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By R Dunne, W McCallum

Continuous improvement might be defined as seeking incremental improvement over time through improved equipment, processes, technology and the efforts of people. Most people working in ore processing facilities embrace the general principles of continuous improvement. However, given the industry-wide issues with skilled personnel and the constantly changing environment in ore processing facilities, it is often difficult to identify improvements in a facility over a given time period. The driver for these outcomes is the use of basic principles and technology to achieve best practice targets. The process involves four stages: develop standards of practice to define best practice in specific areas; write procedures to guide the organisation towards these best practices; implement the procedures and develop a review process to provide a method of measuring performance against best practice.By reviewing performance against best practice on a regular basis, the organisation measures progress towards the best practice targets and the incremental improvement between these regular reviews is a measure of continuous improvement.This paper provides the background for developing standards of practice for metal accounting, metallurgy and metallurgical management. The paper also describes how standards of practice can be used to develop continuous improvement and the skills set of the departmentÆs leadership team.CITATION:McCallum, W and Dunne, R, 2012. Metallurgical management tools for continuous improvement, in Proceedings 11th AusIMM Mill OperatorsÆ Conference, pp 225-230 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Oct 29, 2012

By Z Fu, E Topal, O Erten

"Mine waste rock management involving waste rock movement and placement, is a critical aspect in the planning of open pit mining operations, as the waste rock haulage cost can be the largest portion of the mine operating cost. The concept of sustainable development in the mining industry also encourages environmentally friendly waste dumps that have zero hazards to people and the surrounding environment. Therefore, a detailed waste management schedule must satisfy economic and environmental considerations. However, the available tools in the market cannot provide optimal waste dumping schedules to meet all these constraints. This paper introduces a user-friendly and automatic tool to optimise the waste dumping schedule, which minimises the haulage cost, and covers the encapsulation of reactive materials to minimise acid mine drainage problems. This tool has been developed by using a new mixed integer programming (MIP) mathematical model that considers both single-lift and multilift dumping scenarios. The application of the proposed tool on a data set collected from a gold mine shows that the multilift dumping scenario has provided a more flexible and economical waste dumping schedule than the single-lift scenario, and both scenarios satisfy environmental requirements.Citation:Fu, Z, Topal, E and Erten, O, 2016. A Modified Software Tool for Mine Waste Rock Dump Planning, in Proceedings Ninth AusIMM Open Pit Operators' Conference 2016, pp 229–242 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Nov 15, 2016

By R Butler

Contract m1n1ng in New Zealand developed in the coal industry and has become an element in the success of recently opened hard rock gold mines. At Martha Hill, the mining contractor is undertaking a wide range of activities from open pit mining, crushing, conveying, waste embankment construction and drainage.

Jan 1, 1991

By M A. Harrington-Baker, J M. Trudnowski

Sulfate-reducing bacteria (SRB) have the ability to immobilise dissolved metals by precipitating them as sulfides, provided that a favourable biochemical environment is created. Such an environment includes the presence of sulfate, anaerobic conditions and the availability of organic carbon. If such conditions are engineered within a reactive barrier or field-bioreactor, most metals can be effectively removed. To demonstrate this concept, three passive SRB field-bioreactors were constructed in 1998 at an abandoned mine site in the vicinity of Butte, Montana, USA to treat acid mine drainage with characteristic elevated concentration of metals and low pH. Performance of the field-bioreactors, using aqueous samples, was monitored over 32 months until the project was terminated, field-bioreactors were decommissioned and solid matrix sampling of the reactive matter was performed. The most important analytical results are presented in this paper together with conclusions regarding the appropriateness of the field-bioreactors construction features. Only Zn, Cu, and Cd were being removed as sulfides due to SRB activities. Changes in concentrations of other metals (Fe, Mn, Al, As), which do not necessarily precipitate as sulfide, seemed to be affected by SRB only in an indirect manner by responding to increased pH caused by SRB activity. An innovative cellular containment system used for placing organic matter worked very well in preventing settling of the organic matter and ensuring uniform flow of AMD throughout the entire cross-section of the organic carbon with no preferential flow paths This demonstration was funded by the US EPA and was jointly administered by the EPA and the US DOE under DOE contract number DE-AC22-96EW96405. The project was implemented by MSE Technology Applications, Inc, Butte, Montana, USA.

Jan 1, 2003

By T Baumgartl, J Burgess, B Emmerton, P D. Erskine

Large-scale open cut mining in the Bowen Basin has been undertaken for over 40 years. During this period, improved mechanical capability and economics have allowed extraction to greater depths, resulting in post-mining landforms of increasing height. Rehabilitation practitioners face significant challenges in stabilising these landforms and require a comprehensive understanding of the Bowen Basin Coal Measures strata likely to be disposed of during mining. Knowledge regarding the potential behaviour of differing spoil materials (following disturbance) provides a rationale to maximise short- to medium-term surface stability of constructed landforms by identification, salvage and advantageous reuse of cladding resources as a means to minimise erosional risks.CITATION:Emmerton, B, Burgess, J, Baumgartl, T and Erskine, P, 2016. Bowen Basin coalmine spoil classification for improved mine rehabilitation outcomes, in Proceedings Life-of-Mine 2016 Conference , pp 142–147 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jun 28, 2016

By C Taylor, E Retz

Sequential Gaussian conditional simulation of wide-spaced exploration data has been completed in order to optimise a drilling grid at Fortescue’s Eliwana deposit. The aim of this drill grid is to improve the confidence in the Inferred Mineral Resource. A mineralised domain within the Joffre Member of the Brockman Iron Formation was selected to be tested as it makes up a large proportion of the Inferred Mineral Resource and is drilled at a reasonable spacing.One hundred realisations of Fe, SiO2 and Al2O3 grades were completed in the domain. Three realisations were selected for each analyte to represent the range of equiprobable values and a further realisation was selected to represent the truth data set. These realisations were used to flag theoretical drill holes on varying spacings and patterns. The theoretical drill holes were used to estimate into block models using ordinary kriging.These estimates were analysed and the accuracy and precision of each drill spacing was assessed. It was concluded that the greatest improvement in estimation results was noted at either a 100 m × 50 m or 50 m × 50 m spacing.CITATION:Taylor, C and Retz, E, 2015. How much do we need to drill?, in Proceedings Iron Ore 2015, pp 491–500 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

Tasker (1985) has detailed the accepted practices for constructing polygonal blocks of influerrce in the estimation of ore reserves. Further he suggests that users might fall into traps such as omission or overlap when determining the area of influence for each sample point.As an example of these types of errors Tasker (1985) describes under "Coverage ofthe Area" how 25 per cent of the exploration area will not be included in an equiangular triangular grid where hexagonal blocks of influence are used.The introductory suggestion of Tasker (1985) of "incorrect procedure" by Rudenno (1983) (and Armstrong (1983)) reiterated around the Figure 2a of Tasker (1985), is based on the brief description of the polygonal area of influence by Rudenno (1983). That description is not too different from that given by King, McMahon and Bujtor (1982).

Jan 1, 1985

By C Zschiesche, alam, A Abadias Llamas, A K

An integrated experimental and thermodynamic modelling study of the phase equilibria in the FeOFeO1.5- SbO1.5-SiO2 system in equilibrium with liquid Sb and Sb-Ag metal has been undertaken to develop thermodynamic model of the Na-Si-Fe-O slag system with S-Sn-Sb-Pb-As minor elements based on the experimental investigation of the selected sub-systems. New experimental phase equilibria data at 575–1600°C were obtained for this system using high-temperature equilibration of synthetic mixtures with predetermined compositions in sealed silica ampoules, Fe3O4 basket in sealed silica ampoule, or Re foils, a rapid quenching technique, and electron probe X-ray microanalysis of the equilibrated phase compositions. Experimental results on phase equilibria in the Fe-Sb-Si-O+Sb metal system obtained helped to produce initial set of model parameters in the slag. The primary phase fields of quartz/tridymite/cristobalite (SiO2), 2 high-SiO2 immiscible liquids, olivine (Fe2SiO4), wustite (FeO1+x), spinel (Fe3O4), schafarzikite (FeSb2O4) and valentinite/ senarmontite (Sb2O3) were identified in the binary Sb2O3-FeO, Sb2O3-SiO2 and ternary FeO-Sb2O3- SiO2 systems. Further refinement, particularly the distribution of excess Gibbs energy among the ‘FeO’-Sb2O3-SiO2 and ‘FeO1.5’-Sb2O3-SiO2 interactions, required the study at more oxidising conditions. Oxygen potential was increased using an inert metal (Ag) rather than using the gas flow due to the high volatility of Sb-containing gaseous species. Liquid Ag-Sb alloys with low concentrations of Sb of a few percent were used. At these conditions, the concentration of AgO0.5 in slag was below 1 mol per cent, which had a small effect on observed phase equilibria in the system. In addition, important information on the solubility of silver in slags is produced, which can be valuable when treating electronic recycling materials or primary silver-containing ores through the Pb process. Two main areas were addressed: the spinel-tridymite boundary (40–70 per cent SiO2 in slag) and spinel liquidus near 15 per cent SiO2 in slag. This allowed to deconvolute the separate contributions of the FeO-Sb2O3(-SiO2) and Fe2O3-Sb2O3(-SiO2) systems.

Jun 17, 2024

By S S. Kanchibotla, S Morrell

In recent years there has been a growing recognition of the impact that mining practices have on the efficiency of mineral processing operations. Head grade, dilution, particle size distribution and their variability are known to have a significant effect on the throughput and recovery achieved in mineral processing plants. Improved process monitoring and modelling have provided the opportunity to identify and quantify some of these impacts and to define very significant incentives to optimise the overall operation from the mining face through subsequent comminution and processing. The Julius Kruttschnitt Mineral Research Centre has been undertaking research to optimise æMine to MillÆ performance through a major AMIRA research project and through individual research contracts with mining companies. This work has resulted in a broad range of field and laboratory experience in terms of both the challenges and the opportunities encountered when tailoring blasting operations to suit the overall æMine to MillÆ production chain. This paper describes the objectives of æMine to MillÆ blasting to optimise the system of rock breakage involved in the blasting, crushing and SAG milling of hard, brittle ores. The design of such blasts falls outside the conventional envelope of experience for most engineers and requires the consideration of some critical factors if the objectives of such blast are to be met and some of the potential problems are to be avoided. Experience to-date has also found that the quality of implementation is critical to the success of æMine to MillÆ blasts.

Jan 1, 1999

This paper attempts to draw together the experience of over 30 years of research and practice in the United Kingdom on the rehabilitation of abandoned metalliferous mining wastes. The reliance on water when the mines were operating has implications for water quality and the techniques used to restore sites to alleviate the principal impacts of the mines. Drivers of reclamation included concerns about human health from wind blown dust and pollution of watercourses as well as perceptions of dereliction. Techniques of reclamation used involved removal of spoil from near to surface watercourses, capping of spoil, diversion of watercourses, use of impermeable membranes, prevention of surface sinks into underground workings and the use of constructed wetlands. The issues to be dealt with in mine reclamation have become more complex and sometimes diverge. The schemes in the 1990s described have been effective in dealing with pollution from spoil heaps and small but significant adit discharges; however, significant issues, particularly those of large flows of polluted water from mine sites, still need to be dealt with. Although the paper describes the legacy of mining, which largely finished in the late 19th/early 20th century, similar issues but on a larger scale are to be found in more recent mining, for example Eastern Europe. In many of these areas minerals still remain to be won and dealing with this legacy may fall on new mining developments.

Jan 1, 2006

By I Minniakhmetov, J Ashford

Orebodies constitute naturally occurring, commonly highly variable concentrations of minerals in the earth’s crust formed through varying and highly unpredictable processes. Orebody knowledge is a core foundation of a mining company’s asset base underpinning all decisions about Mineral Resource and Ore Reserves, future production, development and ultimately the profitability and competitiveness of a mining enterprise. The decision to invest in a mineral project is usually based upon a techno-economic evaluation of the project and having clear approval pathways to gain local community support and address social and environmental impacts. The main objective of the techno-economic evaluation is to determine the optimum development sequence for the particular orebody in question and to estimate the economic viability of the project and the future return on investment to its stakeholders, balancing the inherent value of the mineral in the ground against the costs of development and market pricing. With the exception of market-driven commodity prices, virtually all revenue and cost estimates fundamentally stem from the understanding and subsequent modelling of the orebody. A reliable estimate of the ore deposit grade and other geological value-drivers is the foundation upon which the business case for future mine development and operation is intricately dependent. Orebody knowledge is, therefore, the fundamental driver of the mineral project cycle, influencing the progression of studies and consequently, the resource company’s ability to declare Exploration Results, Mineral Resources or Ore Reserves which govern the source and cost of funding available to the project. Drilling provides a ‘vector’ to the true nature of the orebody and effectively buys time to manage the technical risk associated with the orebody. Despite its perceived high cost, in both time and money terms, drilling is the only available technology for acquiring the necessary orebody knowledge to support technical and economic studies and to minimise orebody-driven cash flow uncertainty and volatility. However, like all costs, pressure to minimise drilling budgets is ubiquitous across the minerals industry. Paired with inappropriate key performance indicators, drilling is often regarded as a cost to be minimised, rather than an investment to be optimised. Furthermore, as future deposits get deeper and more complex, the collection of orebody knowledge is increasingly on the critical path for project development. The increasing cost of data collection pertaining to these deposits increases the temptation to minimise orebody knowledge gathering at the cost of long-term value as the reduction or postponement of drilling results in greater orebody knowledge risk at all stages of the value chain. Indeed the true cost of the decision to drill less is rarely known until the mine is in operation, well after the mine project evaluation team has moved on. This paper aims to promote orebody knowledge as the fundamental source of endogenous project financial risk and, consequently, its critical importance in project financial evaluation. Furthermore, the report documents experimental research into the development of an econometric model for valuing orebody knowledge. Using the density of drilling data as a proxy measure of orebody knowledge, the proposed approach integrates well-established stochastic grade modelling techniques with the mathematical mechanics of Decoupled Net Present Value (DNPV) which, combined with stochastic grade modelling (conditional simulation), lends itself to the financial International Mining Geology Conference 2022 | Brisbane, Australia and Online | 22–23 March 2022 3 assessment of orebody knowledge risk. Based on this approach, a metric is formulated, representing the minimum value of the orebody knowledge added by additional drilling

Mar 22, 2022

By M Sparrow

The Victoria Park Tunnel project is an inner-city alliance project in central Auckland, New Zealand. The existing two-directional viaduct will be modified to single-direction flow, and a new northbound 440 m cut and cover tunnel will be constructed beneath Victoria Park. Three-dimensional (3D) visualisation media were used to communicate key design innovations to stakeholders and the general public. The 3D visual material has proven a useful tool for informing motorists of a new safety barrier method adopted for traffic management.This presentation will explain how 3D visualisation was incorporated in the project and will showcase the 3D visualisation media created for the project.

Mar 8, 2011

By K Sommerville, J Parkinson

"Open pit mines today have more technology and data available. The challenge is to effectively use resources to analyse and identify mine productivity improvements. AMC Consultants Pty Ltd (AMC) has completed more than 100 benchmarking studies worldwide. In the process of gathering cost and productivity data, insights have been gained on how mines are using data to drive productivity. This paper aims to share good practice on using data, what benchmarks operations should be aiming for, where mines are currently sitting, high value areas to target, and how to best prioritise improvement to meet operational goals.A key purpose of data is to assist in managing and improving operations. Key information is used to drive meetings, decisions, budget estimates and reports. Safety, equipment productivity, available stocks, grade and spatial reconciliation are examples of where data is important for management systems. The key is to keep reporting simple whilst maintaining access to source data for troubleshooting and analysis.Some operations still have paper-based reporting systems. Some operations collect data directly off machines and instruments, use cameras and have off-site control centres. The level of technology is a fit-for-purpose choice.Comparisons of productivity assumptions commonly used in feasibility studies with good practice productivity numbers sourced from AMC’s benchmarking database will be shared in this paper. A typical activity mining cost breakdown will highlight where the high value areas for productivity improvement sit.In addition to examining the productivity of each mining step it is also important to examine the impact on the mine plan. Equipment numbers, strip ratio, grade and material hardness can impact the results of bottleneck analysis. A bottleneck example case study will highlight how productivity and other factors can be used to identify and prioritise improvement opportunities.Keep it simple. Use only the critical data for meetings, decision-making, reports and plans. Knowing and communicating the key performance indicators (KPIs) you are striving for aligns the operation and prioritises improvement plans.Citation:Parkinson, J and Sommerville, K, 2016. Getting the Most Out of Technology to Drive Mine Productivity Improvements, in Proceedings Ninth AusIMM Open Pit Operators' Conference 2016, pp 84–93 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Nov 15, 2016

Subsurface development requires some geotechnical conditions and challenges. Most of then are related to the compatibility between tunnelling system and surrounded ground conditions, and design criteria. Design criteria usually involve lining pressure and ground control of displacements. In order to fulfil these requirements, geotechnical parameters have to be obtained as well as construction aspects have to be taken into account for predicting the tunnel behaviour. The Brasilia Metro is presented as a case history illustrating the geotechnical conditions and challenges for its implementation. It is 42 km long, including tunnels excavated in collapsible porous soils by the New Austrian Tunnelling Method. The Brasilia porous clay presents some characteristics, which may lead to large deformations due to structural collapse. Empirical methods were calibrated for collapsible porous soils and then applied to predict tunnelling-induced settlements. Settlements due to soil structural collapse modify completely the expected settlement profile, increasing their values from the tunnel crown to the ground surface. Consequently, surface settlement trough volumes were also greater than the ground losses around the tunnel. In this case history, structural collapse of porous soils played an important role and must have been taken into account to predict correctly the settlement trough and profile. Numerical simulation has shown that settlement magnitudes due to structural collapse are strongly dependent on the soil stiffness reduction after collapse and the extent of the collapsible zone.

Jan 1, 1999

By S J. Hawke, L A. Dominguez

In non-ferrous metal mining operations, it is generally necessary to crush and grind the ore to a very fine particle size to effectively liberate the contained mineral from the host rock. Fragmentation by blasting is the first stage of this comminution process.Numerous studies and independent modelling of the Mine to Mill process have demonstrated the potential for significant downstream productivity improvements from improved blast fragmentation. However, safety and environmental constraints associated with the blasting process usually limit the extent to which blast energy or powder factor can be increased.An effective blasting solution has been identified that enables the safe utilisation of powder factors several times higher than those used conventionally to provide significant improvements in fragmentation. The solution uses a static ‘blanket’ of broken rock overlying the blast to contain this increased blast energy and control rock movement. To produce this broken layer of rock, the subdrill in each blast is significantly increased to preblast (or precondition) the entire stemming region of subsequent blasts on the next mining bench.The solution has been evaluated at a large open cut poly-metallic mine in Mexico. Results from the application of this technique have shown significant improvement in run-of-mine fragmentation, with subsequent downstream productivity improvement indicated.CITATION:Hawke, S J and Dominguez, L A, 2015. A simple technique for using high energy in blasting, in Proceedings 11th International Symposium on Rock Fragmentation by Blasting, pp 321–326 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 24, 2015

Operating metallurgists spend a significant part of their time running plant trials to compare two or more conditions in order to improve the process, such as a new reagent, flow sheet or piece of equipment. The best way to conduct such a trial is as a paired experiment when testing two conditions (eg 'old' and 'new') or a randomised block design when testing more than two conditions. These experimental designs should always be preferred over alternatives if their requirements can be met, because they block the effect of uncontrolled variables ('covariates') and are the most statistically efficient, ie they will lead to the required level of confidence in the outcome faster than other methods. Sometimes, however, it is not possible to switch condition easily, which is a prime requirement of these methods. In such cases the only option may be to switch condition once only, and compare the process performance before and after the switch. Examples are testing grinding media, large equipment, or long residence time processes such as leach trains or CCD thickeners. This paper considers some data analysis methods to deal with this situation. Modelling with intervention analysis (IA) uses regression models with a dummy variable to indicate the presence or absence of the test condition. IA with a time series model ensures that the residuals are uncorrelated. IA with a process model helps to deal with the problem of covariates. The reference distribution is a method free of any statistical assumptions but is less powerful than the other methods. Cusum charts are a helpful visual aid to interpreting time trends. A combination of these methods can help improve the confidence in the final decision. None are as good as a formal experimental design such as a paired trial.

Jan 1, 2008

By M Laxman, A Kundu

After multiple tailings dam failures in recent times, the owner organisations have made increased efforts to step up the governance systems to industry best practise in the design, construction and operational management areas. The measures include but are not limited to, site investigation, rigorous peer review (both internal and external), certification through appropriately qualified personnel and improvement in operational management practises. While a lot of focus is on design and operational practices, the construction stage requires adaptation (both in terms of materials and approved design) and immediate decision making on site. Work undertaken in these areas is mostly irreversible and sometimes poses serious threat to the future TSF raise/ expansion planning and may lead to reduced life of the TSF and additional risk to the Owner.This technical paper will discuss some challenges and highlight the importance of appropriate processes to achieve a successful construction regime. The process will include a robust quality control/ quality assurance process, a team of designer-constructor-owner with suitable skills and technical understandings and robust documentation of the entire construction process from day 1 to the completion of construction.CITATION:Kundu, A and Laxman, M, 2018. Robust construction and quality assurance culture for tailings storage facilities – equally important as robust design and review practice, in Proceedings Mine Waste and Tailings Stewardship Conference 2018, pp 111–116 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 23, 2018

Knowledge of the crystal chemistry of carbonate apatites is very important for the development of the concept of biomineralisation and the creation of a scientific base for new biocompatible materials for medical purposes. The present work is devoted to research results on various synthetic and biological carbonate apatites obtained at Saint Petersburg University over many years. All-important problems will be considered such as the location of CO32- ions in the apatite structure, the ionic substitutions in various biological apatites and the development of synthesis methods for their analogues. Syntheses of apatites were realised by precipitation methods and under hydrothermal conditions (from solid compounds and by calcite treatment). Biological samples used in this study were physiogenic and pathogenic apatites formed in the human organism, eg in teeth and in renal and salivary stones and dental calculi as well as apatites from fossils of different taxonomic families (brachiopods, conodonts, fishes, reptiles, mammal) with different geological ages and burial conditions. The study of the crystal chemistry of carbonate apatites has been carried out by powder (including high-temperature measurements) and single-crystal X-ray diffraction methods, IR-spectroscopy, thermal analysis and various chemical analytical techniques.

Jan 1, 2008

The author reviews design evaluation theory and existing optinustion tools and then describes how these have guided recent developments in Whittle Programming's strategic mine design package: Four-X. A new package - Reserve Estimator is also d

Jan 1, 1998

By K P. Crameri

The Beta Hunt orebody is situated on the south western limb of the Kambalda dome. It is one of the nickel occurrences in the area which fall into the category of æKambalda Style OrebodiesÆ. These orebodies are renowned as being continuous uniformly mineralised ribbons of nickel sulfide mineralisation. Interestingly, Beta Hunt does not conform to this notion of continuity and uniformity and is in fact highly irregular in its ore distribution due largely to the influence of post depositional structure. In an attempt to understand the ore distribution at delineation stage rather than development stage a detailed footwall topography model is created using all available drilling data. To augment this drilling data, the routine use of downhole EM and borehole radar has been introduced to provide data beyond the confines of the drill core to enhance the geological interpretation of the footwall topography and the distribution of the mineralisation. The implementation of a detailed footwall model and the use of downhole geophysics has proved to be very effective in resolving the orebody complexity issues. Ongoing development of the methods used will continue to refine the interpretation of the geology to enable more efficient extraction of the orebody.

Jan 1, 2006