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By Bawden WF, Paynter JT

This investigation involves laboratory testing and stability analysis of paste fill at the Golden Giant Mine. Site-cast samples are tested in unconfined, confined, and consolidated-undrained triaxial compression. Pore pressures during shear and consolidation characteristics are measured to determine both drained and undrained shear strength parameters and assess the potential for undrained loading. Liquefaction potential is also considered. A limit equilibrium solution is used to obtain factors of safety against failure of the fill during mining of adjacent stopcs

Jan 1, 1998

By L P. Trout, D G. Reid

PanAust Limited (PanAust) has successfully constructed and commissioned two mining operations in Lao PDR over the past decade and undertaken major studies for three new mine developments. The management of potentially acid generating mine waste and tailings in close proximity of local communities sensitive to water discharge quality have been recurring themes that have confronted PanAust’s project study, development and operational teams. Further compounding challenges, such as the effects of intense annual tropical monsoonal conditions, staging of embankment raises and regular lifting of spillway structures, integrating mine waste and tailings management into production plans and ensuring the long term stability of structures, have been addressed by implementing leading practice management solutions.A recognition of the criticality of managing the substantial business risks associated with these crucial activities led to the early establishment of a governance structure to ensure that the highest standards are embraced for planning and execution. Importantly, these are guided and monitored by a panel of highly experienced and qualified international specialists reporting directly to PanAust’s Managing Director – the Tailings Independent Review Panel. The stewardship process has been effective in identifying potential shortcomings in management systems and has led to enhanced executive commitment to risk informed designs, assurance and overall process rigour.CITATION:Trout, L P and Reid, D G, 2018. PanAust Limited’s approach to mine waste and tailings stewardship, in Proceedings Mine Waste and Tailings Stewardship Conference 2018, pp 135–155 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 23, 2018

By H Ishikawa, H Zhou, M Spagnolo, R Halomoan, S Palaniandy

The Karara Mine concentrator commenced operation in November 2012 to produce high-grade magnetite concentrate. The circuit consists of three stages of comminution plus magnetic separation at each stage for early gangue rejection. High-Pressure Grinding Rolls (HPGRs) are used for fine crushing, followed by ball mills and TowerMills in secondary and fine grinding duties respectively. In recent times, the plant throughput rate has had to exceed design by 18% to maintain the targeted concentrate productivity. Meanwhile, the ore hardness has increased by 25% to 15 kWh/t, leading to changes in the circuit operation and design. These changes led to coarser and harder feed to the TowerMill circuit that affects the subsequent separation processes. Nippon Eirich (the TowerMill manufacturer) has partnered with Karara Mining Limited (Karara) to optimise the TowerMill circuit operation to achieve a circuit product with an 80% passing (P80) of 35 µm. Several activities, including a TowerMill circuit audit and performance evaluation, multi-component analysis, modelling and simulation, were carried out as part of the optimisation exercise. The circuit audit results revealed that the TowerMill circuit feed size F80 had increased and ranged from 67–75 µm. The circuit product P80 ranged between 42–55 µm. The average circuit specific energy was 3.4 kWh/t. Moreover, the differences in density between magnetite and gangue minerals had affected the hydrocyclone performance where the efficiency curve exhibits coarse end deflection indicating that low-density coarse material was bypassing to the overflow stream. A multi-component analysis was carried out to further investigate the coarse end deflection of the hydrocyclone efficiency curve. The analysis showed that the magnetite and gangue minerals had different cut sizes of 32 and 64 µm respectively. Furthermore, 33% of the magnetite (below 35 µm) was being recycled back to the mill due to the density effect. Based on these findings, several recommendations for process improvement were identified and implemented including:• converting to a bottom feeding configuration to improve the grinding efficiency in the mill• additional grinding power in the fine grinding duty to compensate for the increase in plant throughput and ore hardness• improved classification efficiency by converting to smaller size hydrocyclones. Simulation studies carried out to evaluate the impact of these implementations had indicated that a P80 close to 35 µm with a steeper size distribution could be achieved by using the bottom feed configuration with additional grinding power. The TowerMill circuit was converted to bottom feed configuration and the performance was evaluated. The operating work index, size specific energy and circulating load were 30% lower than the top feed configuration, indicating that the bottom feed configuration had a higher grinding efficiency. This paper discusses the outcome of the circuit audit, multicomponent analysis, circuit simulations, improvement strategies and quantification of the improvements. CITATION:Palaniandy, S, Spagnolo, M, Halomoan, R, Zhou, H and Ishikawa, H, 2017. Fine grinding circuit process improvement at the Karara mine concentrator, in Proceedings MetPlant 2017, pp 101–120 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 11, 2017

In considering the organization of research, it is necessary to know just what research is, what objects are in mind when setting out to conduct research, and what are the functional units which are required to enable a coordinated effort in research to proceed.The dictionary defines research in the following terms: Laborious and patient search, as for truth, diligent inquiry or examination in seeking facts or principles; inquiry, scrutiny; to search or examine with continued care; to seek diligently; to search again; to examine anew.This is, of course, simply a formal definition, but the reference to "labour", "patience" and "diligence" should be noted.The following quotation from an answer to the question "What is Research?", published recently in a technical journal, puts some life into the formal definition:- Essentially, it (Research) is nothing but a state of mind a friendly, welcoming attitude toward change. Going out to look for a change instead of waiting for it to come. Research, for practical men, is an effort to do things better... The research state of mind can apply to anything: personal affairs or any kind of business, big or little. It is the problem-solving mind as contrasted with the let-well-enough-alone mind . . . It is the "to-morrow" mind instead of the "yesterday" mind. Note the statements that: Essentially, it (Research) is nothing but a state of mind, and the research state of mind can apply to anything.

Jan 1, 1950

By R Schiller, E Chait

"Quebrada Blanca is a porphyry copper deposit located in the Eocene-Oligocene belt of Chilean Andes. Operation started in 1994 and original reserves for supergene mineralisation gave a life-of-mine (LOM) of 20 years; however, further exploration extended the LOM until 2020.In order to optimise the remaining five years of supergene resource, geometallurgical variables were added to the geological model including copper recovery and acid consumption. LOM plan encompasses finishing the phase number eight and the future development of phases 11 and 13.LOM lithologies include diorites, quartz monzonites, porphyries, igneous and tourmaline breccias. Main alterations are: potassic, phyllic and argillic. Litho-alterations or geometallurgical units were formed by combining five types of rocks with three types of alteration. According to statistical information, the deposit can be represented with 12 litho-alteration units, which cover 98 per cent of the LOM volume.For copper recovery information, there were 40 mini-columns tests made in order to obtain kinetics curves and copper recovery values after comparing the difference between head and tails grades. Acid consumption was obtained using an automatic neutraliser device-based test.Historical data said that copper recovery in pads after 450 days of irrigation is around 75 per cent of recoverable copper while acid consumption is around 5.5 kg/t.According to this study, lower recoveries are related with potassic-altered diorites and argillic-altered quartz monzonites with values around 60 per cent. On the other hand, best recoveries could be found in potassic-altered quartz monzonites and argillic-altered diorites with values closer to 80 per cent.It was also revealed that the most reactive rock is the potassic-altered diorite with 12 kg/t of acid consumption. This rock covers approximately 40 per cent from phases 11 and 13.The final geomet model was calculated using a program that relates each geometallurgical unit with a specific copper recovery and acid consumption value. Results found after comparing model-obtained information with historical leached pads data were used to validate the model.CITATION:Chait, E and Schiller, R, 2016. Adding Copper Recovery and Acid Consumption Variables to the Geological Model of Quebrada Blanca, in Proceedings The Third AusIMM International Geometallurgy Conference (GeoMet) 2016, pp 257–266 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Jun 15, 2016

By A G McLean

This paper will first discuss the fundamental requirements for reliable discharge of backfill by gravity alone at high per cent solids. This discussion will include brief mention of the underlying principles of saturated solids flow contrasted to that of stirred tank or dilute discharge systems. Here the need to possess full knowledge of the flow properties of the stored material will be highlighted. In regard to attainment of reliable discharge it will he revealed flow from a backfill silo will only occur provided: ò the flowing material in the converging channel is yielding throughout; ò slip is occurring along the walls; ò an arched stress field is present in the vicinity of the outlet; ò the flowing backfill must be dilating to flow in response to the dilating stress field; ò sufficient dilation water is injected, in the hopper, to eliminate the formation of adverse interstitial pressure gradients; ò sufficient dilution water is injected, downstream from the hopper outlet, to generate a pumpable slurry of maximum per cent solids; ò the silo level must be sufficient to prevent the pump suction forming a rathole; ò the system must be configured and operated to generate stable discharge density; and ò the system must be configured and operated to minimise damage to the pump liners. In addition proper account must be made of the silo overflow weir and settling capacity to match plant throughput. Here opportunity will be taken to highlight the complexity of this multi-phase flow situation as well as the general yet paramount requirements for reliable solids flow. It will be shown that by proper attention to the multi-phase considerations gravity discharge of slurries as a consolidated bed with minimal water content is possible. Such high solids discharge results in greatly reduced demand for process water. In addition pumping costs are reduced as is the delay time associated with the mine drainage operation. Confirmation of successful applications will be highlighted by reference to several recent case studies. In the concluding phase mention will be made of the key yet very simple and effective operation techniques which enhance reliable Discharge.

Jan 1, 1998

By M Haest

This study demonstrates the application of HyLogging™ technologies for mineralogical characterisation of different iron ore types throughout the Hamersley Province (Western Australia), including a channel iron deposit (Murchison Metals Ltd) and bedded iron deposits in the Brockman and Marra Mamba Iron Formations (BHP Billiton Ltd).Drill core from these deposits was analysed using CSIRO’s hyperspectral drill core logging systems (HyLogging systems), which are commercially available at the AMDEL and AMMTEC laboratories in Perth (Western Australia), through a leasing agreement. These HyLogging systems provide high resolution photographs at 0.1 mm pixel resolution as well as visible and infrared spectroscopic refl ectance data at 1 cm spatial resolution. The minerals identified include haematite, goethite and its subtypes (ie vitreous and ochreous goethite), AlOH-clays (kaolinite, Al-smectite and white mica), carbonates, gibbsite, chlorite, amphibole and hydrated silica as well as water content. The abundance and composition of these minerals was established from the spectral data and was validated against XRF analyses.The full potential of HyLogging systems in the iron ore industry is only starting to be unveiled, but some major benefits have already been demonstrated:• HyLogging systems can delineate different ore zones by mapping the vitreous and ochreous goethites. This has a potentially large impact in mine planning and operations, as hard, vitreous goethite and soft, powdery, ochreous goethite have different processing characteristics that can affect plant throughput if not carefully managed.• HyLogging mineralogy can also be used to support stratigraphic interpretations of the host, for example in subdividing the Dales Gorge 1 - 4 submembers of the Brockman Iron Formation.• HyLogging can have a potentially signifi cant impact on waste rock characterisation, as many of the waste materials can be identifi ed and quantifi ed with hyperspectral data (eg clay-type,• hydration state).• HyLogging can provide accurate three-dimensional (3D) mineralogy to iron ore companies that will empower them to improve future exploration and resource planning.• Application of high resolution photography to further improve ore deposit domaining is also to be considered.

Jul 11, 2011

By C S. Kelsey, J R. Kelly

Australia is presently enjoying the fruits of a booming iron ore market. Expectations are that market strength will be supported in the short to medium term by increasing feedstock demands from steel mills, as world economies rebuild post-Covid-19. However, as cost and environmental pressures increase the longer-term market outlook will be dominated by product quality. The ‘flight to quality’ will place increasing demands on direct shipping ore miners as they compete to maintain their standing in the iron ore marketplace. China will progressively disengage from its dependence on Australian imports, leaving miners under increasing pressure to boost product quality and diversify outlets globally. Australia has vast deposits of low-grade magnetite ores located mainly in remote and arid regions of the continent. This paper proposes a dry grinding and magnetic separation process to produce premium concentrate grades from the low-grade ores, to assist in meeting future product quality demands. The premium grade concentrates could be either blended with lower quality direct shipping ores or marketed separately. The proposed dry concentration process involves the pairing of Vertical Roller Milling (VRM), a mature technology widely used in the cement industry, and Planar Magnetic Separation (PMS), a new methodology, which has been developed to the threshold of commercialisation by the private Australian company Cyclomag P/L. Two laboratory prototype planar magnetic separators with field strengths of 1800 gauss and 6000 gauss have been built and tested on a range of magnetite ore types over the past three years. In each case, following grinding to liberation sizes, a combination of roughing and cleaning operations has produced pellet grade concentrates. Vertical roller milling has competed successfully with conventional media milling in grinding cement clinker, limestone and blast furnace slags. A key advantage of dry VRM/PMS processing is its potential adaptability to stepwise modular development, which can minimise initial capital investment, while generating early revenue streams to cope with unpredictable market volatility.

Nov 8, 2021

By M Pyle, R Ch, T Vizcarra, ramohan, G Lane, G Ballantyne

Preconcentration, through gravity separation (Wallace et al, 2015), magnetic separation and particle size (Clout, 2013), has been used in many historical projects to convert low grade material into ore. More recently, pre-concentration technologies such as bulk sorting (Kurth, 2017), screening (Bearman, 2014) and coarse particle flotation (Vollert et al, 2019) have also demonstrated their ability to progressively reject waste through the value chain. These technologies can not only deliver stepchange improvements to the economics of mining operations, but can transform the environmental and social aspects by minimising water and energy consumption and significantly reduce the quantity of fine tailings produced. However, implementing progressive waste rejection requires technologies and approaches to be combined and applied in the right way to capture the value. From a technical perspective, progressive waste rejection introduces challenges related to the orebody, equipment performance, engineering and understanding the value chain from the resource through to final product. From a management perspective, the key issues are related to people and processes, in particular; motivating the business, challenging the paradigms, and introducing new ways of operating within the constraint of existing management structures to manage risks and minimise lost opportunity costs. This combination of technical and management issues means that progressive waste rejection is a complex undertaking for mining companies, yet the reward for the business and other stakeholders is potentially high and should not be ignored. This paper presents how progressive waste rejection can offer step-change improvements to the business case for high and low grade greenfield and brownfield projects based on case studies completed by Ausenco. The paper then outlines different implementation approaches from concept studies to execution to address the various technical and management challenges outlined above.

Nov 10, 2020

By T Horberry

This paper describes work conducted as part of an overall research project that aims to identify current and emerging trends in the development of automation and remote mining technologies, and to provide an operator-centred perspective to the design and deployment of such systems. More specifically, this paper outlines a research and development process being constructed to examine the issues of the human skills and capabilities required to operate or maintain automated/remote controlled mobile mining equipment. A human factors approach presented here, where the focus is upon designing equipment interfaces to fit operators, rather than purely designing and deploying the equipment based on a technology-centred approach. However, the importance of training to help develop the required skills and capabilities is also emphasised.The work built on a full review of the literature about the effects of automation in mining and elsewhere, extensive interviews with different stakeholders in mining automation and recognised best practice regarding designing for the human element in automated systems. The human element research and development process proposed is in four stages, ranging from understanding the tasks involved in both manual and automated equipment operation through to user trials to ensure that the automated systems are acceptable to operators and are fit for purpose.It is outside the scope of the current paper to present the full data collection described by this four stage process, but an overview of what will be collected is presented. As such, this paper focuses on the broad methods being developed, rather than the specific results to be obtained. The ultimate objective is to apply a broad ‘technology assessment’ approach to the design, deployment and evaluation of automated mining technologies, in particular by considering the user-centred design implications of these technologies.

Nov 22, 2011

By G Harbort

Traditional engineering design for flotation circuits use the “Rule of Thumb” approach. Typically this uses a nominated maximum head grade for design. A scale-up factor is applied to laboratory flotation tests for residence time. This scale-up factor is usually based on a designers experience at other flotation sites and may or may not be relevant to the circuit being designed, or the flotation equipment being used. A small number of locked cycle tests are assumed to represent the ore body and the results of these are often used for financial analysis, independent of changes in mine plan throughput and mineralogy.The engineering “Rule of Thumb” approach is only strictly accurate where there is very little variability in throughput, head grade and mineralogy. It may provide accurate design for mature established operations where a brownfield expansion is being considered but is unlikely to provide accurate design for a new, greenfield site.The use of geometallurgical modeling with floatability component simulation provides a design methodology with significantly less associated risk. The use of geological data for optimisation of operating plants has become a significant part of the modern process mindset. The underlying principle is to use spatial metallurgical information to drive production planning, mine planning, blast design, blending strategies and plant set-up. At a design stage the process designer can use geometallurgical information to evaluate bottle necks and potential design flaws and propose the best investment strategy for the project benefit.This paper details the geometallurgical characterisation of the Andash deposit and methodology used to review the project’s detail design and projected production.

Aug 8, 2011

By J Nell, J Petersen, X C. Goso

The feasibility of increasing the deportment of titanium species and the stability of the pseudobrookite solid solution (M3O5) in a titaniferous slag was investigated, to facilitate the valourisation of titaniferous slags. Thermochemical simulations using FactSage™ software, ver 8.3 (by Thermofact/CRTC and GTT-Technologies), and equilibration-quench experiments were conducted using an appropriate synthetic titaniferous slag composition in an oxygen partial pressure (pO2) ranging from air to 10-16 atm under non-isothermal conditions. The temperature-pressure phase stability diagram for the synthetic slag containing 37.19 per cent TiO2, 19.69 per cent SiO2, 13.12 per cent Al2O3, 16.00 per cent CaO and 14.00 per cent MgO showed that the spinel solid solution (M3O4) was the primary phase until a pO2 of 10-10.5 atm, thereafter M3O5 was the primary phase until a pO2 10-13.2 atm. M3O4 again was the primary phase between a pO2 10-13.2 and 10-16 atm. The changeover of the primary phase coincided with an increase in the liquidus surface. When cooling the slag in a pO2 of 10-16 atm, M3O5 crystallised as a ternary phase that showed a rapid increase in mass while that of the primary M3O4 phase decreased and that of the secondary perovskite (CaTiO3) phase increased at a slower rate. At 1300°C under sub-liquidus conditions, the contents of M3O5, M3O4 and CaTiO3 were about 20 per cent, 15 per cent, and 11 per cent, respectively. Experimental results showed that the Ti3+/Ti4+ mass ratio in the M3O5 phase, ie a measure of the reduction of titanium species, is not considerably sensitive to equilibration temperature in the reviewed range. Slow cooling and minimum/no oxidation during cooling of titaniferous slag would increase the deportment of titanium species to, and the growth and stability of the M3O5 phase.

Jun 19, 2024

By P Hagan, S Wang, D Li, B Loh

A study was undertaken to quantify the differences in performance between a full-length encapsulated cable bolt and a partially encapsulated cable bolt. Much research has been reported on the differences in cable bolt design and operational parameters such as borehole diameter and grout type with much of this based on the Laboratory Short Encapsulation Pull Test (LSEPT). However, there is a gap in knowledge surrounding the effect of anchorage length on load transfer and cable bolt performance particularly with respect to the role of the bulb in modified cable bolt designs. The objective of this study was to expand the existing knowledge base of cable bolt performance with the intent of developing a revised design criterion. Alongside a comprehensive review of current cable support theory, design and practice, a series of pull tests was undertaken to compare each anchorage method using a high capacity modified cable bolt. The results serve to confirm earlier work on fully encapsulated anchorage. Both the peak load capacity and stiffness of the fully encapsulated cable bolt were nearly double that of the partially anchored cable bolt. When the tests were repeated in an oversized borehole, while there tended to be more variation in performance, there was little significant difference in the mean results. In addition to anchorage length, there are other factors that contribute to cable bolt performance including in order of sensitivity: embedment length, water-to-cement ratio of the grout, type of grout and borehole diameter. CITATION:Loh, B, Hagan, P, Li, D and Wang, S, 2018. A comparison of the performance of fully versus partially encapsulated cable bolts based on laboratory-scale testing, in Proceedings The Fourth Australasian Ground Control in Mining Conference (AusRock), pp 291–302 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 30, 2018

By C McCracken, R Landers, B Hesse

Minnovare identified the potential to improve production drilling outcomes in underground long-hole stopes through the adaptation of new technology which was under ongoing development. An approach to Evolution Mining resulted in the companies agreeing to a collaborative agreement to further develop the technology for use on underground long-hole drilling equipment. During a period of six months in FY2018, a series of trials were conducted to compare drilling accuracy using two different methodologies and the subsequent impact this had on ore dilution. Testing was conducted at Cracow underground gold mine in Queensland, Australia. The drill rig’s existing setup/alignment process was compared to the new technology system with the following observations: • Using the existing process only 20% of holes surveyed recorded toe points within the +/ 300mm (11.8in) tolerance blast-hole deviation. • The new technology was proven to limit rig setup/alignment error, reducing average blasthole deviation and increasing the number of holes drilled within tolerance by 160%. The increased accuracy reduced stope dilution by reducing over-break of subgrade ore: • Stopes drilled using the new technology recorded 62.6% less average dilution. • This contributed to an overall reduction in dilution for the full year (FY18) of 5 percentage points compared to FY17 - from 22% to 17% (a net decrease of 22.7%). • With the system implemented as standard practice following results of the FY18 trial and continued success, overall dilution for full year FY19 showed continued reduction to 12% Evolution has continued use of the new technology at Cracow, where the improved accuracy has allowed the extraction of narrower stopes where drilling accuracy is critical. Evolution has also deployed the technology at the Mungari operation and has stipulated that the contractor use the technology at the Mt Carlton operation, which is currently under development. Future implementation of the Development Optimiser system should be verified by commencing additional trials to include a larger data base for validating the initial trial results.

Mar 15, 2021

By E J. B van Etten

Pit lakes may form when open cut mining leaves a pit void that then fills with ground and surface waters. This often replaces terrestrial ecosystems that existed prior to mining with an aquatic ecosystem, affording an opportunity to improve regional aquatic biodiversity values through targeted aquatic restoration (McCullough and van Etten, 2011). Restoration theory provides guidance when restoring disturbed systems towards landscapes that are of regional value and relevance. But how do we identify a restoration target for a novel aquatic habitat that only exists in the new post-mining landscape? This paper presents a process of first identifying and then surveying local representative aquatic systems, to provide a direction for pit lake restoration efforts and achievement criteria for pit lake relinquishment, using a case study from a sand mining operation amongst wetlands in south-western Australia.The company mines silica sands following mechanical removal of topsoil and then extraction of the ore from below the watertable by dredging. Assessment of wetland and riparian vegetation was achieved through the establishment and measurement of temporary monitoring transects across five natural wetlands in the Kemerton area. Several more regional wetlands were also visited and observations made to supplement and validate these data.Distinct vegetation zonation was found across each wetland, although typically wetland basins were unvegetated or filled with younger woody plants with patchy distributions. Fringing riparian vegetation consisted of few species (commonly the paperbark Melaleuca rhaphiophylla and the sedge Lepidosperma longitudinale), but community composition and structure were variable between wetlands. The pattern of vegetation seen across natural wetlands was best explained by topography and soil chemistry, with low lying wetland areas more likely to experience regular flooding and accumulate organic matter and nutrients.In conclusion, where they are available, regional natural waterbodies may constitute the best valid restoration goal. Nevertheless, the goal may need to consist of a range of closure design opportunities, rather than a single target.

Oct 5, 2011

By A Parbhakar-Fox, S C. Dominy

The prediction of acid and metalliferous drainage (AMD) from mine waste materials is critically important during all stages of the mine value chain. However, to determine such geoenvironmental characteristics static and kinetic testing of individual waste units must be performed on representative samples. The importance of sample selection cannot be underestimated; it is the single most critical aspect of any geoenvironmental investigation. Poor sampling techniques and inadequate sample selection will contribute to excessive variance, difficulties in interpretation and incorrect assessment. By undertaking mesotextural characterisation based on hyperspectral mineralogical data (with sulfur assay data if available), opportunities to improve sampling strategies are presented. Such data will inform the selection of samples for low-cost total sulfur, paste pH and geoenvironmental logging, which collectively will allow for accurate AMD forecasting and improved sampling practices to be achieved. Once sampled, robust quality assurance/quality control (QA/QC) protocols must be developed where the use of international certified reference standards become obligatory. This is currently not practised, resulting in inter-laboratory discrepancies when undertaking waste classification. Further improvements in geoenvironmental characterisation testing lies in the adoption of blended static testing protocols, whereby blends of waste materials can be efficiently tested so as to give an early forecast as to whether they will produce acidic or metal-laden drainage. Such information is integral in developing a waste schedule that will allow for a non-acid forming waste landform to be constructed right from the start of the operational phase. Ultimately, improvements in this discipline lie in technological innovations with regards to mineralogical characterisation, and by offering geoscience and minerals engineering students a competent education in the discipline. Collectively, this will empower a step-change in AMD prediction and waste handling, and will make the realisation of the United Nations Sustainable Development Goals a reality, rather than a dream.CITATION:Parbhakar-Fox, A and Dominy, S C, 2017. Sampling and blending in geoenvironmental campaigns – current practice and future opportunities, in Proceedings Eighth World Conference on Sampling and Blending , pp 45–54 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2017

By J Siliézar

The Ernest Henry Mine (EHM) is situated 38 km north-east of Cloncurry in the Mount Isa – Cloncurry mineral district of northwest Queensland. The EHM orebody is an iron oxide copper gold deposit with an average grade of one per cent copper, 0.5 g/t gold and 23 per cent magnetite, with current reserves of approximately 88 Mt.The copper concentrator is a single line plant with a nominal throughput rate of 1300 tonnes per hour. An average of 350 000 tonnes of concentrate is produced each year containing around 100 000 tonnes of copper metal and 120 000 troy ounces of gold.In December 2009, Xstrata Copper announced approval of a $589 M investment to extend the life of EHM to at least 2024, through the transformation of open pit mining operations to a major underground mine together with the construction of an associated magnetite extraction plant.The EHM magnetite plant extracts the magnetite from the copper concentrator’s tailings stream. It will produce approximately 1.2 Mt of magnetite concentrate per annum at full capacity for export to Asia, making EHM Queensland’s first iron ore concentrate exporter. Construction of the magnetite extraction plant commenced in July 2010 and was completed in January 2011.This paper gives an overview of the development of the EHM magnetite extraction plant flow sheet from the early mineralogy and laboratory test work through to the plant commissioning and early operation of the base plant. It has a major focus on the commissioning learnings from the plant start-up and includes a review of the operational performance of the plant versus original design and expectations.

Jul 11, 2011

By B Reynolds

The process design for green- or brown-fields metallurgical plants typically starts with two fundamental elements: the detailed mass and energy balance and the plant flow availability. The detailed mass and energy balance is generally developed using process flow-sheet simulation software and represents the steady-state operation of the plant at normal operating conditions. The plant flow availability, also known as a range of other industry-specific terms such as ‘flow availability’ and ‘operating factor’, describes the ratio of plant production to the steady-state mass balance. These elements are then used together as the basis for equipment selection and design.Plant flow availability takes into account a myriad of production loss factors including planned and breakdown maintenance, feed availability and composition changes, variability in operational performance and the interaction of batch and continuous unit operations. The combined impact of these loss factors are complex and as such plant flow availability is usually derived using a top-down approach such as comparison to an existing operation, a group of similar operations or to an anecdotal ‘industry leading’ benchmark. These top-down approaches are fraught with risk however, as they cannot factor in changes to equipment selection, flow-sheet or plant operating philosophy, and can result in over-expenditure of scarce capital or shortfalls in plant production.The use of dynamic simulation to provide a bottom-up alternative to quantifying the plant flow availability in metallurgical plant design has been growing rapidly in recent years. It provides a technique to quantify the combined impact of the loss factors described here and a tool to support process design and equipment selection by facilitating a range of sensitivity and what-if analyses. This paper presents a case study of how dynamic simulation has recently been used to support the

Aug 8, 2011

By J Seppelt, G S. Lane, E Wang

Newcrest’s Cadia concentrator operated from 1998 to 2012 with a traditional SABC grinding circuit treating Cadia open pit ore. The Cadia comminution circuit was well characterised through surveys and data that are available in the public domain, and became a benchmark standard for the industry and practitioners modelling large SAG mill based circuits. In 2012, the HPGR-based crushing circuit was introduced in front of the SAG mill to increase throughput when treating the Cadia East ore that was derived from an underground block cave. This ore was expected to be more competent and have a coarser run-of-mine size distribution.Numerous previous papers have described the design and commissioning of the Cadia HPGR-based circuit.This paper describes the improvement in comminution energy consumption resulting from the introduction of the HPGR, including identifying the impact of process complexity and an increase in ancillary energy consumption for conveyors, screening, and crushing.CITATION:Lane, G S, Seppelt, J and Wang, E, 2018. Quantifying the energy efficiency transformation at Cadia due to HPGR crushing, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 141–152 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

By A Takahashi, Y Uchisawa, M Hayashi, T Watanabe, M Susa

Owing to the deterioration of iron ore, the Al2O3 concentration in iron ore increases, and thus it is important to investigate the effect of increment in Al2O3 concentration on the microstructures of iron ore sinters. During the sintering process, a melt is present in the sinter for only a few minutes, and therefore the microstructure of the sinter doesn’t reach thermodynamic equilibrium. Nevertheless, the formation process of the microstructures can be interpreted and predicted to some extent from the equilibrium phase diagram. This study investigated the liquidus isotherm in the CaO-SiO2-Fe2O3- 5 mass% Al2O3 system at 1240°C in air and the phase equilibria of silico-ferrite of calcium and aluminium (denoted by SFCA) and SFCA-I by XRD (X-ray diffraction analysis) and electron probe micro analyzer (EPMA). The following results were obtained: 1. The ferrite melt region with a high Fe2O3 concentration shifts to the lower Fe2O3 side than the liquidus isotherm in the CaO-SiO2-Fe2O3 system. 2. The compositional region of SFCA extends in the CaOꞏ3Fe2O3-4CaOꞏ3SiO2 direction than the silico-ferrite of calcium (denoted by SFC) composition region with a 0 mass% Al2O3. 3. SFCA-I is observed in the present system, which suggests that the increment in the Al2O3 concentration contributes to the stability of SFCA-I. These results imply that an increment in Al2O3 concentration in iron ore leads to a decrement in the volume fraction of the bonding phase and that the fraction of the SFCA phase increases, and those of 2CaOꞏSiO2 and slag phases decrease in the bonging phase. The SFCA-I phase is also precipitated from the slag with an Al2O3 concentration around 5 mass%.

Jun 19, 2024