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Olympic Dam Operation is located in the Stuart Shelf Geological Province approximately 520 km north-north-west of Adelaide in South Australia. It is estimated to be one of the worldÆs top five copper orebodies by size and the biggest single occurrence of uranium. The deposit was discovered by Western Mining Corporation in 1975. Exploration was based on a conceptual model for the formation of sediment hosted copper deposits together with gravity and magnetic anomalies.The capital cost of the current expansion is estimated to be A$ 1.64 billion. The underground expansion includes a total of 36 km of lateral development, a railway haulage system delivering ore from a series of ore passes to a new crusher station and a significant increase in ventilation capacity and mine services.In the current underground expansion the mining method will essentially remain unchanged. The ore handling system will incorporate some recent advances in technology, improving efficiency and safety standards.Major infrastructure excavations are designed by a team of engineers attached to the Olympic Dam Expansion Project and a number of consulting groups. Once the expansion is fully completed it is expected to increase the current annual underground production level from 3.4 Mt to 9.0 Mt of ore by the year 2000. Mine design engineers working for the Olympic Dam Operation have recently completed a three year final design plan to achieve this target.Access to the existing mine is through the decline and Whenan shaft. The Whenan shaft was originally sunk as an exploration access and later upgraded for hoisting. The 4 km long service decline connecting to the Whenan shaft was later constructed to accommodate the increase in service demand. The Robinson and Sir Lindsay Clark shafts were developed at later stages to cater for the hoisting during and following the expansion lead up.

Jan 1, 1999

By E Widzyk-Capehart, P Vallejos, R Asenjo, J Ruiz-del-Solar

Throughout the minerals industry, it is evident that a new wave of technological innovation is needed as the mining sector looks for ways to achieve higher security and safety as well as higher production rates with less investment. Innovation has always been one of the key factors in achieving success within the mining industry. However, its importance will be especially relevant in the coming years if negative trends in commodity prices and new challenges facing the industry (lower grades, deeper mines and economy of scales) are to be overcome and the future sustainability and profitability of the sector ensured.The drive towards fully autonomous operations has begun, with the implementation of automated systems in both surface and underground operations. However, these automated systems are currently planned and realised with well-defined automated tasks within structured environments and isolated spaces. Currently, there is no interaction between automated systems, manned systems or humans, which creates physically isolated environments.For fully autonomous and continuous operations, the automated systems need to operate in environments that enable flexible interactions between automated machines, tele- and manually operated machines and humans.In this paper, we address the automation paradigm considering the synergistic collaboration between humans and automated systems. In this paradigm, humans and machines would interact in a flexible, collaborative and synergistic way without the need for isolation. The implementation of this concept within mining operations will have to be underpinned by science and technological developments and will require adaptation from many fields, including robotics, automation, distributed systems, communication, human factors, pattern recognition and mine design.The paper also presents the research and development work being undertaken at the University of Chile’s Advanced Mining Technology Center, in collaboration with the Chilean mining industry. This will provide the basis for flexible interactions between humans and technology-based systems towards a future of autonomous and continuous mining systems.CITATION:Ruiz-del-Solar, J, Widzyk-Capehart, E, Vallejos, P and Asenjo, R, 2015. Synergistic collaboration of humans and automated systems – innovative steps towards fully autonomous and continuous mining systems, in Proceedings Third International Future Mining Conference, pp 83–94 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 4, 2015

The total cost of horizontal development can be minimised by optimising the cost of each of the component operations (eg drilling, blasting, etc). Component costs should not be minimised. To optimise blasting results (ie the mean advance per round, muckpile characteristics and overbreak), operators need to optimise the blast design and drilling and blasting procedures. The costs of pulling extremely long (say >6 m) rounds, producing unnecessarily fine fragmentation, and minimising overbreak are excessively high. Operators should continually consider how they can shorten the cycle period by saving time at the face. To enable it to be matched to the pertinent rock properties, the blast design needs to be based on as much relevant experience as possible. To develop the most valid correlation between blasting results and blast design, the latter must be implemented carefully and accurately, but without sacrificing speed excessively. The total cost can often be reduced by using: 1. computer-controlled jumbos (to reduce the period and cost of drilling and to increase drilling accuracy); 2. larger diameter (51 mm to 64 mm) and longer (4.5 m to 6 m) blastholes; 3. at least three large diameter ( ¦89 mm) relief holes that are 0.2 m to 0.3 m longer than the blastholes; 4. explosive products that are selected on the basis of proven reliability and overall cost efficiency rather than price; and5. stemming (to increase the amount of effective work done by each kilogram of explosive and, hence, to reduce the powder factor and possibly the number of blastholes and the costs of drilling and initiation). Non-perimeter blastholes should be charged with ANFO or a bulk emulsion of established performance. Upper perimeter blastholes should be charged with a bulk explosive with a much lower effective density. But where geology varies considerably, greatest control over overbreak could possibly be achieved with the versatile pre-assembled charge shown in Figure 1. This paper presents numerous potential ways in which the total cost of development can be minimised. It concentrates on recommending blast design features and the safe, rapid, cost-effective implementation of designs.

Jan 1, 1998

The purpose of this paper is to look at the costs of tailings disposal, and in particular the comparative costs of different disposal methods in different situations. Costs are often the hidden design parameter. We know that they are important but sometimes feel that it is not very respectable to talk about them in public. It is better from a public relations point of view for it to appear that the decision-making process is driven by environmental factors or best practice rather than looking for the cheapest option. But this presumes that the two are mutually exclusive and this need not be so. These issues are discussed later in the paper. It is also commonplace for the scale of the mining operation to change with time, typically involving increased throughput rates and total tonnage. New ideas in tailings disposal make their appearance. The regulatory attitude can change. Having made a decision about the disposal method at the time of original feasibility study and design it is easy to suppose that the mine is æstuck with itÆ. But that also need not necessarily be so. Careful costing of options may reveal that a switch in method could be cheaper in the long run. The designer will often tend to think in terms of initial earthworks and site development costs. Aspects of power consumption, labour, and periodic campaigns to move tailings pipelines and carry out embankment raises are either overlooked or not given the same emphasis. This can distort the evaluation process. It is productive to think in terms of dollars or cents per tonne as a basis of comparison, not just the total sums. Tailings disposal can cost from as little as 10 - 20 ó/t to over $1.00/t which is a big range. There may be good and unavoidable reasons for the high figure but there would need to be to justify being so far over the industry average. At the same time, mining and processing costs, at least for gold, are around $15 - 20/t. Viewed from this perspective tailings disposal will always be a relatively small component of the annual budget.

Jan 1, 2000

By C Claassen, R Balusu

Computational fluid dynamics (CFD) models have been developed based upon field data collected from a longwall mine in New South Wales, Australia to study the behaviour of goaf gas flow in both active and sealed goaf areas. A base CFD model was built to represent the goaf situations when the active longwall retreats near the finish-off line. Results from the base model were calibrated and compared against field goaf gas monitoring data. The base model was then used to carry out parametric studies to investigate a number of operational scenarios and their impact on goaf gas behaviour. CFD modelling results indicate that the overall goaf gas flow pattern changes as the operating longwall retreats towards finish-off line. In all cases, oxygen penetration into the active goaf remains high, reaching 15 per cent or higher, even at some 800 m behind the longwall face.The modelling results also indicated that it would be difficult for early detection of an active goaf heating (on the maingate side) based upon CO readings in the return airflow, as the main stream of the gaseous product will be flowing into the sealed deep goafs in adjacent longwall (LW) panels. Monitoring points (such as tube bundles and bag sampling points) should be selected at deep seated seals along the active goaf so that abnormal CO or C2H6 readings can be picked up for early detection and location of potential heating spots; goaf inertisation can be better achieved by injecting inert gas such as nitrogen at deeper points (>200 m) behind the operating longwall; the injection of in-seam drainage methane into the goaf areas will only have a limited impact on goaf inertisation as much of the injected methane will migrate towards deep and higher parts of the goaf due to its buoyancy effect.

Sep 26, 2011

By LefTvre Y

In May 1991, AZSA commissioned a new conventional Cell House. This paper focuses on the major improvements introduced in the design and the construction of the equipment, machinery and control. An effective control system together with good reporting and routine operation has resulted in quality control of the Cell House at the highest possible level. Consequently the monthly current efficiency consistently averages above 93 per cent with a total energy usage of 3000 AC kWh/t of cathode zinc. The new concept for the year 2000 and beyond is introduced.

Jan 1, 1993

This paper examines some of the important aspects of mineral taxation policies and practices, with reference to the mining tax regimes of selected Pacific Rim countries (see Tables 1 and 2). The following subjects are addressed:what is æmineral taxationÆ?, basis for mineral taxation, types of mineral taxes, objectives of the mineral taxation regime, best practices, and mineral royalties. Many countries, in some cases with the encouragement and assistance of international funding agencies, are actively assessing the international competitiveness of their mining tax regimes with a view to attracting investment. However, these countries recognise that the mining tax regime is not the only consideration that is taken into account by prospective investors. The countryÆs geological prospectivity, physical infrastructure, labour force, political risk, and regulatory system are also important factors in the investment decision making process. Although it is probably true that an attractive mining tax regime will not necessarily attract mineral investment, there is a real possibility that an unattractive regime can drive away investment. For example, Hugo Dummett, general manager for discovery at BHP, hinted recently that BHP could cease exploration in Russia in the absence of positive tax changes. Dummett is reported as saying that if taxes æend up being as onerous as they are now, we really have to rethink why we are hereÆ (Mining Journal, London, November 27, 1998).

Jan 1, 1999

By D Hunter

A production information management system (PIMS) was recently implemented at Queensland NickelÆs Yabulu Refinery. Although a strong business case was developed to justify the significant investment in PIMS some potential beneficiaries remained sceptical of the anticipated benefits. The decision to install PIMS was justified as the on-line availability of continuous production data enabled the optimisation of some crucial operations resulting in significant cost savings, improved throughput and final product quality. Furthermore the rapid access to extended historical data has allowed the cause of repeated failure of equipment to be determined. The investment is expected to pay for itself within two years and has already contributed towards significant savings. This paper focuses on some of the diverse production improvements gained and compares the anticipated benefits in the business case to those achieved. A brief outline of the phased implementation of the OSIsoft PI data historian and complementary client software at Yabulu is included, along with details of the lessons learned.

Jan 1, 2003

By J A. de la Torre, I R. Cerna, G K. Karadjian

The La Colorada underground mine in Zacatecas, Mexico is a mechanised cut-and-fill silver mine with a capacity of 1250 t/d. The project focused on training the mine’s experienced operators for a fleet of underground trucks, through the use of a training simulator. The project was run by the simulator vendor, in collaboration with the mine’s maintenance, safety and production management.A training program was created targeting maintenance reduction, productivity improvement and increased utilisation and availability. Operators were first acclimatised to the simulated environment, had their current performance baselined, then received targeted coaching, with the process repeated to reinforce learnings. Concurrently, production, maintenance, and safety data was being measured in the real world to measure skills transfer. Due to limited telemetry available from the equipment, many of the data points for the project were sourced from maintenance logs, and accounting data.Equipment failure data measured from unscheduled maintenance records showed an overall 6.5 per cent decrease in unscheduled maintenance following the implementation of the training program. This rate of reduction correlated with the significant decrease in equipment abuse behaviours measured within the simulator during this period. Additionally, overall maintenance activities showed a significant decrease, confirming that reductions in unscheduled maintenance were not achieved through increases in scheduled maintenance. The reduction in equipment damage also increased availability and utilisation of the truck fleet. This highlights that the maintenance improvements not only reduced maintenance costs, but made the fleet available for more production. Moreover, the variability of the operator performance was decreased by 86 per cent, and the difference between their best operator and the worst is less than the baseline; this showed a gap where machine abuse, productivity and cost are impacted directly.This project illustrated that even small-scale mining operations with an experienced operator workforce can achieve positive return on investment (ROI) from simulation-based training. It also highlights that in the absence of equipment telemetry, alternative data sources such as accounting data and maintenance logs can be used to quantify ROI from training.CITATION:Karadjian, G K, de la Torre, J A and Cerna, I R, 2017. Innovations in underground hard rock operator efficiency – through simulation-based training technologies and processes, in Proceedings 13th AusIMM Underground Operators’ Conference 2017, pp 53–58 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Oct 16, 2017

By Quilliam B, Richmond G

Aberfoyle Ltd. has utilised a variety of flotation technologies in the Hellyer concentrator in North-Western Tasmania. Hellyer ore, with its slow flotation rates and low rate differentials between values and gangue, requires the use of long residence times and low air consumption rates in the flotation circuit. The operation of the flotation circuit, with a nominal residence time of 7 hours, has necessitated the development of a control system to provide continuity through operator shift changes. Cell selections at Hellyer varied from the 54 m3 hybrid Dorf Oliver / Maxwell (DO/MX) cells, to smaller 32 m3 Maxwell cells, conventional Don-Oliver 300 (8.5 m3) and 600 (17 m3) trough cells, and a column cell. The advantages of the large cells included low specific power consumptions and a low capital cost. However, problems with mixing and the maintenance of consistent froth depth have been identified in the hybrid DO/MX cells. Short circuiting in the trough cells was apparent, causing a considerable reduction in metallurgical performance. The column cell performs to expectation, although the application is not ideal.

Jan 1, 1991

Responsibility for the administration of mineral resources is divided between federal and provincial governments. The paper traces the evolution of mineral policies at both levels of government, from the end of World War II to the present. In the immediate post-World War II years, the emphasis was on supplying the raw material needs of a rapidly growing world economy. Policies favouring growth and development of the Canadian mining industry were instituted during this period. Two decades of uninterrupted expansion (the 1950s and 1960s) ensued. The decade of the 1970s was a turbulent one for Canadian mineral producers. Governments intervened more substantially than ever before. Moreover, the industry suffered from an intense period of competition for resource revenues by the two levels of government. At the same time, far reaching changes were taking place in the structure of world mineral markets. To date in the 1980s, the mineral industry has, perforce, adapted to existing mineral market structures. Mineral policies, too, have shown signs of adapting to the needs of the mineral industry. Whether the resulting mix of policies will permit the revitalization of the Canadian mining sector remains to be seen.

Jan 1, 1986

By Sen G

An amount of explosives, whether it be cylindrical, spherical, etc in configuration, with a hollow cavity in one face or end is known as a hollow or shaped charge. When this charge is initiated, a focussing of explosive energy will occur within this cavity. This focussing, or concentration of detonation products creates an intense localised force greater than just the simple detonation of a conventional explosive, (without a hollow cavity). If this hollow cavity explosive is directed against a target material this concentrated force is capable of creating a deeper penetration than the same amount of explosive without the hollow cavity. If a metallic liner material is used in the hollow cavity, upon detonation of the explosive this liner will form into a high velocity penetrating jet. Depending on the explosive type and the liner material's configuration the jet tip can travel up to 10 km/s. Linear shaped charges were developed using the abovementioned shaped charge concept but instead of being formed about an axis, they are elongated and constructed along the principal axis. Therefore instead of creating a narrow circular penetration jet, it forms a thicker planar cutting jet ideal for linear cutting purposes. Using Linear Shaped Charges (LSC) for pre-splitting is expected to result in more accurate directional fracture propagation, while minimising lateral micro fractures in the surrounding rock mass which is required to remain undamaged.

Jan 1, 1995

Effective pre-splitting is a key feature of wall control blasting. Most mining operations use historical designs or rules-of-thumb for designing pre-split blasts. If productivity and safety benefits are to be gained, these methods need to be improved in order to accurately predict pre-split performance. This will become more pertinent as overburden depths increase, placing more demands on the pre-split operation. A classical qualitative quasi-static description of pre-splitting (Kutter and Fairhurst, 1968) is presented and it is shown to give some useful insights into the pre-splitting process. In particular, it is clear that the time interval between the initiation of adjacent pre-split holes is a very important factor. In terms of this analysis, it is shown that current techniques which employ detonating cord as the surface initiation system are not optimal. A static quantitative model for pre-split design which has been widely reported is then discussed and its simplifying assumptions and their implications are examined. It is shown that several of the assumptions may be reasonably justified in the light of real pre-split results. It is concluded that the model should yield conservative designs. For this model, the key calculation of the blasthole pressure that is needed to determine the required explosive charge is highlighted. Popular methods employed in the literature for describing the expansion of real detonation products are shown to be inappropriate and an alternative method using the non-ideal detonation code, CPeX, is proposed.

Jan 1, 1995

By Whiten WJ

A method that allows data to be mass balanced and screen models to be fitted in a single step is described. The inclusion of several variables to describe the feed data in the fitting procedure allows a mass balance to be conducted at the same time as the fitting of the screen model. Analysis of Groote Eylandt Mining Company screening data has demonstrated that this method is ideally suited to applications where complete stream data are not available. Also, certain random fluctuations in screen model parameters arising from the fitting of consecutive mass balances and screening models are significantly reduced. A cubic spline function with fixed knot positions corresponding to particle sizes and variable (fitted) cumulative percent passing values is used to describe the feed size distribution. When the spline function is interpolated at the experimental feed particle sizes a fitted feed size distribution is obtained. This feed size distribution is then used as input to the screen model calculations from which product size distributions are generated. Since both feed and product size distribution data are used to minimise the residual errors between the observed and fitted stream size distributions, a mass balance is Conducted simultaneously with the screen model parameter fitting.

Jan 1, 1984

By Kerr I. D, Kennedy M

Flash X-radiographs were obtained of commercial electric No 6 and No 8* strength aluminium tube detonators in small-diameter cartridges of emulsion explosive at various times after fusehead operation. The trigger system for the radiography was based on the detection of light following fusehead firing via optical fibres inserted into the fusehead cavity during detonator assembly. These experiments were simulated using a finite element hydrocode with realistic treatment of the non-ideal reaction kinetics. Excellent agreement was demonstrated for the shape and position of the shock waves. In both cases, initiation of the emulsion was predominantly forward from the detonator. For the No 8* strength detonator, this initiation resulted from the shockwave delivered through the sides of the detonator, while for the No 6 strength detonator, initiation was the result of a complex interaction between shockwaves originating both from the sides and from the endcap. In the reverse direction (towards the crimped end of the detonators), initiation was only weakly dependent on detonator strength, being controlled mainly by the competing processes of rarefaction from the cartridge boundaries and comer turning of the detonation wave from the forward initiation. The consequences for field performance of small-diameter emulsions will be discussed.

Jan 1, 1990

Economic and technical reasons forced the mining industry all over the world to increase the unit size of mineral processing equipment. in large flotation cells, this development leads to problems in areas of air dispersion and keeping solids in suspension. Outokumpu, an operating mining company, designed and developed a mixing mechanism for large flotation cells at its own concentrators and also studied problems related to tank design. Ideal conditions for flotation can only be achieved if the flow pattern created by the mixing mechanism fits well into the tank configuration and the risk of short circuiting is minimized. In large deep flotation cells, four different zones can be found which improve the behaviour of large cells when compared to small cells. Selectivity is increased and in some cases final concentrate grades can be produced from the rougher cell. The largest units have also been used as final cleaners in some installations. When modernizing old plants by installing fewer larger flotation cells, immediate and substantial savings in power consumption are achieved. Additional power savings are made in pumping costs because of simpler circuit design and decreased circulating loads

Jan 1, 1978

A small-charge rock excavation method based upon the Penetrating Cone Fracture (PCF) technique has been demonstrated to be capable of excavating the hardest of rocks. The PCF technique involves drilling shallow holes in the rock which are then pressurised at the bottom by a propellant charge device. A controlled fracture is initiated at the hole bottom comer and propagates in such a manner as to excavate the rock at an energy efficiency three to five times better than explosives. Due to the low flyrock velocities and airblast pressures realised with PCF breakage, the method may be used in close proximity to equipment and personnel and is thus ideally suited for integration into continuous hard rock excavation systems. Over the past 18 months full-scale testing of the PCF method has been carried out in mines in the US and Australia. This testing has utilised a 76 mm diameter gas injector for hole pressurisation and employed propellant charges ranging from 80 to 320 gm. In addition to extensive data on rock excavation performance, data on ground motion, dust, carbon monoxide and air blast have been obtained. These data indicate that none of the parameters associated with PCF breakage are detrimental to the development of PCF-based, continuous-excavation machines. Machines employing the PCF method may range from simple single-boom machines for secondary breakage and small precision-blasting jobs to integrated systems with several booms, continuous mucking capabilities and ground-support equipment for drifting and tunnelling.

Jan 1, 1993

By R Grobler, D Burger, L Alberts

The current climate in the mining industry is allowing mining companies to further broaden their views and investigate technologies to improve the safety, efficiency and cost-effectiveness of their operations. Furthermore, underground mine environments will become more demanding for mining equipment and personnel as orebodies become deeper in weaker ground conditions with more extreme environmental conditions. Loading and hauling can represent significant components of the production cycle of an underground mine and automation of these activities can offer considerable benefits. Sandvik has accumulated a long history and experience in loading and hauling automation in underground mining. Since the late 1980s Sandvik has actively participated in several major research and development automation programs leading to the commencement of the development of an integrated system for semiautomated loading in 1999. Development work was later conducted to expand the capabilities of the system for automated hauling during 2001 and the AutoMine« system became commercially available. The first delivery of the AutoMine« system was completed in August 2004 in South America, where the system continues to operate in a full-scale production environment and is being expanded as the production area enlarges. Further systems have been delivered and are operational in North America, Africa and Europe. This paper focuses on the AutoMine« system deployed in Block 4 at De Beers Finsch Mine in South Africa. An overview of the mine and the process used to acquire the system and the key drivers which led to the selection of an automated solution are described. An overview of the initial system installation, subsequent expansions and future plans are presented. This is followed by a summary of the implementation and operational experiences associated with automated underground operations. The paper concludes by summarising the benefits that have been realised.

Jan 1, 2008

By P A. Dowd

This paper describes an integrated approach to the evaluation of ore loss and ore dilution via geostatistical simulation of in situ geology and grade characteristics, simulation of blasting mechanisms and simulation of loading from a blast muck pile. The approach is demonstrated on a case study. The sequential Gaussian method is used to simulate in situ bench grades on the scale of the smallest selectable volume within a blast muck pile. The simulated grades of these component volumes are interpreted as the reality that would be available with exhaustive sampling. The simulated bench is subjected to a blast simulator, based on the SCRAMBLE model, which effectively moves each of the component model volumes to its final resting place in the blast muck pile. Ore/waste delineation and selective loading processes are applied to the simulated muck pile to determine the degree of selectivity that can be achieved by various sizes of loader and types of loading and to quantify ore dilution and ore loss. An in situ model representing the reality of knowing only the data and information that are available from specific grade control drilling and sampling grids is obtained by sampling the geostatistically simulated model on a specified grid. The volumes comprising the in situ model are then populated by estimates based only on the data and from the specified grade control drilling and sampling grids. Different drilling and sampling grids are used to generate different models, each reflecting the levels of data and information available. Selectivity is assessed as a function of the drilling and sampling grids as well as the size and type of loader. Performance is assessed against the ideal selectivity that could be achieved on the perfect knowledge model comprising the simulated values of each component volume. Costs, prices and financial criteria enable an optimal selection of the grade control drilling grid, size of loader, type of loading and blast design.

Jan 1, 2004

By J Pan, B-J Shi, X-B Li

The granulation behavior of specularite fines which possess poor ballability was studied with limonite fines as a function of nuclei particles and adhering fines. The results show that the permeability of granules deteriorated as the ratio of specularite fines increased in the mixture, and the optimal granulation moisture content also decreased. The granulation kinetics results demonstrate that the adhering load of specularite fines increases rapidly within three minutes and then levels off. With increasing specularite fines ratio, the adhering speed is accelerated but the granulation duration needs to be longer to reach adhering balance. The microstructure of granule quasi-particles indicates that the fine limonite particles act as binders to bond together the specularite particles which are dispersed in the adhering layers. This can improve the adhering strength of the granules. Hence, the granulation behaviour of specularite fines can be improved by blending them with fine limonite ores which have high adhering capabilities.CITATION:Zhu, D-Q, Li, X-B, Pan, J and Shi, B-J, 2015. Granulation behaviour of specularite fines in ferrous sinter mixtures, in Proceedings Iron Ore 2015, pp 91–96 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015