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By D A. Vogel

"Sampling may be mandatory for safety or environmental reasons. It may be because the value of a sale needs to be determined or to provide important data for investments. Whatever the reason, an incorrect sample will come at a risk. Only the person that relies on sampling data can imagine what the potential cost of such risk is.Sampling itself has a cost too; the direct cost of a quality control department and indirect cost for interrupting a process, such as stopping a conveyor belt during loading. If all material is the same then only one small sample is enough. But if all the material is different, then a very large sample must be tested; in the conveyor belt scenario it must be stopped very frequently and the associated cost will be high.A good sampling plan finds the proper balance between risk and cost. A good sample must be small enough to handle yet large enough to be representative for what information is required. All good samples have three things in common: there was proper access to the material the sampling tool allowed equal probability of particles being selected nothing was disregarded, everything was included.This too is the core of Gy’s ideal sampling scenario, where all particles have the same probability of being selected and included in the sample. There is risk of bias when part of a lot is excluded from the sample. Extra care is needed when sampling particularly heterogeneous, segregated or layered materials. The sampling tool should never systematically leave out a portion; it shall not push aside large or hard particles. Wet samples shall not stick to the sampling tool. This extends to sample preparation too when reducing particle size and dividing the sample in the process.CITATION:Vogel, D A, 2017. Access, select, include – a review of the commercial sampling of traded bulk commodities in the context of Gy’s Theory of Sampling, in Proceedings Eighth World Conference on Sampling and Blending, pp 367–378 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

May 9, 2017

By T Graham

Traditional iron ore wet beneficiation plants are large multilevel structures, often integrated into centralised processing plants. They are characterised by sizeable footprints, substantial water and power consumption, inflexible design and low scalability. Significant design changes that address these issues need to be made before relocatable modular plants become feasible. Firstly, large amounts of processing water are required in standard wet plants, so it is vital that water consumption is reduced to an absolute minimum. Secondly, the process of depositing tailings into tailings storage facilities (TSFs) is environmentally destructive, consumes significant power and requires lengthy approvals to be completed. Thirdly, modules need to be easily and quickly relocatable.The solution to reducing water usage and eliminating TSF requirements is accomplished by providing a tailings dewatering and dry-stacking capability into a separate module. This equipment needs to dewater tailings to a point (typically below 20 per cent moisture) where dry stacking becomes possible – design is mainly driven by material rheology and particle size distribution (PSD). In this respect, a flexible and scalable strategy is employed to dewatering modules, allowing a variety of components such as dewatering cyclone clusters, paste thickeners, fine mesh vibrating screens and filter presses to be used to achieve the necessary moisture level, enabling the final dry stacking to be accomplished by a simple telescopic stacking system. Plant relocatability also requires modules to comply with mass and dimensional constraints, as well as ‘plug and play’ ease-of-use features.For coarse particle upgrade, jigs provide a low-cost and effective solution, whereas fine and ultra-fine Fe units can be recovered using Wet High Intensity Magnetic Separation (WHIMS). Recently, sensor sorting – a dry process using X-ray fluorescence, X-ray transmission, laser or other sensors – has begun to make an impact in coarse particle separation, although capacities are still low. The overall objective of a plant is to provide an Fe upgrade of four to five per cent with a feed of up to 4 Mt/a and a recovery of approximately 50 per cent.CITATION:Graham, T, 2017. Relocatable modular beneficiation creates value from waste, in Proceedings Iron Ore 2017, pp 167–172 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 24, 2017

Knowledge of true block grades is obtained from a mathematical model of an orebody, simulated with sample grades normally distributed and spatially correlated according io a spherical semi-variogram model.The superiority of kriging to the polygonal method of estimation is demonstrated on this modelled deposit by comparing the true values with the kriged and polygonal estimates obtained from sampling the deposit. Finally, selection of blocks of the deposit on the basis of the estimated values, shows that if kriging is used, what is predicted is largely mined, whilst if the polygonal method is used large biases can occur depending on the position of the cut-off grade.

Jan 1, 1978

Roasting of a Copper Sulfide Concentrate

Sep 13, 2010

In mining industries, materials loading and handling costs represent a significant component of the total (capital and operation) costs. A variety of methods have been applied in surface mine equipment selection in order to select the suitable loading and haulage system with the lowest total cost. The optimal size and number of equipment calculation are very important task for mining engineering because loading and haulage equipment are major proportion of open pit mining cost. Capital and operating cost are considered in objective function with respect to interest rate, insurance and tax in non-linear form. Shovel and truck annual productivity constraint, fleet matching constraint and number of truck per shovel constraint are incorporated in this optimisation problem with continuous variables. This formulation will yield total cost minimisation per hour and good accuracy compared to previous methods.

Dec 6, 2010

A study of the swelling behaviour of a single batch of high-grade iron ore pellets during hydrogen reduction in a fixed bed showed that the extent of swelling is governed by the nucleation and growth of crystalline iron protuberances from the wüstite grains. Over the reduction temperature range 650 to 1000°C, it was found that substantial degrees of swelling can occur at temperatures in excess of 850°C, and significant variations in the swelling behaviour of individual pellets from different bed levels are observed under these conditions.The results are discussed in terms of a recent swelling theory and shown to be in general agreement.

Jan 1, 1978

The GPS and information technology industries are now applying considerable development effort to what is being termed machine control and machine information systems, in particular focusing on the industries the of mining construction and agriculture. GPS based systems are demonstrably finding common acceptance and adding commercial value to many machine applications in industry. This has been the first step in the evolution of the information age that is now reforming mining practices. Adding the technologies of wireless data communication, modem computer databases, and networked PC's mining is on the verge of a new era in overall process management. This paper is a general discussion of what the information age means to miners and a general description of new mining operation technologies available to day from the Caterpillar technology alliance.

Jan 1, 1999

This paper focuses on two sites in the Mount Pleasant - McCormacks Bay area of Christchurch where residential development has taken place either within or immediately adjacent to former quarries for the extraction of volcanic rock. At the Quarry Road site less overburden was dumped on adjoining land around the turn of the century, and c.1980 dwelling and related construction took place on approximately 6 m of relatively loose fill material without the recognition of its presence or geotechnical characteristics. Subsequent settlements led to abandonment of a swimming pool and the underpinning of the 3-storey architect-designed house, whilst litigation brought by the owner resulted in findings of negligence against both the architects and engineers. At the Tramways Quarry site the Council approved subdivision of the former quarry area in the early 1980s without requiring any geotechnical evaluation of batter stability or related issues. During development it became apparent that significant blast damage had occurred to rock faces, necessitating a variety of remedial measures, and that waste materials had been dumped down faces without regard to long-term stability. Both case studies confirm the requirement for careful documentation of former quarry sites by territorial local authorities as part of their administrative function, and for detailed engineering geology and geotechnical evaluation of such areas prior to any residential use of the land.

Jan 1, 1998

The formation and distribution of gold placers in active collisional mountain belts are directly related to the tectonic, topographic, climatic and erosional constraints prevailing on either side of the orogen at the time of placer formation. In the absence of pre-existing placer deposits, these factors combine to concentrate placer development on the side of the orogen facing the prevailing winds, where most of the erosion and uplift occurs. Drainage network changes and glaciation can significantly alter placer distribution with respect to source areas within the orogen. After collision stops, placer formation will proceed on both sides of the orogen as exhumation of the mountain belt ensues. Incorporation of pre-existing placers formed on ancient mountain belts into younger placers in subsequent orogens, may be recognised by anomalous placer distribution compared to the above model. Most of the relatively young giant placers such as those inNew Zealand, Chile, Bolivia and Columbia, exhibit these general patterns. Their character and mode of formation have important implications for the formation and distribution of much older placers, such as those in South Africa's Witwatersrand Basin.

Jan 1, 1996

Similarities and Dissimilarities in Florida Phosphate Ore Types - Surface and Bulk Property Analysis of the Flotation Feed, Concentrate and Tails

Sep 13, 2010

Mining and metallurgical processing of gold and base metal ores often results in solid wastes and effluents containing high concentrations of arsenic. In addition, arsenic can be released to the atmosphere from gold roasters and base metal smelters. Speciation of arsenic in roaster products, in a stack sample from a copper smelter, in organic soils impacted by smelter emissions, and in an anaerobic effluent treatment system at a smelter site was determined in order to broaden our understanding of the nature and occurrence of arsenic in a wider range of metallurgical wastes. Micro-XANES spectra obtained from iron oxide particles forming in a gold roaster indicate preferential enrichment of As3+ species in maghemite-rich domains and microlayers. In comparison, haematite-rich iron oxide particles are dominated by As5+ species. It appears that maghemite is retarding oxidation of arsenic and its volatilisation during roasting. Arsenic occurs as both As3+ and As5+ species in a stack sample emitted from a Cu smelter, confined to fine-grained secondary product layers accumulated on the surfaces of spherical Cu particles. This is probably resulting from condensation of As species upon cooling following their volatilisation during the combustion process. Soil samples collected at various distances from the Cu smelter are dominated by As5+ species including monomethylarsonic acid and tetramethylarsonium iodide as the organic arsenic species. The presence of reduced As3+ species highlights the importance of organic material influencing the speciation of arsenic and mineralogical transformations taking place within the soil profile. The XANES spectra indicate that arsenic occurs predominantly as aqueous arsenite species in the anaerobic treatment system, contrary to the conventional thinking of As retention by the formation of secondary sulfides.

Jan 1, 2008

By R L. Brathwaite, S E. Belliss

Linear and semi-circular features were mapped in the volcanic terrain of the southernCoromandel Peninsula, North Island, using JERS-1 synthetic aperture radar (SAR), Landsat-4 Thematic Mapper, and SPOT-2 multispectral satellite data, digital elevation models, and aeromagnetic data. The mapped features typically correspond to recognised physiographic features and are thus a useful aid to mapping the structural trends in the region. Major linear features exhibit a strong N-S to NNE-SSW alignment, and lesser NW-SE and NE-SW trends. All these are superimposed on pervasive, closely spaced, NNE-SSW and NNW-SSE lineaments present over most of the hilly parts of the map area. There are few major E-W aligned features. Some alignment trends correspond to strike directions of veins in the epithermal gold-silver deposits of the region, but none of the known mineralised structures were visible on the remote sensing data.   The volcanic rocks are Late Cenozoic in age and include a variety of rock types: andesite and dacite flows, domes and tuff breccias, rhyolite domes, tuffs and tephra, lacustrine siltstones, and ignimbrites. Mapping of different textures in the SAR image failed to provide additional information on rock types to that derived from the Landsat and SPOT images. A simple discrimination of rock units based on radar texture is apparently prevented by the complex volcanic geology, superimposed hydrothermal alteration, and long period of erosion.

Jan 1, 1994

The Small Pebble Process for Reducing Ball and Power Consumption in Secondary Grinding Ball mills are used widely for secondary grinding. A mixture of ball sizes can be used to optimise grinding efficiency, but the use of balls smaller than about 30 mm in diameter is not normally viable, particularly when alloy steel is required. Preliminary testing of the grinding efficiency of various combinations of 40 mm steel balls and crushed stone in the size range 7 to 25 mm was carried out in a 300 mm diameter mill, which has accurate power measurement.The primary interest was to assess the potential benefit of adding small pebbles (from a primary circuit crusher or mill) to a secondary ball mill, to reduce ball consumption and to improve grinding efficiency. The optimum proportion of pebbles was found to be about 25 per cent by volume. This mixture produced about the same amount of fines as balls alone, but with lower power consumption, due to the lower density of the pebbles. The net result was a 12 per cent saving in power and a 25 per cent saving in ball consumption. The production of fines was partly due to pebble wear. The use of portions of 15 mm balls, (ceramic and steel), was also tested for comparison. A few batch pilot-scale tests were conducted in a 1.2 m diameter, 0.31 m long mill to test the viability of the pebbles at a larger scale. The pilot-scale tests confirmed the reduction in power and that the rate of production of fines was the same as that obtained with balls. The same residence time was used and this implies that pebbles can be added to an existing full-scale ball mill, with no loss in capacity. Samples of secondary mill feed and pebbles were obtained from a copper mine and the steady-state consumption of pebbles was determined by locked-cycle laboratory-scale tests. These tests demonstrated that mill power could be reduced by up 13 per cent and that the consumption of 40 mm balls could be reduced by up to 38 per cent, while maintaining the same throughput and product size. The rate of pebble addition was about 4 per cent of the primary circuit feed rate. Application has been made for patent protection.

Sep 13, 2010

By L Avalos, F Melo Miranda, J Misle, M Ingwersen

"Los Pelambres, majority owned by the Chilean company Antofagasta Minerals, is one of the leading producers of copper and molybdenum in the country. It is located high in Andes Mountains, over 3000 metres above sea level, 316 km from the nation's capital, Santiago.The maintenance service supplied to Los Pelambres over the past 13 years has evolved to the point that FLSmidth now provides an integrated service crucial to the management of their customer's assets. The contract initially involved specialty mechanical, electrical and instrumentation maintenance and has developed to encompass maintenance planning and plant control systems.The integrated partnership has delivered excellent results in the areas of improved availability, reliability and return on investment. The operation is now amongst the industry leaders in plant availability.The integrated maintenance service has delivered: An increase in plant availability from 93%, in the first year, to 96.5% today, generating approximately $50 million additional income per year, Quality work procedures, Process and equipment improvements, Major shutdown planning involving more than 700 personnel, 6000 parts and over 2 000 discrete activities.The ongoing success of the partnership requires a high level of understanding between both companies. A commitment to maintain a long term sustainable relationship, based on a ""win - win"" culture, is the key to this success. In this regard Los Pelambres has been a pioneer in establishing and developing such relationships.This case study will share the lessons learnt, the measures taken to improve performance and the best practices adopted during the 13 year evolution of the maintenance service partnership.CITATION:Misle, J, Melo Miranda, F, Avalos, L and Ingwersen, M, 2013. Integrated maintenance services at the Los Pelambres Mine in Chile - The lessons learnt and best practices developed from a long-term sustainable relationship, in Proceedings MetPlant 2013 , pp 296-331 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Jul 15, 2013

The selection of the best comminution circuit for the preparation of concentration feed is a compromise based on economics, energy efficiency, labour costs, steel consumption, availability and other factors specific to each case. It is postulated that the selection must be a choice of one of the eight basic comminution circuits which can be divided into two basic groups, (1) autogenous or semi-autogenous primary mills with or without a secondary grinding stage and (2) fine crushing usually in cone crushers followed by a rod mill-ball mill circuit or a single stage ball mill circuit. The accuracy of selection may be improved by pilot plant and laboratory tests which are described in this paper. For (1) above, testing includes media competency tests with standard impact crushing, grindability and abrasion tests followed by pilot plant tests. For (2) above, bench scale crushability, grindability and abrasion testing is available. It is suggested that, through these tests, it should be possible to eliminate all but one in each group of basic comminution circuits. Then engineering and economic studies should lead to the best comminution circuit for the specific requirement.

Jan 1, 1984

By M Simpson

Greywackes of the greater Auckland Region (Brynderwyn Hills to Hamilton), when considered on a regional scale, have characteristic ranges of physical, mineralogical and other properties. Some properties (eg density, porosity, crushing resistance, clay index) generally cluster and correlate with the basement greywacke facies, regions and terranes recognised by geologists, and their diagenetic/metamorphic level. Other local factors, particularly variations in mineralogical composition, nature of matrix cement, grain size, and degree of weathering may produce aberrant properties. Some of these local variations, when extreme, have the potential to affect the aggregateÆs performance in roading or the concrete industries.   Smectite and the zeolite laumontite are the major deleterious minerals occurring in fresh greywacke rocks of the Auckland region, although weathered rocks may contain halloysite, an expanding member of the kaolin clay mineral group. These minerals, when found in abnormally high levels in greywackes cause expansion effects in the aggregate. Currently there are inconsistencies in the detailed correlation of shrinkage, clay index, clay mineral content and intrinsic expansion data that need further research to resolve them.  

Jan 1, 2007

Validation and Simulation of Optimised Compressive Crushing Ores and aggregates are used in countless applications all around in the society. The frequent and escalating usage of these natural resources requires efforts aimed at not only making do with what is available, but also undertaking actions to improve the production yield and the processes involved. This strive to improve the performance and efficiency of existing crushers and crushing processes has brought about research concerning optimisation of crushing plants as well as theoretical optimisation of crushing. Previous work shows that different applications and different materials require different compressive crushing in order to accomplish a theoretically optimal size distribution. These optimisation results, obtained by genetic evolutionary algorithms and evaluated with so called fitness functions, convey the theoretically optimal number of compressions and their corresponding compression ratios. Presented in this paper are thus some laboratory crushing tests, which are conducted in order to validate a set of previously optimised crushing sequences. More specifically, interparticle crushing sequences are carried out in a Piston-die testing equipment, where samples are sieved between each compression. The subsequent analysis of these results shows good correlation with model predictions, which combined with a comparative study between presented optimisation results and measured data from a real crusher indicate a significant potential for improvement. However, before redesigning crushers according to what is theoretically optimal, the resulting impact as well as the effects on the outcome of a crushing plant must be examined. Crushing plant simulations using the software PlantDesigner« are consequently performed. Models of existing crushers are altered, resulting in changed particle size distributions from some of the crushers in a crushing plant. Thence, it is concluded that significant gains can be made in terms of capacity, process yield and energy consumption.

Sep 13, 2010

Mt Waruwari, host to the Porgera underground gold mine in the Highlands of Papua New Guinea (PNG), is a prominent ridge of sediments and dioritic intrusives rising approximately 600m above the surrounding valley floor. Consequently, mining occurs in a low stress environment where structural and material considerations are foremost in the design of ground support and reinforcement. Three major rock types are encountered in the underground mine. These are locally referred to as "black sediments" (slightly indurated mudstones and clayey siltstones), "altered sediments" (derived from black sediments by thermal metamorphism), and "intrusives" of dioritic composition. The rocks are moderately to highly fractured, the black sediments being generally weak and occasionally sheared while the altered sediments and intrusives are quite strong but often brittle. Mining takes place from a series of stopes extracted by either slot and mass blast or a modified vertical crater retreat method (VCR), which are backfilled with a cemented rock fill. Ground support and reinforcement has been relatively conserv- ative to date and generally relies on pattern reinforcement of all development with cement grouted "rebar" bolts and mesh, extending to pattern cable bolting with occasional mesh in stope backs. In addition there has been considerable reinforcement of stope hangingwalls in some cases. A programme of broad scale structural mapping, monitoring with extensometers, material property testing, and stress analysis has been devised to allow optimum design of ground support and reinforcement in the future. Considerable work remains to ,omplete this task.

Jan 1, 1991

By D Johnston

Within the first full year of BarrickÆs Cowal Gold Mine operation, the Lake Cowal Foundation Limited (LCF) has already been delivering results consistent with its goal to protect and enhance the natural environment of Lake Cowal and its catchment area. The LCF is a non-profit Environmental Trust established in June 2000 in conjunction with the development consent process for the construction of BarrickÆs Cowal Gold Mine. Its primary goal is to protect and enhance Lake Cowal, a nationally significant ephemeral wetland located 350 km west of Sydney, New South Wales, Australia. Significant concentrations of water birds visit the lake and the Australian Heritage Commission listed Lake Cowal on the Register of the National Estate in 1992. The LCF is managed by a Board of Directors from representative member organisations including the Total Environment Centre, National Parks Association, Nature Conservation Council and Barrick Australia Limited. Although largely funded by Barrick, the Foundation also attracts external funding and works in partnership with a diverse range of other groups and organisations, beyond the mine fence. The total value of currently approved projects is estimated to be in excess of $7.1 million, which includes æin-kindÆ contributions made by the local community and in particular the Lachlan Catchment Management Authority (LCMA) and local farmers. To date, LCF has been involved with the development and implementation of 30 projects with a total of 34 project partners. LCF has worked with over 60 landholders to improve Lake Cowal and its catchment, with 6180 ha of land now being managed for conservation or sustainable farming in the local area. Many landholders have been, or are involved in property planning or participating in other training opportunities. Sustainability of LCF programs and outcomes will be assured by commitments to projects within four key themes: conservation, research and research support, sustainable farming and community education and training. The LCF works independently from the mining company and has no responsibility for the environmental management within the mining lease. It is about capitalising resources generated by the mine to enhance environmental outcomes in the wider Lake Cowal catchment area by working collaboratively with the local community, industry and government authorities to ensure the long-term protection of a unique wetland ecosystem affected by landscape scale degradation.

Jan 1, 2007

Commercialisation of Ni Heap Leaching at Murrin Murrin Operations

Sep 13, 2010