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By P F. Knights, P Boniwell

This paper investigates the causes of low effective utilisation of the production drill fleet at the Telfer Underground Gold Mine, as measured by the percussion hours per shift. The first part of this paper focuses on a site time and motion study conducted to accurately identify shift time allocation and optimal drilling parameters (manual versus automatic, and suitable flushing mediums for varying ground conditions) as well as quantifying the business potential for automated or remotely operated production drilling. The second part of the paper focuses on the rate of successful hole completion for automated production drilling during shift changes. Two main areas of drill optimisation were identified. Firstly, a site-specific drilling procedure was established so as to ensure that all operators were drilling using optimal parameters. Total production metres per rig increased by 10.7 per cent as a result of the implementation of this standard. It was observed that a 25 per cent faster overall drill cycle was achieved using air mist flushing, and that manual drilling achieves a 19 per cent faster overall drilling cycle in comparison to automated drilling. Secondly, routine provision to the maintenance department of automation reliability reports that outlined the principal causes of unsuccessful hole completion led to an increase in production metres of a further 4.1 per cent, measured between January 2007 and August 2007. First hole automation reliability increased from 39 per cent to over 77 per cent over the same time period. Second hole automation completion was increased to 74 per cent, leading to a higher proportion of production achieved through automated technologies.

Jan 1, 2008

By V O’Brien

The suitability of magnetic surveys flown at low altitudes to identify buried heavy mineral (HM) strands has long been accepted. This is despite the low intensity magnetic response often obtained from such strands. The fundamentals of the magnetic survey method dictate that the closer the instrument is to the source the stronger the response. As such the optimal elevation for the magnetometer is at or near the surface. Iluka sought to use a ground based magnetometer to aid in the exploration target generation process and allow accurate targeting of exploration drill holes. Following the initial trial Iluka recognised the potential additional application of data obtained by a ground based magnetometer over known strand deposits. The detail of the ground magnetic images can confirm the assumed strand continuity between cross-sections of close spaced drilling and can aid in the definition of the geometry of different generations of mineralisation. The ability to confidently determine that the deposit has not been truncated by post emplacement erosion of the mineralised deposit may enable reductions in drilling requirements as well as assisting mine planning activities. Iluka intends to investigate advanced modelling of the magnetic data to determine the level of strand geometry and HM content resolution that can be achieved from the ground magnetic survey data and its potential application in the mining grade control process.It is anticipated that the surveying of Iluka’s known resource deposits will provide the ability to correlate the magnetic response from new exploration targets with those from known deposits for a given depth, HM grade and mineralogy suite.

Oct 5, 2011

By F Tang, Ö K. Büyükuslu, M Baben, S Petersen

GTT-Technologies’ ChemApp for Python was developed to provide a powerful, easy to use interface to ChemApp for a programming language highly popular with scientists and engineers. It is used, for instance, by GTT to develop program modules such as the CALPHAD Optimiser for the FactSage™ software, by customers to move from interactive FactSage calculations to perform versatile scripting with Python, and by GTT and its partners in research projects in the area of materials informatics. Computational thermochemistry is fundamental for advancing sustainable metallurgy and creating new alloy compositions for engineering applications. Materials informatics involves handling vast amounts of data and complex workflows. GTT’s approach uses ChemApp for Python and the FactSage thermodynamic databases to design recyclable alloys from the start, incorporating a higher percentage of scraps while aiming to simplify the workflows to simulate material design steps. Challenges arise due to recycling scraps, introducing more elements for consideration. CALPHAD-based databases accurately cover materials from primary metallurgy, but additional data for minority and critical elements is crucial for precise computational modelling. GTT combines machine learning-based ab-initio databases with traditional CALPHAD databases to cover the complete chemical space with appropriate accuracy. The design of a hardfacing alloy through a high-throughput materials informatics approach is used as a demonstrator of the current possibilities.

Jun 19, 2024

By D Walker, A Tsvetkov, P Voigt, O Kloiber-Deane

The GPM Gold Operation has been employing an Albion Process™ plant at its Sotk (Zod) gold mine in Armenia since 2014. Long term data from the operation is now being published for the first time. The data presented includes concentrate throughput, as feed to the Albion Process™ plant (tonnes per day), sulphur grade in concentrate (% S), total sulphide sulphur oxidation in the Albion Process™ plant (% SOx) and gold recovery from Albion Process™ plant residues (%). The data provides a basis for evaluation of the effectiveness of the commissioning, ramp up and operation of the Albion Process™ plant. Notwithstanding the impact of a slower concentrator commissioning than expected, the plant demonstrates Series 1 behaviour on McNulty ramp up curves, indicating successful commissioning and fast ramp up. Interrogation of the data and operational experience indicates that this successful operation is a result of a process that is flexible, robust and stable, one that was designed well based on solid testwork results and pilot plant trials during the study phase undertaken by Glencore Technology and Core Resources, and where the local operators were provided with appropriate training in operation of the plant. CITATION:Voigt, P, Walker, D, Kloiber-Deane, O and Tsvetkov, A, 2018. Ramp-up and long-term performance of the Albion Process™ plant at GeoProMining Gold Armenia, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 339–350 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

By S Bourke, R Stone, B Hill

Since Jameson Cell flotation technology was first installed in a coal flotation application in 1988/89 at Newlands Coal Handling and Preparation Plant (CHPP) there have been fundamental improvements to its design which has led to its current status as the leading technology in Australia for fine coal flotation. These improvements, which include key hardware modifications, consist of the re-development of the orifice plate to produce considerable increase in wear life and reduction in power consumption for a given air entrainment and a significant increase in the amount of air that is entrained. Modifications to the downcomer allow maximisation of residence time and air entrainment while changes to the feed and air distribution system allows a reduction in installation cost and a reduction of solids ingress into the air line. Additionally, operational improvements such as the use of recycle to maintain constant flow to the cell feed are discussed. The recent installation at Hail Creek in the Bowen Basin, which consists of three B6000/20 Jameson Cells (6 m diameter bottom-fed distributor with 20 downcomers) will be reviewed as a case study. The latest design and operability of the cells are summarised and compared against one of the original designs at Riverside CHPP also in the Bowen Basin.

Jan 1, 2005

By P Wilson

The Mt. Wright Underground Mine is located near the town of Ravenswood in North Queensland and is operated by Carpentaria Gold – a wholly owned subsidiary of Resolute Mining Limited. The establishment of the world’s first Sub Level Shrinkage (SLS) mine from a tradition Sub Level Open Stoping operation has proven to be a geotechnical challenge which has required tailored solutions to overcome unique issues. This paper will be broken into two distinct sections that will outline: a brief overview of the mining method and how the SLS method was chosen; and how the SLS is managed and key geotechnical learnings. The story of the world’s first SLS originated from the need of a bulk mining method to ensure the viability of Mt. Wright into the future. Traditional bulk mining methods such as; Block or Sublevel Caving were originally ruled out due to the low natural ‘cavability’ of the orebody and the proximity of the orebody to existing major infrastructure (Decline, Ventilation Rises and Egresses). The first section of the paper will outline the key geotechnical information that helped decide the SLS method in addition to how continuous backfill influenced the design. The second section is intended to address issues that the geotechnical engineers encountered since the inception of the SLS. The feature topic of this section is mining induced stress. Like most bulk mining methods, Mt. Wright had success when the production front was running parallel to the stress (production front being ‘shadowed’ from the stress). This was until a design change, forced by a splitting ore body resulted in this shadowing effect becoming harder to achieve. As a result, rehabilitation and production hole re-drilling become a regular occurrence, which teamed with a strict set of access controls made the production cycle longer and harder to complete. CITATION:Wilson, P, 2018. Mt Wright – geotechnical learnings from a sub level shrink, in Proceedings The Fourth Australasian Ground Control in Mining Conference (AusRock), pp 119–132 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 30, 2018

By J Rutter, D La Rosa, P Walters, M Scott, L Keeney

Bulk ore sorting technologies, whether surfaced based or penetrative, have seen an increased uptake by the mining industry for preconcentration application. As with all technologies, going through the technology validation process is key to de-risking the operationalisation of the technologies and to demonstrate and confirm predicted value propositions. The ability to laboratory calibrate cross-belt bulk sensors is standard practise for sensor vendors, however transitioning the technology from laboratory to real-world application is a non-trivial process. The industry has taken two main approaches to trialling and validating bulk sensing technologies in operational environments, namely:  Construct an off-line pilot facility at scale, or  Install bulk sensing systems on production conveyors Each of these two approaches have significant advantages and disadvantages and require different experimental design programs and analysis methodologies. Consideration of material movement, heterogeneity degradation, logistical requirements, and financial investment all factor into which approach is most suitable for an evaluation scenario. CRC ORE in partnership with mining companies, have conducted several bulk sensor pilot trials utilising different sensor technologies employing each of the two main approaches outlined above. This paper describes the challenges faced, learnings obtained and outlines a position on how to transition bulk sensing technologies from the laboratory into the operating environment. The case studies presented cover a range of commodity types in both open pit and underground operations.

Nov 10, 2020

By M J. Ireland, D P. Horne, S J. Simpson

The Sinclair Nickel Project, wholly owned by Xstrata Nickel Australasia (XNA), includes an underground mine, a concentrator, a village, an all-weather airstrip and associated mine infrastructure. The operation is located 70 km north of Leonora in the prospective and historically productive eastern Goldfields region of Western Australia. Xstrata Nickel has successfully developed the Sinclair deposit into a 350 kt/a operation since its discovery in November 2005, with contained nickel metal production to date in excess of 10 600 t, of which 5500 t is from the underground operation.The narrow, continuous, medium-grade Sinclair nickel sulfide deposit accessed by the Phoenix Decline has a shallow 15¦ - 20¦ plunge that is approximately 1000 m long down dip and open at depth to the north. The flat plunge and low-grade nature of the orebody presents challenges regarding the amount of horizontal waste development that can be economically excavated, which in turn affects ventilation, egress, mine services and diamond drilling.The mineralisation is hosted between an ultra mafic hanging wall and a basalt footwall and is being mined using a bottom up, sublevel open stoping method. The stopes are retreated to a central access, filling voids in the process with waste mullock where possible and using cemented mullock fill where end exposure is required. Tight filling the flat dipping hanging wall has proved to be challenging given the angle of repose for the waste mullock fill is steeper than the angle of the hanging wall.Reconciliations of mine performance against the original feasibility study show positive changes and operational optimisations enabling Sinclair to achieve its mining targets in a safe, sustainable and economic manner. This paper discusses the mining operations associated with the first two years of the Sinclair Underground Nickel Project, providing an overview of the various issues encountered and the lessons learnt in the process.CITATION:Ireland, M J, Horne, D P and Simpson, S J, 2012. Overcoming mine design and production challenges at the Sinclair underground nickel project, in Proceedings Narrow Vein Mining 2012 , pp 37-48 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Mar 26, 2012

By G Harbort, V Lawson

Mount Isa Mines Limited operates one of the worldÆs largest underground mines in North West Queensland. ItÆs mining and smelting complex produces copper anode, crude lead bullion (containing silver), and zinc concentrate. Copper is recovered in the Copper Concentrator from chalcopyrite ore, converter smelter slag and rotary holding furnace (RHF) slag via grinding and flotation operations. During 2002 a project to optimise cleaner circuit capacity was commenced. Its aims were to minimise copper losses and minimise slag/chalcopyrite cross contamination by reconfiguring existing flotation equipment and the addition of new flotation capacity. To minimise cross contamination a Jameson Cell was installed and dedicated to cleaning of slag concentrates, which had formerly been conducted by three flotation columns operating in series. The flotation columns were re-configured to operate in parallel and dedicated to upgrading chalcopyrite concentrate. In addition a Jameson Cell was installed to reject entrained copper from a prefloat concentrate consisting of talc and carbonaceous pyrite. This paper discusses the logic behind the cleaner circuit expansion, recent test work relating to the Jameson Cell and the installation and commissioning phases. Difficulties relating to the commissioning are reviewed and the solutions to problems are highlighted. The benefits the reconfigured circuit has provided to Mount Isa Mines are also discussed.

Jan 1, 2003

By D P. Sainsbury, J Western, B L. Sainsbury, V Mutton, P E. Petrie

Remnant rib pillars at Castlemaine Goldfields Ltd’s Ballarat Gold Project have been sterilised by the placement of loose rock fill in production stopes. The application of selectively injecting low-viscosity grout into the backfilled stopes to form a stabilised material has enabled recovery of the previously sterilised pillars. This paper outlines the engineering design, quality control and quality assurance program implemented to ensure the safe and efficient recovery of the rib pillars. The successful program included laboratory testing, numerical exposure stability modelling and in situ monitoring.CITATION:Sainsbury, B L, Sainsbury, D P, Western, J, Petrie, P E and Mutton, V, 2014. Pillar recovery adjacent to stabilised rock fill at the Ballarat Gold Project, in Proceedings AusRock 2014: Third Australasian Ground Control in Mining Conference , pp 77–86 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 5, 2014

By W Potma, C Brauhart, S Halley, S Urbisinov, A Scogings

Truly integrated, quantitative, 3D GEOmetallurgical (or mineral system) characterisation, classification and 3D modelling should provide a cradle to grave unifying link across the exploration and mining value chain. All too often, spatially representative (quantitative) characterisation and modelling of a mineral system is delayed until feasibility stage, incurring a significant opportunity cost. The application of robust GEOmet characterisation methods early in the project lifecycle (at exploration stage) improves ground selection, exploration, and Mineral Resource estimation outcomes, long before there is a need for metallurgical test work. The value of this early provision of quantitative 3D mineralogy models is compounded at project feasibility stage, and continues to accrue over the entire project lifecycle, delivering cost savings, improved decision making and early warning of issues and opportunities.CITATION: Potma, W, Halley, S, Scogings, A, Urbisinov, S and Brauhart, C, 2018. Putting the ‘GEO’ back in front of GEOmetallurgy: importance of early implementation of quantitative mineral system characterisation, classification and modelling, in Proceedings Complex Orebodies Conference 2018, pp 55–57 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 21, 2018

By A Bagis, T Baker

In 1983 the New South Wales (NSW) Government began to construct a 35 km freight rail line to provide additional rail capacity to Port Kembla in the Illawarra region, south of Sydney, through a direct connection between the Unanderra to Moss Vale line at Dombarton to the Main South rail line at Maldon in the Southern Highlands. The project area lies within the carefully managed Sydney Water catchment and is also underlain by previous coal mining activities.Construction of the line halted in 1988 prior to its completion after the NSW Government reassessed the demand case and found that the project was not as viable as originally forecast. However, by this stage the line was partially constructed, including the majority of civil earthworks, approach structures to the main river crossings and establishing the portals for the Avon tunnel as a precursor to major tunnelling works.In 2012, the Commonwealth Government funded Transport for NSW to undertake the necessary engineering and environmental preconstruction works. Most importantly here, the 1980s rail link was predicated upon the use of electrically powered locomotives, whereas the locomotive fleet in operation today in NSW is diesel powered. This fact has a significant impact upon the approach and development of the Avon tunnel section, as the diesel powered locomotives combined with the length and grade of the tunnel alignment produces a unique set of conditions requiring specialist engineering design and systems to ensure safe and functional operation of the railway through the tunnel section.Given the above, the Avon tunnel will need to be supported by a ventilation and smoke control design based on the heat rejection from the locomotive consist, consideration of ambient air quality compliance, comparison against in-tunnel air quality goals, and providing safety systems in line with the fire and life safety strategy it requires.This paper explores the current development of both the tunnel civil works responding to the geography, geology, rail functional requirements, as well as the tunnel ventilation systems being revised to suit the diesel locomotives.Further, this paper describes the importance of combining the design outcomes with the procurement methodology in order to achieve the project objectives, a functional outcome and value for money across the project life.CITATION:Baker, T and Bagis, A, 2014. Maldon to Dombarton Rail Link – design development of the Avon Tunnel, in Proceedings 15th Australasian Tunnelling Conference 2014 , pp 487–494 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 17, 2014

By P Aspinall

Safe work Australia (SWA) has a number of proposed amendments to existing Workplace Exposure Standard (WES) values that may dramatically change how mining workplaces using personal gas monitoring instruments will operate. In consultation with leading gas monitor manufacturers and distributors, an assessment of common Australian alarm settings values and analysis of potential frequency of increased alarm likelihoods has been conducted. This assessment explores the relationships between current monitoring practices, using instruments as health and not just safety tools and identify what will be needed to minimise worker ‘alarm fatigue’ and for common tasks to continue safely. This paper provides the necessary information to aid industry and hygienists to be ‘future ready’ given the likely impact that order of magnitude reductions in time weighted average (TWA) values for NO2, SO2, H2S and other common gases will have on current working practices. Reductions to gas alarm values will provide significant challenges to existing work methods and will require, practical application of the pending future values. Improvements and awareness of instrument capabilities by safety and hygiene professionals will better utilise gas monitors real-time data monitoring capacity and no longer be just ‘safe or not-safe’ instruments. The presentation seeks to promote the practical steps required in setting alarms based on risk consequence and likelihood, increase general awareness of the tools and data available in modern instruments and will enable industry professionals to better manage the challenges of any potential future changes.

Apr 16, 2024

By S Gezgin, F Beckstein, M Müller, D Rapp, D Sergeev, J Qi, A Lichtinger

Salts and their mixtures play an important role for industrial and energy sectors, eg metallurgy, biomass gasification and combustion, nuclear and solar powerplants and electrochemical processes. Depending on the composition of salts (eg Li+, Na+, K+, Mg2+, Ca2+ // NO3-, F-, Cl-, CO32-, SO42-, etc), the temperature range for different applications can vary starting from room temperature and going up to 1500°C. For the proper design and modelling of heat exchangers and other equipment, it is necessary to have reliable and validated data sets of thermophysical properties. The 50 mol per cent NaNO3 – 50 mol per cent KNO3 salt mixture as a well-studied composition was selected for validation of relevant thermophysical properties (heat capacity, enthalpy of phase transitions, thermal expansion, viscosity and thermal conductivity). To study these properties of the liquid phase, special crucibles and approaches should be implemented. Verification of these crucibles for different methods (differential scanning calorimetry (DSC), thermomechanical analysis (TMA), laser flash analysis (LFA) and rheometers) has been performed. The low thermal conductivity of salts is one of the main problems in implementing latent heat storage. In this project, the authors intend to develop a fundamental solution to this problem using chemically bonded metals with salts. These are known as metal-salt solutions. To fit the main parameters of new phase change materials to the requirements of thermal energy storage, a wide variety of possible combinations should be considered. CALPHAD modelling is used together with thermal analysis for the development of a consistent thermodynamic database including chloride salts (Li, Na, K, Mg, Ca // Cl) and corresponding metals (Li, Na, K, Mg, Ca). The results of the study of quasibinary and multicomponent metal-salt (eg Mg-KCl and Ca-KCl) systems as well as the selection of suitable crucible materials and challenges by studying of these systems will be discussed.

Aug 21, 2024

The paper describes data from test work programs on a range of magnetite ores in Australia and overseas. The analysis looks at the behaviour of material of different sizes fed to the rolls and the change in product size as a result of that, the conclusion being that there is a logarithmic relationship. The paper develops a form of equation to predict the product size from a given feed size distribution. The behaviour of the various magnetite ores is compared to more standard test methods such as crushing work index and unconfined compressive strength.

Jan 1, 2009

By Golubkov OL, Fedotov PB, Shkylar FR

One of the fundamental parameters of the race- way is its extent (a{ o), which has a significant effect on the distribution of gas and material flows in the lower region of the furnace. pp The known relationships for determination of aC o in most cases link the length of the raceway with the parameters of the blast, while the para- meters of the coke layer, in which the raceway is formed, are either ignored or else expressed in terms which are difficult to determine experimen- tally. Furthermore, the coke combustion propert- ies are not always taken into account in current blast furnace operating practice with combined blast. A complex dimensionless parameter, which re- flects the properties of the interacting media, is the ratio of the kinetic energy of the hot, com- bined gas stream to the potential energy of the coke flow, burning at the tuyere in a gas of known composition. Statistical processing of experimental data on the extent of the raceway zone, obtained from literature and our own work on operational furnac- es, has led to a working formula of the following Form:

Jan 1, 1981

The A J Parker Cooperative Research Centre for Hydrometallurgy has recently been established by a major grant from the Australian Commonwealth Government. The participating institutions in this centre are the CSIRO Division of Mineral Products, Curtin University of Technology, Murdoch University and the Chemistry Centre (WA). The Australian Mineral Industries Research Association is also a partner. Information is presented about the research activities of the Parker Centre, which are focussed on the solid/solution interface. Three research programs have been established in the areas of leaching, precipitation and surface processes (adsorption). The initial projects within these three programs are described. Details are also given of the Centre's education program which include honours degree training, masters and doctoral degrees by research, a masters degree by course work and workshops. The importance of collaboration with industry to the successful operation of the centre is stressed.

Jan 1, 1992

By P D. Munro

"This is a reprise of the paper ‘Back to the Future – Why Change Doesn’t Necessarily Mean Progress’ presented to the Tenth Mill Operators’ Conference in 2009. It was observed that the ‘boom and bust’ cycles of the industry, together with trends in tertiary education and the effects of fly-in fly-out (FIFO) operations raised serious questions about the sustainability of human capital in the mineral processing sector.In 2016 we find ourselves in a ‘bust’ after enjoying a decade of the longest commodity price ‘boom’ in a century. In the ‘boom’ did we:make any technological breakthroughs?put measures in place to improve our human capital, especially in the area of ‘professional formation’?The paper makes observations on the current performance of mineral processing engineers and the organisational milieu in which they operate. It questions whether mineral processing engineers are actually ‘adding value’ at some sites given their organisational and operational practices.Some technical trends are examined and what it might mean for mineral processing engineers.Given the above and demographic trends for mineral industry professionals, changes to the seemingly current laissez-faire model of professional development are proposed.Citation:Munro, P D, 2016. Back to the Future - Still on the Dark Side, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 341–348 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

The industrial practice of separating finely' around valuable minerals from associ- ated gangue materials by froth flotation is well known. Despite the obvious importance of this industrial process, the predictive tools for plant engineering evaluation of flotation process variable changes are still in a developmental stage. Consider, for example, the situation where an operating engineer is faced with evaluating a change in an existing chemical reagent scheme, possibly based on batch laboratory data. When all is said and done, the engineer must still perform detailed physical testing of the proposed reagent change on the actual equipment in plant use to be confident even of the direc- tion of change of plant results, let alone the economic viability of the change. The theory behind chemical reagent behaviour in froth flotation has been studied extensively, e.g., (Aplan {1980}, Fuerstenau {1976}, Fuerstenau {1962}, and Somasundaran {1980}), and, certainly, important progress has been made. Unfortunately, the nature of the flotation process, with its complicated heterogeneous surface chemisty activity operating on highly variable and difficut to characterize ore surfaces, coupled with com- plex mass and momentum transfer phenomena, :;l riously compromises the plant scale predictive capability of theoretically based models.

Jan 1, 1978

By F Diaz, G Hovestadt, B Friedrich, D Latacz, M Sommerfeld

The metallurgical sector significantly contributes to the global carbon footprint and encounters the challenge of developing more sustainable production methods. This study introduces novel approaches aimed at reducing CO2 emissions within the industrial sector, some of which have been developed up to the demonstration scale. In two case studies, urban waste from the agricultural sector (corn, olives, coconut etc) and waste electrical or electronic equipment (WEEE) recycling residues (shredder light fractions (SLF)) were subjected to thermal treatment. The resulting materials were then used as substitutes for conventional fossil-based reducing agents in both the copper and ferroalloy industries. Furthermore, hydrogen was employed at different scales to assess its efficacy as a reducing agent for recovering metal oxides from fayalitic copper slags. Our findings reveal promising prospects and defined specific challenges for the integration of these alternative reducing agents in the industry. The synergistic use of pyrolysed SLF, bio-coke, and hydrogen presents a viable pathway to significantly diminish CO2 emissions while simultaneously improving the sustainability of the metallurgical sector.

Jun 19, 2024