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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 S France

The Waterview Connection will complete a strategic Auckland motorway route linking the south, west and north. The project will comprise 2.5 km of ‘undrained’ driven tunnels and 900 m of drained cut-and-cover tunnel and portals.The project is aligned beneath a stream valley of Oakley Creek incised through alluvium and in places overlain by landfill, between Mt Albert volcano and a ridge formed in alternating sandstones and siltstones. The hydrogeology of the area is complex with perched aquifers in compressible soils, cascading water levels in fractured rock aquifers, and discontinuous higher permeability units resulting in artesian water levels and groundwater springs.Numerical groundwater modelling was undertaken to assess the potential effects of tunnel construction and long-term operation on the groundwater system; the magnitude and extent of changes in groundwater level and the resulting potential for settlement, buoyancy effects, contaminant migration and adverse effects on creek base flow. Modelling also provides inputs to tunnel design such as groundwater seepage volumes and water pressures.The driven tunnel will be ‘undrained’ long-term so potential effects on the groundwater system are limited to short-term dewatering during construction. Significant project time and cost savings can be made if the portal areas are permanently ‘drained’, but this means potential effects are greatest in the long term condition.This paper summarises the investigations, implications of the complex hydrogeological setting on tunnel design and environmental assessments, and groundwater modelling undertaken during the planning stage of this project. The groundwater modelling has been used to incorporate mitigation options in tunnel design and construction sequencing; a comprehensive monitoring program will be used to trigger appropriate responses should effects differ from those predicted.

Mar 8, 2011

By R McCarthy, P Hawke

FerrAus Ltd's Robertson Range and Davidson Creek Projects are located in the Hamersley Province about 100 km east of Newman, Western Australia. Significant iron mineralisation defined by an aggressive exploration program within the Marra Mamba Iron Formation is shallowly north dipping at Davidson Creek, and mainly shallowly east dipping at Robertson Range, forming part of a regional scale anticline with the granitic and greenstone basement of the Sylvania Inlier as its core. With minor exceptions, the stratigraphy is comparable with that seen in the main Hamersley Basin. Granite and greenstone basement rocks of the Sylvania Inlier are unconformably overlain by shales and volcanic rocks of the Fortescue Group. The overlying Hamersley Group is locally represented by interbedded chert, banded iron-formation (BIF) and shales of the Marra Mamba Iron Formation (Nammuldi, MacLeod and Mount Newman Members), and dolomites, cherts, BIF and shales of the Wittenoom Formation. Iron enrichment occurs predominantly in the Mount Newman Member, and to a lesser extent in the West Angela Member of the Wittenoom Formation. Enrichment varies from 20 - 30 m in thickness in elongate bodies up to 3 km in strike length, and generally thins down dip. At Davidson Creek iron mineralisation is a haematite-goethite-ochreous goethite assemblage, while at Robertson Range this assemblage is consistently overprinted by a later, goethitic alteration related to 'hardcap' weathering. Near surface hardcap alteration in both project areas comprises more siliceous, aluminous and vitreous goethite. Initial exploration completed by Rio Tinto Exploration between 1999 and 2001 indicated the potential for about 20 Mt of iron mineralisation at Robertson Range. Since 2005 a detailed exploration program undertaken by Australian Manganese Pty Ltd (a wholly owned subsidiary of FerrAus Ltd) has defined a global indicated and inferred resource totaling 164.4 Mt at 58.6 per cent Fe (ASX: FRS 17 April 2009).

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

By S Doudle

The Iluka Resources Ltd Jacinth-Ambrosia heavy mineral sand mine (South Australia) is located in an undisturbed semi-arid landscape consisting of sparse trees, shrubs and grasses. The soil interspaces are covered with biocrusts, a living soil cover also found worldwide in arid regions. Biocrusts are composed of lichens, cyanobacteria, algae, mosses, liverworts, fungi and bacteria, and live on and within the first few millimetres of the soil surface. Biocrust organisms bind soil particles, sequester carbon and many fix atmospheric nitrogen making them important structural and functional components of ecosystems. Despite their important role in ecological processes, biocrusts are susceptible to disturbance; nevertheless they can recover provided sufficient inoculum is present. Cyanobacteria are the early colonisers and they capture atmospheric and landscape resources and establish conditions that subsequent successional seres can capitalise on. Research conducted in countries including China, Spain and South Africa has been focused on methods to either encourage rapid regeneration of cyanobacterial remnants or to introduce new material from cultured cyanobacteria. We have been investigating the extent and diversity of biocrusts across the 4500 ha mine lease and their potential to improve mining rehabilitation outcomes. Approximately 46 per cent of the soil surfaces are colonised with biocrusts and 33 taxa have been identified. Laboratory experiments were designed to mimic massive soil disturbance and treated with a range of water qualities. Within 22 days, treatments irrigated with fresh water were colonised by new cyanobacterial filaments with a mean surface coverage of 65 per cent. Secondary tests revealed that differences in the photosynthetic yield of the crust were dependent on the salinity levels of the irrigation water used. In 2011 this program is expanding from the laboratory into field scale trials designed to assess both the potential and practicalities of up scaling these techniques to provide crushed biocrusts and cyanobacterial bio-inoculum for use in mine rehabilitation.

Oct 5, 2011

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 T McLeod, B Catto

AngloGold Ashanti Australia’s (AGAA) Tropicana gold mine (TGM) geology department seized the rare opportunity of building a new geology department for a new operation: the philosophy, the people and the processes. Not satisfied with the status quo, or simply repeating what was familiar and already known, the vision was for an innovative, agile, multidiscipline, high performance team, capable of delivering on expectations.To achieve this, the geology department has operationalised key components of human resource management (HRM).This paper describes the operational design and implementation of key HRM components: job analysis, organisational design and organisational development. The benefits of this approach are presented in terms of engagement and autonomy in roles, opportunity for role variety and flexibility of the organisational structure. The result is a geology department that provides the functions of mine geology, resource development, regional exploration, survey, data management, geographic information systems (GIS), resource modelling, scheduling, sample preparation, resource coordination and hydrogeology, and even geotechnical engineering for a year!Considerations for application in other geology departments are presented in terms of fundamental requirements and lessons learnt. Fundamental requirements for success have been the sustained support of the general manager, valuing the scrutiny that comes with continuous improvement, high quality HRM systems and tools within the organisation, and a committed leadership group within the department. One of the most important lessons learnt is that a robust process of ‘induction to role’ is critical – the process of familiarising new starters with who we are and the way we work.CITATION:Catto, B and McLeod, T, 2017. Rewriting the rule book – geology organisational design, in Proceedings Tenth International Mining Geology Conference 2017, pp 137–142 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 20, 2017

By D Deb, R Pramanik

This paper presents a generalised methodology in smoothed particle hydrodynamics (SPH) framework to analyse dynamic failure process of rock mass having natural joint under blast-induced stress wave and expansion, and penetration of high pressure gaseous product. The necessary interactions of gas-rock are incorporated in the model which describes features of coupling between damage and plasticity in tension and compression respectively. A Drucker-Prager formulation of plasticity is used to model the behaviour of aggregate field and the Grady-Kipp damage model is employed for tensile strain. These two material behaviours are then brought together within the framework of interacting continua. The model relies on the Drucker-Prager plasticity surface to predict the dilatancy aspect of the material response and to account change of strength according to the strain rate effect. Three numerical examples are presented with rock joint and multiple blastholes.CITATION:Deb, D and Pramanik, R, 2015. Smoothed particle hydrodynamics modelling of blast-induced fracture processes in naturally jointed rock medium, in Proceedings 11th International Symposium on Rock Fragmentation by Blasting, pp 65–70 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 24, 2015

By D Yan, D Connelly

Beneficiation of magnetite is an integral part of the future of iron ore processing. Historically, the focus of Western Australian producers has been on exporting direct shipping ore (DSO) namely haematite. The future for new DSO resources is limited so companies are changing their emphasis into processing the very large, undeveloped magnetite ores in Western Australia (WA), using beneficiation to produce shippable magnetite concentrates. These magnetite resources require higher cost processing techniques such as fine grinding and beneficiation to produce saleable concentrates. This distinct difference, from the DSO ores, has led to the development of a number of new technologies. This paper reviews: the different techniques used for magnetite beneficiation and provides some case studies in the WA industry; the use of mineral liberation analysis (MLA) to describe the nature, grain size, occurrence and associations of the mineralisation;the consideration of coarse cobbing as a critical upgrading; the application of high pressure grinding rolls (HPGR) to save energy; how the field of magnetic separation has resulted in new machines with higher field strength (SLon Separators); ultra fine grinding requirements of magnetite concentrates; andthe application of reverse flotation to reduce silica in the concentrates.

Jan 1, 2009

By G Simpson, S Dressler, A E. Levett

Tailings storage facilities often represent a mining operation’s most significant liability, posing serious environmental, social and safety risks. Almost all mining operations dispose of wet tailings (Valenta et al, 2023), which represents a risk of failure due to the potential for a rapid strength reduction of the unconsolidated materials leading to static liquefaction and subsequent dam wall failure. As a waste stream, tailings disposal, decommissioning and relinquishment aim to be inexpensive processes, ruling out many highly engineered solutions. Advantageously, tailings consolidation does not need to be immediate, opening the door for relatively passive, inexpensive consolidation methods that aim to gradually increase the strength of tailings over extended periods (ie years). In this paper, we present the prospect of novel in situ tailings stabilisation, learning from studies that have investigated the most erosion-resistant landforms on Earth.

Aug 2, 2023

By Minglin W, Zhixing L

The laws of detonation wave velocity variation in propagation process along the charge under channel influence are investigated widely in this paper. The result is obtained by blasting experiments. Bore hole is simulated by plastic tube or steel pipe (with outer diameter 45 nun, inner diameter 40 or 41 mm). Blasting experiment is carried out with a cylindrical charge of 32 mm diameter. The author analyses the characteristics of energy distribution along the charge under above-mentioned conditions. Reasonable initiating position and initiating direction are also analysed. A double-direction initiating method which consists of several initiating charges is put forward. The blasting effect of this initiating method when used in underground mining is stated out.

Jan 1, 1990

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

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 D FitzGerald

A critical component of any new tunnel design in a complex geological setting is the development of an integrated three-dimensional (3D) geology model with a full set of geotechnical properties of the rocks present. A novel means of predicting the geology based upon sparse observations of structural geology at the surface and from drill holes has been developed and used in several major tunnel studies in Europe.An example of this is the Lyons-Turin twin rail tunnel which is still in a development phase. This tunnel has been in planning and development for over 15 years already. An important aspect of this work is to characterise geological uncertainty along various possible tunnel paths as an input into early design optimisations for time, cost and risk avoidance strategies. Once the tunnel works commence and more detailed geological data is collected by daily mapping, progressive refi nement of the geological model is desirable; geological conditions still to be encountered can be more accurately predicted. Faults and their offsets, dykes, geological unconformities, folding, as well as standard sedimentary processes are all correctly modelled in the software. It is important to allow for seamless interchange of geological models at various scales with CAD workflows so that sufficient detail can be readily accessed at the required scale. Also, the proposed tunnel in its correct geometry can become a ‘section’ in its own right. Progressive detailed local geology models in the vicinity of the advancing head are created from the regional scale work by cutting and pasting a starting model, then adding all the extra detail for the required engineering geology work.For all rocks, most standard geotechnical quantities such as sonic velocities, Young’s modulus and Poisson’s ratio are handled. These and any other phenomena from borehole observations can have variograms calculated and stratigraphically constrained estimations made in a least biased geostatistical manner, in advance of the tunnel. RQD, or a prediction of rock fractures, is handled by the faulting and folding modelling facilities. This is probably the more interesting issue to pursue, as the fractal nature from small scale fractures and joints, to large-scale faults, can now be characterised more convincingly.

Mar 8, 2011

A Kellogg type computer model of the slag fuming process is applied in reverse to derive some thermodynamic properties of components in lead blast furnace slag. At 1200¦C, the average activity coefficients calculated were 3.40 (S.D. 0.50) for ZnO referred to the pure solid; 0.657 (S.D. 0.022) for PbO referred to the pure liquid; for the ratios y 3.175 y (referred to the Feo.9450, Fe304 pure solids) 4.19 (S.D. 1.15), and for yCaS/ 1CaO (referred to the pure solids) 5.10 (S.D. 2.96). Statistical relationships were derived for these activity coefficients and ratios as functions of the composition of slag, which contained in molar percentages 1.9 - 12.6% ZnO, 19.8 - 24.9% Fe0.9450, 0.9 - 1.6% Fe304, 0.002 - 1.9% PbO, 16.1 - 18.6% CaO, 25.9 - 31.0% SiO2, 4.8 - 5.5% MnO, 9.2 - 10.3% A101.5, 1.2 - 1.4% CaS, and 5.1 - 9.6% "Mgo" (the balance).

Jan 1, 1980

By Frew J. A, Harris M. C, Manlapig E. V

The recovery achieved in a flotation process is a function of both the characteristics of the feed stream and the operating conditions within the flotation cell. In this paper, the flotation characteristics of the streams within the Red Dog le

Jan 1, 1997

By H Kurth

High specification Prompt Gamma Neutron Activation Analysis (PGNAA) has been successfully applied to conveyed flows at iron ore operations since 2002 to representatively measure ore quality for improved quality management and process control. While the PGNAA technique has changed little since that time, significant improvements have been made in measurement capability. Elements previously unable to be measured well or at all using this technique are now measurable and one of these is phosphorus. Aluminium and magnesium are also key elements in addition to calcium and silicon in determining sinter basicity in ironmaking. Other elements measured routinely in iron ores include iron, carbon, potassium, sulfur and manganese. The benefits of representative measurement cannot be overstated as iron ore mining operations in South Africa, Europe, Australia, Asia and the Americas have discovered. The technology is applicable to any conveyed flow where elemental analysis in real time assists with quality management, from raw materials in ironmaking through to scrap steel in steelmaking and coal quality for coke-making. Major benefits are realised when raw material processing is optimised and this often includes diversion of material meeting a required quality so it can bypass unnecessary processing. This includes waste rock which can be diverted from a plant feed stream in 30 sec increments or ore that meets product quality being diverted to bypass beneficiation. Analysers are successfully utilised to identify ore types that assist with upgrade optimisation in jig plants; measuring feed, product and discard flows to also account for metal content. Product flows to stockpiles help manage production flows and stockpile qualities for different products and assist in blending ores into trains or ships to confirm specification compliance. Technologies can be used in magnetite processing but are predominantly used in hematite and goethite ore processing operations. The paper details examples of the above applications at various operational sites providing estimates of economic benefit as well as operational improvements.

Sep 18, 2023