critical role people, including executive leadership, have in ensuring the successful introduction of this technology.The paper draws on published case study material, equipment supplier information and research findings. The aim is to offer a high-level insight into what is required for the application of autonomous haulage technology and its successful implementation in underground mines.CITATION:Pratt, A G L, 2016. Autonomous haulage systems in underground mining – what is required for success? In Proceedings International Mine Management Conferenc, pp 35-52 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jun 22, 2016

By A R. Heath, I Arbuthnot

Feed slurries are typically flocculated in a thickenerÆs feedwell to increase the settling rate, underflow density and overflow clarity. High molecular weight polymeric flocculants are normally used, but present a number of challenges in terms of make up, dilution, delivery and mixing with the feed slurry.Various aspects of the flocculant dilution and delivery system have been studied with a combination of flow visualisation and computational fluid dynamics (CFD). An open topped flocculant dilution/mixing box has been developed to replace a conventional flocculant manifold, with improvements to the mixing, fault diagnosis and ease of determining the flow split to the various dosing points. The addition points to the feedwell have also been studied, both in terms of where the flocculant is added, and how. While conventional multi-hole spargers are effective in dispersing flocculant, they are prone to blocking and have been replaced by open-ended pipes. The required dispersion is provided by an efficient mixing element placed in the dilution port. Adding the flocculant into the feedwell dilution stream prior to mixing with the slurry also provides super-dilution of the flocculant that can further improve the flocculation process and reduce flocculant consumption.CITATION:Heath, A R and Arbuthnot, I, 2013. Advances in thickener flocculant delivery, in Proceedings MetPlant 2013 , pp 86-92 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 15, 2013

By J Watt

The Hidden Valley Gold Project is located in a remote and mountainous area of the Morobe Province approximately 30 km south of the township of Bulolo and approximately 90 km south-southwest of the provincial capital, Lae. The Hidden Valley deposit was discovered in 1984 with the nearby Hamata and Kaveroi deposits discovered in 1987 and 1992 respectively. Reserves (Harmony, 2009) at these three deposits are 42.1 million tonnes of ore containing approximately 2.9 million ounces of gold and 45 million ounces of silver. A further 5.4 million ounces of gold and 84 million ounces of silver are in the resources category. The process plant is designed to treat 4.2 million tonnes per year of gold/silver ore extracted by open cut mining methods. Ore is classified into three ore types according to oxidation state: oxide, transition and primary. The silver to gold grade ratio is high for the Hidden Valley and Kaveroi ores, generally in the range 15 - 20:1, and much lower for Hamata, typically 1 - 2:1: Primary ore is the dominant ore type at Hidden Valley with sulfur grades up to about two per cent sulfur. Oxide and transition ores are more prevalent at the Hamata deposit, but its primary ore has up to five per cent sulfur grades. Variable ore types, particularly in the initial years of operation, high silver to gold ratios and limited plant site area, due to the challenging terrain, present the main processing challenges for this project. This paper describes the operating strategies and process development for the main areas of this circuit, highlighting selections of processes and equipment that achieve cost effective, yet flexible solutions to the treatment of ores from these deposits.

Jan 1, 2009

The granulites and related "dry" igneous rocks tend to be passed over during exploration for metals. Preliminary data show that high trace concentrations of eu, Ni, and other metals of economic interest are commonin orthopyroxene and some of the other granulite minerals. During retrograde metamorphism of granulites, pyroxenes are converted to amphiboles or phyllosilicates, and significant quantities of metals are released andbecome available for incorporation into new mineral phases, or may be transported elsewhere. S-rich scapolite is the normal scapolite of granulites. Its retrogression to secondary plagioclase provides much S which scavengesCu and Ni, from pyroxenes undergoing retrogression, thus producing ore-fluids. A full analysis of a scapolite with 5·10 per cent SOg is given.Beryl is unstable in granulites but the rare Be mineral taaffeite (Al4Mg(Be, FeII)Os) with 5·50 per cent BeO occurs in central Australia as a pale green tabular mineral easily confused for chloritoid in hand-specimen.Metamorphic differentiation and mobilization of primary ore concentrations are major factors controlling their post-granulite attitude and grade.Zones of retrograde metamorphism are commonly found cutting or engirdling granulite terranes. As the "volatiles" for the new hydrous minerals of many of these zones are of deep-seated origin and may be juvenile, sulphide mineralization in them may also be of mantle origin. However, it is likely that much of the metal content could be scavenged from the granulites as they are down-graded by juvenile volatiles. Major Bouguer gravity anomalies delineate some granulite terranes (e.g. Fraser Block, Western Australia), and are related to deep-seated geosutures and mantle disturbances.Many granulite terranes are linear belts and appear to be welded to older cratonic blocks.

Jan 1, 1969

By J Merrells

Fluor, together with our clients, has yielded significant reductions in the total cost of mining projects by employing a systematic and methodical process of cost reduction. This paper outlines this structured approach to reducing the total cost of projects through the gathering of information, the evaluation of the zero base design, and the development of the execution strategy for the project in the study phase.Over the recent iron ore boom the cost of growth projects escalated rapidly due to a variety of factors including the engineering cost of re-designing facilities, construction in remote areas and an increase in the ‘perceived’ capital requirements for maintainable and operable facilities.Fluor has made strategic steps towards safely reducing the capital intensity of projects, by working with clients to develop zero base designs which utilise the minimum technical requirements in order to meet the function of the plant and then add cost for safety, maintenance and operability only where clearly justified.This paper has set forth a structured three phased approach to focus the team on reducing capital cost while maintaining a low increase in engineering effort.The initial ‘gather’ phase focuses the team on acquiring information and identifying decisions that will need to be made so that the team can prioritise and focus the attention on areas that will provide the greatest benefit. Within this phase the identification of zero base design requirements, review of lessons learnt and analysis of capital cost levers, allows the team to identify the key decisions on the project that will affect the capital cost.In the subsequent ‘evaluation’ phase the team established the zero base design, using the hierarchy of cost reduction as a guide to focusing the team’s attention on high yielding cost saving opportunities.In the final phase the team develops the execution strategy which will yield the least cost using strategies and tools such as modularisation, standardisation, replication, strategic sourcing and 3D design.CITATION:Merrells, J, 2017. Reducing total project cost in the study phase using zero base design, in Proceedings Iron Ore 2017, pp 621–626 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 24, 2017

By D Brown, K Markovic, Z Tabor

From ancient times to the modern world, the mining industry has played a pivotal role in shaping the society that we live in today. It remains an integral part of everyday life and is a catalyst for both technological and economic growth. With finite resources on Earth, and growing pressures surrounding climate change and the environment, space mining opportunities have become of increasing interest. Recent discoveries have shown celestial bodies including the Moon and surrounding asteroids, contain an abundance of critical minerals, as well as resources necessary to sustain human life. These discoveries coupled with a transition into the digital and autonomous age, offer an innovative solution to solving some of the mining challenges currently being faced on Earth. Similarly, they also offer a pathway to enabling deep space exploration and off Earth exploratory missions. However, like with mining operations on Earth, space remains and immensely challenging and complex operational environment. The inhospitable nature of space poses new challenges, including communication barriers, lunar dust, cosmic radiation, and gravity. The challenges and risks are not just technological, as Environmental, Social, and Governance (ESG) factors must also be considered to prevent unintended consequences and hazards. Furthermore, future workforce, law, financial, and security systems must evolve to enable space mining to take place. These are all known aspects to begin with, but as the complexity of the space grows it becomes apparent that a holistic approach to assess and manage these factors will be required.

Sep 1, 2024

Permian coal seams from the Tomago Coal Measures in the Northern Coalfield, New South Wales, were analysed petrographically and reflectance measurements made for each. Vitrite contents were moderate to high for most of the coals but for two they were very low.The mineral-matter contents were low to moderate by Australian standards. Different profiles of a particular seam could be correlated by petrographic methods.Standard seam profiles were drawn up and from these an idealized Tomago seam sequence was compiled. All the coals were of high-volatile bituminous rank. Their carbon contents, but not thcir reflectances, varied significantly with the quantity of vitrinite present.

Jan 1, 1968