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By D Misra, R Ganguli, S Bandopadhyay

The objective of this paper is to assess the accuracy and applicability of recent state-of-art methods such as the machine learning algorithms (MLA) for mineral resource estimation. Conventional methods such as geostatistics have been predominantly used in the mining industry for this purpose with varying success. Recent advances in the use of MLA have provided a fresh approach to obtain improved accuracy in the estimation of mineral resources. Two MLA methods: the neural network (NN) and the support vector machine (SVM) have been used to estimate a polymetallic ore deposit in Alaska.The general characteristic of SVM and NN emphasises the fact that they can approximate any multivariate non-linear relation among variables. Although neural network models are able to capture the nonlinear spatial relationships that may be present in the data, they are usually difficult to optimise under sparse data settings. Of the various NN alternatives, despite their effectiveness, the model selection and estimation process is typically difficult as it involves solving complex integration and optimisation of parameters. In support vector modelling (SVM), estimating of parameters involves optimisation of a convex cost function. The working principle of SVM makes it robust against noisy and extreme value data. At the same time, it can capture the spatial distribution of ore grade more effectively with careful modelling and selection of SVM parameters.The outcome of the MLA methods were compared to those of the geostatistical ordinary kriging (OK) application to study their generalisation ability. The comparison was made using the following goodness of fit criteria: mean-squared error; mean absolute error; mean error; and coefficient of determination. The results indicated that the MLA methods may improve the predictability of ore deposits and thereby reduce the inherent risk in mineral resource estimation.

Sep 26, 2011

By I Brunton

Blast fragmentation can have a significant impact on the profitability of a mine. An optimum run of mine (ROM) size distribution is required to maximise the performance of downstream processes. If this fragmentation size distribution can be modelled and controlled, the operation will have made a significant advancement towards improving its performance. Blast fragmentation modelling is an important step in Mine to MillTM optimisation. It allows the estimation of blast fragmentation distributions for a number of different rock mass, blast geometry, and explosive parameters. These distributions can then be modelled in downstream mining and milling processes to determine the optimum blast design. When a blast hole is detonated rock breakage occurs in two different stress regions û compressive and tensile. In the first region, compressive stress waves form a æcrushed zoneÆ directly adjacent to the blast hole. The second region, termed the æcracked zoneÆ, occurs outside the crush one. The widely used Kuz-Ram model does not recognise these two blast regions. In the Kuz-Ram model the mean fragment size from the blast is approximated and is then used to estimate the remaining size distribution. Experience has shown that this model predicts the coarse end reasonably accurately, but it can significantly underestimate the amount of fines generated. As part of the Australian Mineral Industries Research Association (AMIRA) P483A Mine to MillTM project, the Two-Component Model (TCM) and Crush Zone Model (CZM), developed by the Julius Kruttschnitt Mineral Research Centre (JKMRC), were compared and evaluated to measured ROM fragmentation distributions. An important criteria for this comparison was the variation of model results from measured ROM in the fine to intermediate section (1 mm to 100 mm) of the fragmentation curve. This region of the distribution is important for Mine to MillTM optimisation. The comparison of modelled and Split ROM fragmentation distributions has been conducted in harder ores (UCS greater than 80 MPa). Further work involves modelling softer ores. The comparisons will be continued with future site surveys to increase confidence in the comparison of the CZM and TCM to Split results. Stochastic fragmentation modelling will then be conducted to take into account variation of input parameters. A window of possible fragmentation distributions can be compared to those obtained by Split. Following this work, an improved fragmentation model will be developed in response to these findings.

Jan 1, 2001

By A Deakin

It has been almost a decade since the release of the International Council of Mining and Metals (ICMM) Health and Safety Critical Control Management: Good Practice Guide (2015a). During this time the ICMM member companies, along with many others across industry, have been busy designing, deploying and enhancing their own critical control management (CCM) programs. So, what have we learnt? This paper discusses the scope, application and learnings from the implementation of CCM within the mining industry. What’s going well? What are the common challenges? What are the opportunities to strengthen the approach? What are the threats to successful implementation? The paper draws on the author’s experience as one of the key contributors to the development of the CCM Good Practice Guide and an adviser to many mining companies, including six of the ICMM members. The paper focuses on the practical (operational) application of CCM and the cycle of identifying, defining, implementing, verifying and improving critical controls at the frontline. The paper also includes a discussion on the safety performance of the ICMM member companies over the past decade and provides a recommendation for how CCM can be incorporated into a more proactive model to measure safety performance. The paper concludes with practical recommendations that mining companies, regardless of their CCM maturity, can consider as they look ahead. They are supplemented by three additional recommendations for consideration at the industry level.

Apr 16, 2024

By Y Hansen, J Petrie

Life Cycle Assessment (LCA) is increasingly being used as a decision-support tool within mining and minerals processing and metals production. However, a number of initiatives have highlighted the current limitations of LCA to accurately reflect the environmental performance of minerals and metals. These programs include:the Mining, Minerals and Sustainable development project (Stewart, 2001); the United Nations Environment Programmme/Society for Environmental Toxicology and Chemistry (UNEP/SETAC) workshop on LCA and metals (NRCan, 2002); the UNEP SETAC Life Cycle Initiative; and the review of the existing ISO 14 040 set of environmental management standards. Together, these initiatives highlighted concerns relating to the ability of LCA to engage with and support metals recycling, to adequately reflect the impacts associated with products from a multi-product orebody, the ability to adequately reflect the toxicity potential of metals in the natural environment and the fact that resource depletion focuses on mining (and not consumption) as the depleting activity in the life cycle of a metal. Additional impact categories to be included in LCA were also suggested. In this paper we demonstrate how existing initiatives are addressing LCA limitations. Finally we present the state of the art in Life Cycle Impact Assessment (LCIA) for two impact categories:resource depletion; and impacted land footprint for solid wastes.

Jan 1, 2004

By A Dennis, T Hunter, R Coleman

For metallurgical plant design, it is necessary to progress through successive phases of test work, piloting and process development before involving all the other engineering disciplines and “freezing” the process design criteria and flow sheet. This process usually relies upon the experience, skills and personal preferences of various technology providers, study and engineering entities, test work and metallurgical laboratories and, most importantly, the owner’s team and its operators. Current industry trends include lower grades, more complex orebodies, geometallurgy in defining orebody variation and design envelopes, more common “hybrid” plant processes and the market demands for more reliable, timely and predictable early plant performance.This paper will discuss interaction of these trends and provide guidelines for the level of detail and technical complexity required for a number of different “typical” examples. The paper will pay particular attention to the study definition level translated into the required detail and certainty needed by the overall process “owner” and original equipment manufacturer (OEM) equipment suppliers to ensure the best real plant performance. Some recent case studies will be discussed. In many projects, at a late stage of project definition, it has become common practice to undertake a “value engineering” phase. Although it could be argued that this should be undertaken earlier, it is largely driven by an overall need to reduce capex and “optimise” the perceived “fat” built into the project during the detailed design process. This value engineering can be very counterproductive to project timing and operational performance and warrants discussion.The paper is intended to promote discussion on a topic of wide interest. The authors’ diverse backgrounds and experiences are integral to the views in this paper.CITATION:Dennis, A, Coleman, R and Hunter, T, 2017. Critical process design considerations from test work to operations, in Proceedings MetPlant 2017, pp 12–30 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 11, 2017

By D L. Head

Critical risk management (CRM) has become one of the latest safety buzz terms in mining. Everyone seems to be doing it, everyone seems to know about it, yet we are still having fatalities in our industry from well understood hazards such as mobile equipment amongst others.

May 5, 2022

By C Young

In the vast expanse of Western Australia’s mining sector, a critical issue has come to light: many mining operations overlook the power of a Broad-Brush Risk Assessment (BBRA) to uncover their critical risks. This oversight has led to a cascade of challenges, where some mining endeavours find themselves grappling with: - Unidentified and unmanaged fatal risks, casting a shadow of uncertainty and heightened compliance risks. - A bewildering landscape where the concept of critical risks remains enigmatic, with some mistaking the risk register for the BBRA. - A fog of confusion surrounding the guardianship of these critical risks, leaving safety responsibilities blurred and undefined. Yet, the solution lies within our grasp. An effective BBRA empowers organisations to: - Pinpoint with unwavering certainty every ‘true’ critical risk. - Clarify ownership for each critical risk, ensuring accountability and swift action. - Create a prioritised roster of critical risks, illuminating the path to safer operations. - Lay the foundation for essential follow-up actions like bow-tie analysis, the identification of critical controls, and the fortification of the safety and health management system. Join us in this presentation, where we delve into the heart of an industry-leading BBRA process. Discover practical insights that will enable your organisation to craft and implement BBRA strategies, bridging the gaps in your journey toward preventing fatalities and fortifying safety protocols.

Apr 16, 2024

By J Rola

This paper outlines a laboratory-based design method, founded in critical state soil mechanics, for identification of an appropriate compaction specification to ensure dilative conditions prevail across the design TSF stress range. The method makes use of the critical state line (CSL) and consolidation tests prepared at varying compactive efforts. The CSL and consolidation curves are plotted together in e-log p’ space, with the compaction curves transformed from vertical effective stress to mean effective stress using the coefficient of earth pressure at rest (K0). Consideration is given to the sensitivity of K0 as it is generally not available during the design phase. An example of the design method is illustrated with laboratory data.

Jul 1, 2021

The U.S. Bureau of Mines has developed a prototype cross well acoustic logging system and complementary tomogr`aphic image reconstruction software for the detection and delineation of abandoned underground mines and associated subsidence failure in relatively shallow environments. The logging system uses a piezoelectric, cylindrical bender as an acoustic source. A triaxial accelerometer assembly, designed to be rigidly locked in the borehole, is the receiver portion of the logging system. Both the source and receiver probes operate at high frequencies, thus providing short wavelengths capable of resolving small features in most rock types. A modified van with a dual-drum wireline winch, 4-channel data acquisition system, power amplifiers, and waveform generator supports field operation of the logging system. A field study was conducted at a test site in San Antonio, Texas, to demonstrate the cross well acoustic logging system. The underlying rock at the test site is similar to stratified sediments in coal measures. First- arrival travel times were interpreted by tomographic reconstruction of the velocity field in the two-dimensional cross section between the source and receiver boreholes. The resulting image correlates well with geological borehole logging data for the test site.

Jan 1, 1992

By Szymanski J, Planeta S

For many hard rock mines with near surface deposits, the surface crown pillars form the first line of protection for the immediate underground workings. Underground stopes are typically contained by crown pillar, which protects the level above, rib pillars, and a sill pillar through which the ore collection system is cut. This paper discusses the mining of these pillars, with particular emphasis on the overall stability of the mined out upper part of the mine areas. An area of interest is located in the Canadian Shield, where the mining has progressed below four thousand foot level in the ultramafic high grade sulphide type of orebody.

Jan 1, 1995

My topic for today is the Crown Minerals of the future. New work initiatives are underway and the organisational structure is being overhauled. These are not insignificant changes and in this paper briefly summarises these proposals. These new work initiatives and changes to the organisational structure will have implications for the industry as a whole and also for the way individual clients interact with Crown Minerals.

Jan 1, 2003

By Howell IJ, Kirsopp R

In June/July 1981 Mount Isa Mines Limited was confronted with a crisis situation in the crushing operation of the Lead/Zinc and Copper Concentrators. Three crusher mainframes developed serious cracks in the upper rim area. The type of cracking indicated that major failure of these mainframes could be imminent. Operational crushers could not be sensibly inspected and it was therefore assumed that more than three mainframes were seriously cracked. The crisis was averted as described in the following text.

Jan 1, 1978

By Bearman R. A, Parkin R. M

Traditional quality control procedures for aggregates production within the quarry industry rely on off-line laboratory analysis, resulting in poor performance and inconsistent product quality. A high speed on-line aggregate classification system is described here. A product sampling system directs aggregate through an inspection chamber where a novel imaging system digitises the particle geometry. Data processing algorithms extract dimensional data and image features, while a neural network classifier assigns a qualitative shape descriptor to each rock particle. This system provides each sampled batch with a complete analysis of size and shape distributions, complementing a new generation of cone crusher technology to maximise product quality and plant efficiency.

Jan 1, 1995

CrusherMapperTM - A New Tool for Crusher Condition Monitoring The efficiency of mineral processing plants is entirely dependent on the availability of the plant equipment critical path. This typically concerns comminution circuits consisting of primary crushers and primary grinding mills. Crusher and mill availability are determined by the frequency and duration of maintenance shutdowns, which are primarily driven by the need for replacement of sacrificial liners. The change of crusher and mill liner shape over respective life cycles also strongly affects plant efficiency. It is therefore highly desirable to accurately monitor the condition of mills and crushers in order to optimise plant efficiency through maximised availability and targeted liner shape. Traditional comminution liner and other production parameter condition monitoring has been attempted through ineffective methods which prevent satisfactory management of crusher and mill maintenance and reduce operational control. This situation has recently dramatically improved for grinding mills through the development and commercial deployment of MillMapperÖ, a technology based on three-dimensional laser scanning data and dedicated software (Franke, Lichti and Stewart, 2006; Franke and Lichti, 2007; 2008; Franke, 2008; Franke, Redman, Johnson and Michalek, 2009). At the time of writing in late 2009, MillMapperÖ is in successful use at a rate of approximately 170 surveys and associated reports per annum at processing plants in Australasia, South America, North America and Africa. This paper presents the introduction of CrusherMapperÖ, the MillMapperÖ equivalent for crushers. CrusherMapperÖ also utilises high density, high accuracy laser scanning data, and features dedicated algorithms for three-dimensional monitoring of wear on crusher concaves and mantles. This facilitates the detection of wear hot spots or zones or localised liner failures, and accurate forecasting of reline tonnages and dates. It also for the first time provides the means to establish optimised concave and mantle shapes in order to achieve production targets. In contrast to any other currently utilised condition monitoring method, CrusherMapperÖ data collection can occur remotely and does not require any shutdown or crusher isolation. This method therefore does not interrupt crusher production while at the same time eliminating any confined space risk normally associated with taking measurements inside the crusher cavity.

Sep 13, 2010

By R Bearman

The importance of crushers in the mining industry declined with the introduction and resultant dominance of AG and SAG based circuits, but the recent move to consider more energy efficient circuits has caused the industry to re-consider the role of crushers.Different types of comminution equipment have different efficiency in the way the energy is applied in the size reduction process. Because of the general trend towards more sustainable production processes and emission of carbon dioxide, energy use has become more important. To fully understand how crushers can contribute to optimising the energy application in comminution circuits, detailed models of process performance are required. Such models need to take into account the mechanical design factors and how the crusher performance changes in response to feed conditions, the control strategy utilised and the wear of the crusher liners.It is also critical to analyse the total circuit, not just the individual crushers. To fully understand the performance of the entire circuit, dynamic simulation should be applied. Without the holistic understanding of the total circuit and the incorporation of transient effects, the full circuit performance cannot be adequately determined and the true energy picture will not be quantified.Based on detailed mechanistic modelling of crushers by the authors and the application of dynamic simulation, the opportunities to optimise the use of crushers for energy efficiency are examined.

Aug 8, 2011

By Koginmo V. I

The concentrator at Bougainville Copper Limited has an annual throughput of 48.2 million tonnes/year producing approximately 175,000 tonnes copper, 16.1 tonnes gold, and 50 tonnes silver. Conventional three stage crushing and screening are used to reduce run of mine ore to an average product d80 size of 6.7mm. The primary objective of the crush- ing plant is to provide a continuous supply of ore to the 12 primary grind- ing mills via an intermediate 300,000 tonnes capacity stockpile. Since ball mill performance improves with decreasing mill feed size, the crushing plant continually strives to produce the finest possible product for mill- ing. This has been achieved by increasing plant availability and total installed power, and improving crusher manganese liner life, screen cloth life, and plant operating practices. A recent innovation was the installa- tion of a 35 million tonnes/year preconcentration screening plant in Janu- ary 1987 to recover high grade fines from low grade run of mine ore types in which the mineralisation occurs preferentially along fracture planes in the parent rock.

Jan 1, 1988

Mine ore, reduced to minus 71/2 in. by primary crushers, is stockpiled. Size reduction of the reclaimed material by secondary and tertiary crushers is achieved in a closed circuit crushing and screening plant. Screen products of minus 30 mm plus 6 mm lump, and minus 6 mm fines are stockpiled by conveyor and stacker systems prior to rail despatch 10 port facilities at Dampier. Crusher settings, determined from experience, are closely maintained to obtain the desired lump/fines ratio. Chemical and sizing analyses from automatically taken samples are used to maintain product specifications. The beneficiation plant upgrades the fines product when this is necessary. The recorded wear life of individual plant components is the basis of a planned maintenance programme.

Jan 1, 1970

By Russell J

A sustained drop in the grade of Mount Isa lead-zinc-silver ore occurred in mid 1980. It was decided to increase concentrator throughput from 200 000 to 240 000 tonnes/four week period to maintain budget metal production. To achieve this increase whilst maintaining acceptable grinding and flotation performance, crushing plant final product size had to be reduced from 100%-13mm to 1000-11.2mm. The goal in the crushing plant was to achieve a 20% increase in throughput with a 20% decrease in the top size of the product. This was achieved by operational changes to improve plant availability and optimisation of the existing crushing and screening equipment Performance.

Jan 1, 1978

Crushing Plant Process Optimisation Design of processes in order to find the most efficient solution to a specific task is a difficult problem. Often the number of solutions are large and the optimal solution is therefore difficult to identify. Crushing plant process design is no exception from this statement. In order to find the best solution issues like equipment selection and process configuration must be mastered. The solution must both be technically feasible and preferably have a low operating cost. Since crushing plant design is a complex task with a large solution space it is basically impossible to master without a specialised tool. For a long time simulation softwares have been used to assist in the design process. These tools only give answers for how a user defined plant will operate. There are no tools with capabilities to consider different design options in order to determine what the most efficient solution looks like. In this paper a method for crushing plant design optimisation is presented. The novel method utilises a combined optimisation routine and expert system in order to find the most cost efficient solution to a given process task. The user will only need to define the feed material properties, the process capacity, and the end product requirements. The developed system will find the solution lowest production cost per ton.

Sep 13, 2010

Single station group velocities of fundamental made Rayleigh waves over the period range 15-100 s are carguted for five provincial profiles of the West Pacific. Based on recordings of earthquakes around the West Pacific by the W~ (World Wide Standard Seismic Network) stations AFI (Afianalu), HNR (Honiara), WEL (Wellington), PAR (Raratonga) and RAB (Rabaul). The inversion of the derived dispersion curves for average shear velocity-depth structure of the crust, LID and LVL shows that (i) the over-all structure beneath the profile 'westernSamoa-Micronesia-Mariana' is in between that of regions 3 and 4 of Pacific Ocean (Yu and Mitchell, 1979), except that the velocity is slightly lower, (ii) the uppermost mantle beneath the 'Vitiaz Trench' profile between AFI and HNR is similar to that of region 2 of the Pacific - in other words, thin LID and thick LVL; (iii) the structure beneath the ' Ibnga-Keradec Ridge' profile has a thick crust with thick sediments, and LID-LVL velocity and thickness are similar to region 3 of the Pacific; (iv) beneath the profiles ' Tonga/ Kermadec Trench events-RAR station' the structure is intermediate between regions 3 and 4 of the Pacific Crean; (v) from decomposition of the 'Solomon-meriana' profile, the structure beneath the Cntong Java Plateau has a thick crust with thick sediments and the uppermost mantle is similar to that of region 3 of the Pacific clean.

Jan 1, 1990