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By H Haghighi

Haul roads are often permanent unsealed access roads used by heavy haul trucks to transfer minerals. These roads can deteriorate rapidly which results in potholes, deformations and dust. Downer EDI Works has successfully provided efficient solutions to the mining industry to maintain their haul roads. HaulPac as a solution package is a process in which a bituminous emulsion is used to create a stable and durable pavement. The emulsion penetrates the road and binds the particles together, creating a stable base. It also seals the surface and prevents water from penetrating the underneath layers. Bituminous emulsion can increase the strength of the pavement material and decrease the road surface degradation which results in dust suppression. However, the everincreasing price of commodities, the necessity of reducing carbon emissions and the increasing use of autonomous haul trucks have made it vital to invest in novel maintenance solutions that can meet the needs of the mining industry in a cost-effective manner. This paper outlines the benefits of bituminous emulsion in terms of productivity, safety and environment followed by Downer’s approach to evaluate the suitability and to optimise the amount of product. The potential for changing the colour of the treated surface is explored and an initiative that incorporates end-of-life tyres of haul trucks into the pavement is introduced. And finally, an innovative method using artificial intelligence to estimate dust emission is presented.

Sep 18, 2023

By H Bao, M Nehring, M Kizil, P Knights

The mining sector, a notably energy-intensive industry worldwide, is a major consumer of fossil fuels, leading to significant carbon emissions globally. The move towards electrification, coupled with advancements in battery technology, has redirected focus from traditional diesel-powered solutions to battery-powered alternatives. This paper introduces a novel mining haulage system, termed the Battery Trolley system, and examines its theoretical foundations, configurations, and operational processes. It offers a comprehensive analysis of the system’s characteristics and limitations. Through a hypothetical road simulation, the study analyses various battery mining trucks, calculating energy consumption based on force parameters and tailoring battery sizes to contemporary materials and technology. When assessing various battery truck alternatives—considering aspects such as battery size, effective payload, duty cycle, energy efficiency, productivity, and single-shift production—a range of performance outcomes and characters become apparent within the mining context. The findings indicate that Battery Trolley configurations, requiring smaller battery capacities, entail lesser compromises on effective payload. Consequently, these configurations achieve a higher duty cycle, reduced energy consumption per tonne, heightened productivity, and enhanced singleshift production capabilities compared to Battery-only alternatives. The comparative analysis of Battery Trolley with stationary charging (BT-S) and Battery Trolley – dynamic charging (BT-D) underlines that battery Trolley systems are capable of overcoming the challenges associated with battery size, thus successfully fulfilling the production demands of large truck applications in mining. This positions Battery Trolley systems as a more advantageous option for the decarbonisation of mining fleets, underscoring their potential in contributing to the sector’s sustainable evolution.

Sep 1, 2024

By S Utili, A Agosti

The Overall Slope Angle (OSA) of pitwalls plays a crucial role in the financial return of an open pit mine. In current practice, pitwall profiles are designed to be planar in cross-section within each rock layer, ie the profile inclination across each layer tends to be constant. A new slope design software, OptimalSlope, has been recently proposed to determine the geotechnically optimal profile shapes for the pitwalls of mines. OptimalSlope seeks the solution of a mathematical optimisation problem where the overall steepness of the pitwall to be designed is maximised for an assigned stratigraphy, rock properties (unit weight and strength) and Factor of Safety. The geometry of the benches is provided as input to OptimalSlope. The results obtained so far on three mine case studies in isotropic rock masses (Utili et al, 2022; Agosti et al, 2021a, 2021b) show that optimal profiles are up to 5° steeper than their planar counterparts – ie the planar profiles exhibiting the same FoS – leading to realising significant saving on waste rock and as a consequence Net Present Value increments and carbon footprint reductions. OptimalSlope algorithms have been modified to deal with anisotropic rock masses characterised by direction dependent shear strength. In the paper, the case of rock masses in banded iron formations (BIF) is tackled. A data set of anisotropic rock shear strengths typical of Western Australia is considered. The Snowden modified nonlinear model was employed to characterise the anisotropy of the rock mass shear strength. From the OptimalSlope simulations performed emerges that optimal pitwall profiles can increase significantly the Overall Slope Angle in comparison with planar profiles featured by the same Factor of Safety. LEM stability analyses of all the profiles were also performed by Rocscience Slide 2 to independently verify the FoSs of the optimal profiles obtained.

Nov 29, 2022

By M Andrew, H Reynolds, R Mills

As the global mining industry continues to grapple with ‘black swans’ (high consequence / low frequency events) for health, safety and environmental losses, the focus is shifting from risk assessment of these events to risk management using selected purposeful controls that reduce the risk.Fundamental to critical control management (CCM) is a soundly based rationale for selecting the right controls for each and every risk. The approach should be based on a thorough understanding of the dynamics of the event: What causes it? How frequently will it occur? How likely is the consequence to be realised? This is typically done through a bowtie and methodical numerical risk analysis. Core to this step, then, is the structure and content of the bowtie; specifically, the analytic architecture that is used to construct the bowtie. Different architectures yield different constructions, and bowties are no different.Although bowties for operational health and safety (OHS) hazards appear to have a common architecture, they are not generic. It is important to stress that they contain site specific information, are prepared by site based operational teams, and vary from site to site to reflect each site’s operational conditions. They are often a product of the knowledge and understanding of the operational teams involved, may be prone to human error, and potentially miss latent hazards that may have been embedded early in the planning, design or construction phase of a mine or facility, or within the mining equipment. Overcoming these deficiencies through constant re-evaluation of the risks, and challenging the content on the bowtie will help to minimise the chance that something will be missed.This paper will cover key themes in bowtie architecture, introduce the concept of barrier models for high consequence event (HCE) bowties and present a relevant case study to illustrate the issues that determine quality in bowtie construction and critical control (barrier) selection and management.CITATION:Mills, R, Andrew, M and Reynolds, H, 2016. Can we stop a black swan breeding? Advances in bowties and critical control management, in Proceedings International Mine Management Conference, pp 105-114 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jun 22, 2016

By Nemick JA

Recent advances in computer simulation together with field measurements of caving and microseismic activity about longwall panels, has allowed a much better understanding of the caving process and the variability due to geology. The joint research between SCT Operations and CSIRO Division of Exploration and Mining has initiated new methods of computational modelling predicting various caving patterns and strata failure far ahead of the longwall face. This work was validated by field measurements of caving and microseismic activity at the longwall face.The rock fracture distribution and the caving characteristics of a range of strata sections have been simulated by computer methods. Validation studies of the method were addressed together with case studies. The interaction of caving with support convergence and face control is presented. The method allows the simulation of longwall support behaviour under various geological conditions. The system also allows a prediction of the monitoring data, which is best suited to give an early warning of weighting events or signal various key caving characteristics.

Jan 1, 1998

By R Zhang, J Xu, X Lv, C Bai, S Zhang

This paper studies the grinding behaviour of vanadium-titanium magnetite concentrate in a ball mill. The grinding kinetics, surface morphology, lattice distortion, wettability and moisture capacity were analysed. Grinding kinetics equation was established based on population balances model with the size distribution data from a laser diffraction technique. The SEM photos of the ground concentrate showed that the surface gets rough with increasing grind time. Agglomeration of fine particles was enhanced when the grinding time reached 30 minutes. X-ray diffraction results showed that a loss in crystalline occurred with increasing the grinding time. The peaks of the X-ray diffraction patterns are significantly broadened with increasing grinding time. Wettability, characterised by contact angle between the material and water, improved due to the fact that the surface roughness increased with increasing grinding time. Moisture capacity of concentrate ascends abruptly in the first three minutes and then changed slowly with increasing grinding time. The water transfer coefficient in the particles increased rapidly in the first six minutes and then decreased quickly until grinding time reached 12 minutes.CITATION:Zhang, R, Lv, X, Bai, C, Xu, J and Zhang, S, 2013. Wet grinding of ?vanadium-titanium magnetite concentrate in a ball mill, in Proceedings Iron Ore 2013 , pp 511-518 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 12, 2013

This paper discusses considerations to be made for the selection of rock tunnelling machines, as opposed to drilling and blasting. A systematic approach is presented in terms of utilizing data frcm site investigations to accurately forecast machine performance for estimating and planning purposes and to help minimise associated risks. Useful rock index properties are identified, and correlations for predicting advance rates for roadheader and full face machines are presented together with a simple method of characteristing rock mass conditions for estimating machine utilization and the savings to be gained in support costs. Finally considerations for tunnelling in adverse ground, for advance probing and for large sized tunnels are outlined.

Jan 1, 1987

By M Liang, C Putzmann, D Gokaydin

The mining industry faces numerous challenges in swiftly evaluating and exploiting new mineral deposits to meet the escalating demand for critical minerals and metals. These challenges necessitate the adoption of innovative techniques and technologies to expedite development cycles and facilitate the efficient exchange of knowledge and expertise. Traditional mineral exploration methods rely heavily on data governance, visualisation tools, and expert interpretation skills, often operating in isolation and limiting the integration of valuable data and knowledge (Lindsay and Perrouty, 2019). To address these integration challenges and bridge the industry’s knowledge gap, the concept of a digital twin offers a holistic solution (Ahn, 2021; Nagovitsyn and Stepacheva, 2021).

Sep 1, 2024

By A Hacket, M Haest, I Vitins

Infrared spectroscopy has the ability to accurately measure mineralogy of drill cores, allowing for better spatial characterisation of iron ore deposits and potentially improving the prediction of key mining and processing parameters at the deposit scale. BHP Billiton Iron Ore is using infrared spectroscopic drill core logging to provide fast and accurate mineralogy for diamond cores and reverse circulation (RC) samples.Mineralogy can be predicted from infrared spectroscopic drill core data with errors on estimates ranging from six to 12 weight per cent. The error on the clay estimates is significantly lower than for hematite and goethite content estimates. This manuscript presents the results from a study on a bedded iron ore deposit, hosted in the Brockman iron formation, for which infrared spectroscopic data were collected on all of the diamond and RC drilling. Results show that these mineralogy estimates improve drill core logs, the geology model and the metallurgical block model.CITATION:Haest, M, Vitins, I and Hacket, A, 2013. Infrared spectroscopic drill core logging - making inroads to deposit scale 3D mineralogy, in Proceedings Iron Ore 2013 , pp 251-258 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 12, 2013

By A Krishnan, C Garcia, I Luna-Berbesi

The discovery and exploration of deposits are progressively shifting to extremely remote regions and greater depths. As a result, exploration costs and the economic risk of a bad investment increase. Current megatrends in the exploration and mining sector indicate a growing demand for the implementation of automation, digitalisation, and machine learning techniques. The implementation of a multi-sensor-based core logging device (DMT, 2024) was done on 400 m of drill cores to optimise interdisciplinary processes in terms of time and quality, by using interlinked and consistent data in real-time, to obtain reliable predictions that support and speed up decision-making. The results are consistent with the laboratory data previously obtained by the mining company, highlighting the benefits of introducing ANCORELOG into their core logging procedures.

Sep 1, 2024

By Woodcock J. T, Millett R. N

It was shown that manganese dioxide could be used as an oxidant in acid thiourea leaching of a gold ore. Manganese dioxide could generate high redox potentials and was as effective as hydrogen peroxide in the leaching process. Results obtained under closely controlled leaching conditions confirmed that high redox potentials enabled faster dissolution of gold to be obtained but led to extremely high reagent consumptions (thiourea, acid, and manganese dioxide). Additions of sodium sulphite solution in an attempt to lower thiourea consumption by reducing formamidine disulphide back to thiourea were only marginally successful. Although thio- urea consumption was slightly decreased, the consumption of acid and manganese dioxide was substantially increased and there was no net benefit in using sulphite. Tests in which a single addition of mangan- ese dioxide was made before addition of thiourea minimized overall reagent consumption and gave only a slightly lower dissolution rate of gold. This is a promising technique for further Investigation.

Jan 1, 1987

By Morrison RD, Peberdy NJ

Simulator training provides a cost effective method of training operators in both the process and control aspects of a metallurgical plant. The components and requirements of a training simulator are described along with the benefits to be gained from simulator training. A table summarizing some applications of metallurgical training simulators is Given.

Jan 1, 1991

By D Macfarlane, T McMorran

  This paper describes the design and construction of the upper section of the Pike River Mine Access Road. The road extends 11 km from Logburn Road alongside Big River on the West Coast of the South Island of New Zealand up Pike Stream to the new mine portal on White Knight Stream (Figure 1). This new road starts on alluvial terraces, then partially follows an old logging road before entering virgin bush and traversing the true left bank of a steep sided gorge on Pike Stream some 50 - 100 m above the stream before dropping down to the mine entrance. Its development has been an extended process from route selection, consenting through to design and construction.   The paper focuses on the 1 km section of road between the Amenities Area (Figure 1) and the portal. This section of road is a steep section through the gorge, principally on Conservation estate, and has presented the most challenges and required the greatest effort to obtain the regulatory approvals, prepare the design and to construct. This paper outlines the history of the challenges faced and how the road was successfully developed.

Jan 1, 2007

By Corbett GJ, Leach TM

A continued exploration programme has further defined the geology of the Tolukuma vein system, verified the resource indicated by Newmont, and identified potential for additional mineralisation. The resource at Tolukuma Hill, designated as zone C, is a mine recoverable 432,000 t at 18.1 g/t Au & 46 g/t Ag. Mining will be by a combination of open pit and underground at a rate of 100,000 t per annum. Processing will be by SAG mill, gravity circuit and CIL plant. A diatreme breccia, localised at an intersection of structures and a relationship of gold to base metal sulphides, are indicative of a strong porphyry association. Typical epithermal features such as crustiform banded quartz and quartz pseudomorphing platy calcite are also present and locally contain lesser gold mineralisation. Pre-existing dilatant structures have acted as a host to the ore fluids, resulting in the formation of the semi-continuous Tolukuma-Gulbadi veins over a 1100 in strike. A fluid flow model suggests that mineralizing fluids were sourced from a diatreme margin and migrated laterally along dilatant structures. Bonanza gold grades are interpreted to be derived through fluid quenching in the flexure between a hanging wall split, which hosts much of the Tolukuma Hill resource, and the feeder graben structure. Thus, the relationship between the pre-mineral structural geometry and fluid upflow at the margins of a diatreme breccia, controls the ore setting.

Jan 1, 1995

By Tagawa H

In Japan, geological condition do not only vary in a wide range of strata but are also extremely complex with the existence of faults and aquifers. With respect to rocks, in particular, it is very rare that homogeneous rocks are distributed uniformly. In general, geological conditions are distributed in a wide variety, ranging from earth, sand, soft and medium rocks to hard rocks. Under these geological conditions, when planning of the tunnel construction is to be made out, either blasting method or tunnel boring machines must be selected taking into consideration the geological structures along with the designed tunnel route,' possibility of encountering aquifers, hardness of rocks anticipated and also, the adjacent environ- mental conditions. In the process of select- ing an excavation method,, it is important to make a comparative investigation between the above two methods considering the advantages and disadvantages with regard to the respective operating efficiency, economical efficiency and the conditions and scope of application as well. Furthermore, in addition to these considerations, the recent environmental restriction, which does not allow the blasting in the surroundings of residential areas, must also be taken into account. Because of this, in some cases there is no alternative but to use a static excavation method or a tunneling machine even when these are less efficient than blasting.

Jan 1, 1987

By Lumley G. I, Duffy W. J

The risk involved with incorporating new/unfamiliar technology into mines has, in the past, largely been evaluated by the supplier of the technology. The implications on safety and productivity has been accepted as part of the process of `getting up and running'.This has changed. As companies see the lost productivity and accidents actually costing significant dollars, risk assessment is becoming an important part of the implementation of new equipment. Regulatory authorities are also seeing the preventable incidents and in some cases are now requiring a risk assessment to be undertaken on new equipment at a Mine.

Jan 1, 1992

By G R. F Alvear Flores

Mineral resources are becoming more complex in composition and structure making it more difficult to produce clean concentrates for primary metal smelting. In parallel, providing technological solutions to the recycling and recovery of end-of-life materials is becoming more important in moving towards the goal of increasing circularity. The availability of fundamental thermodynamic data and advanced thermodynamic tools greatly assists in evaluating these complexities and their impact on existing and new processes. In addition, it is fundamental to support the economic performance of smelters. This paper describes several examples on how fundamental work can be applied to industrial processing..

Jun 17, 2024

By J P. Evert

Didipio gold-copper mine operation is situated in the island of Luzon, approximately 270 km north of Manila in the Philippines, in an area of high seasonal rainfall. The hydrogeological water flow model implied that there would be high connectivity between regional structures and underground operations. This model predicted that underground mine groundwater inflows were expected to quickly rise as the decline progressed to a peak of 510 L/s. Designing a capital pump station to deal with 510 L/s has its own challenges, however developing the decline down to the required level, always dealing with 300 L/s of water and constructing the pump station is extremely challenging and required a robust water management plan and mine design. When dealing with expected high volumes of water, underground mine design and scheduling plays a key role in protecting electrical infrastructure, equipment, secondary pumps, and the decline from flooding. A good drainage system and controlled dewatering plan is essential for safety and progress. This paper details the dewatering techniques and mine designs required to accomplish decline development with high water inflows as used in the Didipio project. It will describe the learnings and outcomes that are achievable with a flexible design, as new structures are mapped, and water intersections are increased. It also highlights the potential for adaptability in mine planning to provide evolving improvements or to evade problems that are expected from the constant reconciliation of data recorded during development.

Mar 29, 2023

By G Gibson, B Bessen

In coal preparation, large dense medium cyclones (DMC) at low pressure heads (typically 9D where D = cyclone diameter) are the norm. This contrasts with high density mineral applications where, largely for historical reasons, smaller cyclones at high heads are the standard. There are advantages in preferring large diameter cyclones at low heads, assuming that metallurgical performance does not suffer significantly. These include simpler plant layouts, easier maintenance, smaller spares inventories, reduced wear, reduced medium pumping demands, smaller buildings and overall lower capital and operating costs. In 2008, therefore, Xstrata Zinc decided to trial a single DSM-design 800 mm cyclone in one of its four DMC lines at Mt Isa, replacing the four 400 mm cyclones previously installed. Circumstances allowed a low head of 9.5 D to be trialled, compared with the existing 400 mm head of 21.5 D. This paper describes the trial, including tests using painted ore particles as tracers, estimates of yield and metal recovery, and wear monitoring. The larger unit performed well. There was no evidence that metallurgical performance in terms of metal recovery and waste reject rate suffered, and there was some evidence that it may have improved. Cyclone life increased, and preliminary data suggest that the replacement cost of the 800 mm cyclones is less than half that of the 400 mm units, and this is expected to improve. The plant layout and operability have also improved significantly. Xstrata has therefore decided to convert the whole plant to four low head 800 mm units, replacing the original 16 high head 400 mm units. The paper includes an explanation of the effect of static head on DMC separating force. It also reviews earlier research on diamond applications, and applies a general DMC process model to the Xstrata case, both of which confirm that large, low head cyclones are appropriate in mineral applications, contrary to conventional practice. Such units could significantly reduce both the capital and operating costs of DMC plants in mineral applications.

Jan 1, 2009

By M Zaluski, D Bless

An innovative, biological treatment process has been designed by MSE Technology Applications, Inc to treat and control acid mine drainage (AMD). A field-scale demonstration is being conducted under the Mine Waste Technology Program using water flowing from a historic mine in Montana. A successful demonstration of an in situ process will allow it to be employed at numerous other abandoned or remote mines, which discharge AMD, an acidic, metal-contaminated water. Conventional treatment methods are costly and are often impossible to use at remote locations. MSEÆs technology uses a biological system to clean up AMD. The In situ Passive Biological Treatment Process utilises nonpathogenic bacteria, which are able to neutralise acidic mine water and remove contained toxic metals. These bacteria live within a series of pile-type reactors inside the mine. The bacteria are fed inexpensive waste products. The resulting discharge is clean water flowing from the mine. This presentation will show that this technology offers a natural cleanup method for the nationÆs numerous abandoned mines. Work on this project was conducted under Interagency Agreement No DW899388-70-01-1 between the US Environmental Protection Agency and the US Department of Energy (DOE), and was performed at the Western Environmental Technology Office through the DOE National Environmental Technology Laboratory (DOE Contract No. DE-AC22-96EW96405).

Jan 1, 2003