Search Documents

By D. L. Sober, D. Ince, T. V. Vasudevan

Separation of dolomite from Florida phosphates was achieved by first conditioning the feed with fatty acid at pH 10 followed by reconditioning at pH 4 or below, before flotation. Observed selectivity of this two-stage conditioning process was attributed to the amount as well as changes in the nature of adsorbed collector species upon reconditioning. In this paper, bench-scale flotation results of optimizing the major process parameters, such as reconditioning pH and collector dosage, for upgrading natural high dolomitic phosphate samples from Florida are discussed.

Jan 1, 1991

By Stratton-Crawley R., G. E. Agar

"A study has been done of the scale-up of laboratory bench-scale flotation to continuous plant circuit performance. It was found that the impellor speed and the air flow rate influenced the results and in this case extreme values of these operating variables were required in order to reproduce the plant rougher results in the laboratory. Despite the experimental uncertainty introduced by these extreme values, it was demonstrated that the plant performance could be predicted and experimentally reproduced with bench-scale tests.IntroductionThe mineral processing industry relies heavily on batch flotation testwork to design flowsheets, evaluate reagent s and compare various types of ore. The batch tests are generally regarded as being directly comparable within themselves, but quite often they relate poorly or not at all to continuous circuits. Obviously this dilemma generates considerable uncertainty with wide-ranging ramifications. One of the manifestations of this unfortunate situation is the commonly expressed opinion that ""it may work that way in the laboratory, but it will never work that way in the plant"".In a previous publication, a method was described whereby the results of batch bench-scale tests could be used to simulate a locked cycle flotation test series. The work to be described here is a continuation of that investigation with an extension to the simulation of an actual plant circuit. It would have been preferable to progress from laboratory batch data to a continuous pilot plant and then finally to a full-scale plant operation. However, because that possibility did not present itself, an attempt will be made to show that the performance of an existing plant circuit can be successfully simulated from batch data. The success of the procedure can be judged by the agreement among the plant results, a locked cycle test and the predicted results based on batch tests."

Jan 1, 1982

By E. R. Torak

Custom Coals, International has installed and is presently testing a 225 kg/hr. (500 lb/hr.) micronized-magnetite, fine-coal cleaning circuit at PETC's Process Research Facility (PRF). The cost-shared project was awarded as part of the Coal Preparation Program's High Efficiency Preparation Subprogram. The project includes design, construction and testing of a fully-integrated, bench-scale circuit, complete with feed coal classification to remove the minus 30 micron slimes, dense-medium cycloning of the 300 by 30 micron feed coal using three different size micronized-magnetite mediums, and medium recovery circuits using drain and rinse screens and various stages and types of magnetic separators. This paper describes the project circuit and goals, including a description of the current project status and the sources of coal and magnetite which are being tested.

Jan 1, 1996

By S Williams

The primary objective of most mining projects is to maximise the value delivered to the companyÆs shareholders. Achieving best practice performance and maintaining competitive advantage through low-cost production and high productivity is essential to achieving this aim. Benchmarking is an essential tool for the identification and implementation of best practice performance, and to realise continuous improvement by ensuring best practice becomes common practice. But to be successful, that is to deliver long-term value creation, benchmarking must be holistic and align operational performance with strategic intent. This paper outlines a rigorous and structured approach on how to conduct a successful benchmarking program that aligns operational performance with the businessÆs goals. Further it investigates the benefits that benchmarking can provide throughout the project life cycle and provides some key learnings from some of the worldÆs leading miners.

Jan 1, 2009

By Fernando Cillóniz

Benchmarking es un proceso de comparación y medición de los procesos de negocio de una organización, con aquellos que lideran el mercado. De forma que se obtiene información para mejorar el desempeño de las empresas. En ese sentido, el presente texto señala la utlidad del Benchmarking en las empresas donde el uso de la Internet y las tecnologías de la información permiten hacer más eficiente las comparaciones e intercambio de experiencias y conocimientos, así como internacionalizar el proceso.

Aug 25, 2002

By D Clarke, I Minniakhmetov

The Olympic Dam deposit is truly a world-class IOCG-Ag deposit, the world’s fourth largest deposit of copper and the world’s largest known single uranium deposit. Traditional and non-traditional methods have been used to accurately model the geology and mineralisation of the Olympic Dam deposit. Conditional simulation models have long been used as the most robust method for estimating risk and uncertainty in mine planning decisions at other mines around Australia and the world. There are many challenges associated with simulating the Olympic Dam deposit at a selective mining unit size sufficient for underground mine planning purposes. These include the size of the deposit, resulting in hundreds of millions of grid blocks; the disseminated nature of the zoned sulfide mineralisation. And lastly the direct relationship of the relative abundances of the sulfide mineral species that are crucial to the Olympic Dam smelter performance. Several geostatistical techniques have been utilised in the workflow for the Olympic Dam Conditional Simulation model to address these challenges. The key techniques are: • Projection Pursuit Multivariate Transform to de-correlate the main elements before simulation. • Pluri-Gaussian implicit boundary simulation method to simulate the mineralisation domains. • Spectral simulation method of de-trended and de-correlated attributes with account of local varying variance. The resulting conditional simulation models have been validated against histograms, grade-tonnage curves, cross-plots and assessed for variogram reproduction. This paper presents how the final conditional simulation models compare to benchmarking models created using alternate estimation techniques of ordinary kriging and local uniform conditioning. It also presents a validation process using historical samples to test final estimate accuracy of the simulation models.

May 24, 2023

By Ch. Roumpos

The present contribution investigates the way of applying benchmarking for large-scale open-pit mining operations based on sustainability indicators proposed by numerous institutions or groups of experts. These indicators have been developed taking into consideration the legal and regulatory framework that are in force. However, their scope is not only to declare the mining company?s compliance with all legal requirements but also to represent its economic, environmental, and social performance. In this way, sustainability indicators allow assessment of a company?s capacity to produce commodities, to meet the environmental quality requirements and to contribute to a long-term economic, cultural and social development of the local communities.

Jan 1, 2007

By G R. Ballantyne, M S. Powell

A comprehensive Australia-wide survey of comminution energy consumption at copper and gold mines was presented by the authors at the 11th AusIMM Mill Operators’ Conference 2012. The database has been extended to include major overseas mines and used to benchmark comminution energy consumption across the industry. The mines included in this study now represent 15 and 24 per cent of the total global gold and copper production respectively, and almost all Australian production. The comminution energy intensity per unit of saleable metal has been presented in a graphical form similar to a cost curve used in economics. The graphical method has been developed to assess the competitive advantage that can be achieved by reducing comminution energy intensity.This benchmarking tool has been applied to three published case studies to assess its applicability. The first case study indicated that a large reduction in size-specific energy (kWh/t -75 µm) was achievable by converting standard semi-autogenous and ball mill circuits to include high pressure grinding roll and stirred mills. The second case study investigated the metal-specific energy reduction historically achieved by Bougainville with the addition of a preconcentration screening plant. The final case study was conducted by Barrick Gold Corporation and involved incremental efficiency upgrades at three of its gold mines: Cortez, Cowal and Mara North. The application of the benchmarking tool to each of these case studies successfully demonstrated the scale and competitive advantage that was achieved by reducing energy intensity.CITATION:Ballantyne, G R and Powell, M S, 2014. Benchmarking comminution energy consumption for improved efficiency, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 95–100 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

By Alan Tordoir, Mark Roberts

The drill and blast process is a critical function within the production cycle which significantly impacts the ability of an operation to effectively meet its safety and production targets. Acknowledging that D&B design and reconciliation practices were conducted inconsistently across operations, a Group wide initiative was launched to embed a standardized design and reconciliation platform in line with the company’s Operating Model principles. A technical system was selected to deliver the digitalization of critical D&B information and enable ‘analyze and improve’ routines for design compliance monitoring and downstream productivity optimization.

Jan 1, 2019

By K Osten, N Scagliotta, G Lane

Oceana Gold (New Zealand) Limited operates the Macraes Gold Mine near Dunedin on the South Island of New Zealand. The orebody is mineralogically complex and comparatively low grade requiring a series of unit processes and resulting in a relatively complex plant. As part of Oceana GoldÆs ongoing Business Improvement program, a concerted effort has been made to focus on operational efficiency. One aspect of this has been the efficient use of energy in the gold recovery process. A benchmarking process has been developed for the Macraes operation that includes comparison with other operating mines and theoretical design. Criteria for determining operational efficiency have been developed. While benchmarking is, in theory, a simple process, this paper looks at putting benchmarking into practice by catering for variability in ore and associate processing methods. The unit processes discussed include the comminution circuit, flotation plant, pressure oxidation plant and gold recovery circuits.

Jan 1, 2004

By G Davies, D Dunn, C Mawdesley, O Bertoli

The coal industry in Australia has been actively working in recent years towards the (re)integration of geostatistical techniques to the process of coal resource estimation. The benefits of using geostatistical techniques, over the current interpolation algorithms in use in coal modelling packages used to generate the grid estimates, need to be illustrated for the methodology to gain a broader acceptance in the coal industry. This paper focuses on the benefits gained at BHP Billiton Mitsubishi AllianceÆs Saraji mine for the estimation of the total product yield value at a 9.7 per cent product ash cut-off of a particular seam of the Saraji deposit. In order to perform this comparison, the results of the alternative estimation methodologies need to be benchmarked, which in most situations is achieved through the reconciliation of the estimates against production and/or process plant reconciliation data. Unfortunately, this benchmarking was not possible as no reconciliation data for the area of interest in the chosen seam was available, as it has not been mined at the time of the study. Where no reconciliation data is available, an alternative method is to use conditional simulations as the benchmark for comparison. The simulated values can be regarded as ærealityÆ, and the alternative estimation methodologies, based on a sampling of the underlying ærealityÆ, can then be compared using the simulated ærealityÆ as the benchmark for comparison.

Jan 1, 2009

By James P. Rider

Significant advances in longwall mining technology and equipment have occurred over the last decade. By the late 1990s, longwall mine output accounted for 40 percent of all underground output in the U.S., and today longwall mines account for approximately 50 percent of coal produced underground in the United States. A 53 percent increase in average shift production rates has occurred over the last fifteen years. This increased longwall productivity has meant that far more dust is being produced and controlling respirable coal dust provides an ongoing challenge for coal mine operators. The National Institute for Occupational Safety and Health (NIOSH) has completed a series of benchmark surveys at longwall operations across the country to identify current operating practices and the types of controls being used. Gravimetric and instantaneous dust sampling was completed to quantify dust generation from major sources on the longwall section and to determine the relative effectiveness of the different control technologies in use today. Substantial reductions in dust levels were realized at sampling locations on the face when compared longwall surveys conduct in the 1990?s. This paper summarizes the results from the underground dust surveys and discusses current longwall dust control technology and operating practices.

Jan 1, 2010

By James P. Rider

Significant advances in longwall mining technology and equipment have occurred over the last decade by the late 1990s, longwall mine output accounted for 40% of all underground output in the U.S. and today longwall mines account for approximately 50% of coal produced underground in the United states. A 51% increase in average shift production rates has occurred over the last 15 years. this increased longwall productivity has meant that far more dust is being produced and controlling respirable coal dust presents an ongoing challenge for coal mine operators the National Institute for Occupational safety and Health (NIOSH) conducted a series of benchmark surveys at longwall operations across the country to identify current operating practices and the types of controls being used. Gravimetric and instantaneous dust sampling was completed to quantify the dust levels generated by major sources on the longwall section and to identify different control technologies in use today substantial reductions in dust levels were realized at sampling locations on the face when compared with ongwall surveys conducted in the 1990s results from the underground dust surveys and current longwall dust control technology and operating practices will be discussed. Mining Engineering, 2011, Vol. 63, No. 9, pp. 74-80. Official publication of the society for mining, metallurgy and exploration, Inc.

Jan 1, 2011

By E. Yan, M. Mankosa, E. Wasmund

"Rougher flotation in sulfide ore applications is typically performed using conventional flotation machines. The trend over the last 100 years has been for these cells to become larger in volume with cells reaching sizes of 600 m3 and in some cases even larger. The associated foundation loadings, transport and installation requirements along with building size have also increased. In an economic environment where projects must be executed with dwindling capital supply, bigger is not always better. More recently, industry is being challenged to identify new technology that allows for improved flowsheets and financial returns through efficiency gains. To meet this challenge, a novel high-intensity two-stage flotation system known as the StackCell™ was tested to potentially achieve installation volume and required retention time gains when compared to conventional flotation circuits. The results from on-site pilot scale work conducted on typical copper concentrator rougher flotation feed showed retention time gains on the order of 6 to 9 times when compared with conventional flotation equipment. This finding has the potential of reducing capital demands for rougher flotation circuit designs when incorporating the StackCell. The results from test work will be discussed in this paper showing comparative test data generated with a Denver bench batch test, pilot StackCell and large conventional cells, all receiving the same feed.INTRODUCTION Over the last few years, a number of flotation devices have been described as two-stage or multi-stage flotation units. The idea behind multi-stage flotation devices is that flotation performance can be improved by utilizing cells with multiple specialized units in series, but not all units of the same type, as is practiced in trains of multiple tank cells or columns. Instead, each unit is specially designed to provide the optimized fluid environment for each stage of the sequential flotation process. This idea has been proposed based on a study of the fundamentals of the flotation process, and the realization that the process consists of discrete sequential processes, that are each optimized with dissimilar process conditions (Finch et al, 1995), (Zhou, 1996). Instead of executing each step simultaneously in a homogeneous fluid environment, where the conditions would be a compromise between particle collection and froth recovery, the multi-stage flotation unit operates in a set of segregated process environments, each with a set of conditions optimized for that step."

Jan 1, 2018

By David Lin

"Modal data from Red Dog Main Pit ores were collected and analysed on a size-by-size basis. The Main Pit data were compared to data from composite samples of Red Dog Aqqaluk ores. The data revealed that a large fraction of the sphalerite in the Aqqaluk baritic ore was tied up in sphalerite/galena binaries. This provided an explanation for its poor leadlzinc selectivity compared to Main Pit ores. The Aqqaluk vein ore exhibited levels of sphalerite/galena binaries comparable to that of Main Pit ores resulting in comparable lead/zinc selectivity.An attempt was made to correlate the modal and metallurgical data for Main Pit stockpiles. It was found that there was moderate correlation between the percentage of sphalerite locked in binaries with galena in the <C5>C6 size fi-action and sphalerite deportment to the leadconcentrate.INTRODUCTIONTeck Cominco’s Red Dog Mine in northern Alaska is one of the richest zinc districts in the world. Red Dog Mine has been in operation for over ten years and produces nearly 1 million tonnes of zinc concentrate per mum. Red Dog Mine is an open pit operation and current mining is conducted in the area known as the Main Pit. The Main Pit contains proven reserves of about 41 900 000 tonnes of ore grading 19.2% Zn and 5.2% Pb (Cominco 2000). To the north of the Main Pit is the Aqqaluk deposit. It contains probable reserves of 56 100 000 tonnes of ore grading 16.6% Zn and 4.1 % Pb. After the Main Pit has been exhausted, the Aqqaluk deposit will be exploited.The Aqqaluk deposit consists of three main geologic ore types: baritic, siliceous and vein. The siliceous ore type is dominant, representing 64% of the mineralisation. Composite samples of these ore types were created from drill core and batch flotation tests were performed on them. The flotation tests indicated that there were significant metallurgical differences between Main Pit ore and the Aqqaluk siliceous and baritic ore. The siliceous and baritic ores were found to suffer from poor lead/zinc selectivity (Lin 1999, G&T 1999). It was suspected that there were problems with the original Aqqaluk composite samples, thus a new set of composite samples were created and batch flotation tests were conducted again. In this set of tests, the new baritic ore still suffered from leadlzinc selectivity problems, but the new siliceous ore provided excellent metallurgical results. A summary of the flotation results is given in Table 1. Stockpile 132, which is typical of Main Pit ore, is given for comparison purposes. The mineral suite at Red Dog is relatively simple. The ore consists of galena, sphalerite and pyrite in a silicate matrix. The low zinc recoveries of the baritic ore were largely due to sphalerite losses to the lead concentrate."

Jan 1, 2002

By S. J. van Wyk, A. S. H. Haagner, A. Abraha

Opencast coal mining is responsible for the greatest area of land disturbance across all of the commodity types in South Africa. Many thousands of hectares have been rehabilitated to date and, although rehabilitation performance is not always measured or reported, a significant database, spanning 24 years, has now been analysed to identify the main shortcomings holding back rehabilitation sustainability across the industry. Data from 48 different collieries with rehabilitation performance scores measured from 2000-2024 were analysed. A standardised assessment framework was implemented at all 48 collieries, focusing on aspects of land capability, soil fertility, landscape form and drainage, vegetation species composition and basal cover, implementation of maintenance programmes, and prevalence of invasive alien plants. The findings show that, although invasive species management, plant species composition, and plant basal cover are often adequate, the implementation of aftercare and maintenance programmes (influencing soil fertility) and deficiencies in overall landform design and drainage systems are most significant in preventing overall rehabilitation progression and self-sustainability. Integrating these during design and rehabilitation execution, followed by intensive maintenance (especially in the first five years post-topsoiling and seeding) will be key for the overall industry performance to improve to acceptable levels. The database is biased towards collieries that actually do undertake rehabilitation and that do measure it, hence the actual industry performance is likely worse than what is presented. Due to the substantial hectarages involved and the main post-mining land uses being grazing and crop production, the industry cannot afford to keep perpetuating deficiencies in achieving the foundational aspects of rehabilitation that would pave the way for sustained economic future use.

Apr 25, 2025

By D Jeffery, R Whittering, G Lane

Most aspects of process design are best addressed via bench scale or pilot plant scale test work. However, as experience is gained, fundamental or indicative data can provide more than adequate information to manage the risk associated with some process aspects of concentrator design.Historical precedence exists where minimal design test work has resulted in successful projects. On many occasions benchmarking, sometimes supported by fundamental data such as mineralogy, has been used to successfully develop effective process plant outcomes. Of course, this style of approach is most common with æfast trackÆ projects and often comes with the usual surprises that result from inadequate geometallurgy to define the project cash flow.This paper explores the risks and opportunities associated with the various facets of process development and design for a base metals concentrator. The paper is intended to provide guidance to project managers rather than address the technical aspects of process engineering.CITATION:Lane, G, Whittering, R and Jeffery, D, 2012. Benchmarking versus test work - How should you manage process risk?, in Proceedings Project Evaluation 2012 , pp 49-52 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 24, 2012

By P J. Harper

Maximising shareholder value is a widely stated strategic goal of many mining companies. Mining projects can be capital intensive and achieving good returns is essential to encourage future investment in the industry. Despite the widely accepted importance of shareholder value, the minerals industry is often accused of providing relatively poor returns when compared to other industries. There are many recent and well publicised examples of minerals companies that have failed to deliver value to their shareholders. There are numerous business improvement initiatives employed within the mining industry to assist mine operators improve performance. Some are more effective at creating value than others. Benchmarking is one technique that is commonly used to identify performance gaps and target and prioritise opportunities for improvement. However to be effective, Benchmarking must be used appropriately and result in actions that lead to measurable operational improvement. When conducting a Benchmarking project it is important to remember that the aim should be to improve value. For this to be achieved, the strategic goals must be incorporated into the process. This paper details a structured and comprehensive approach to conducting a successful Benchmarking project. Focusing on Benchmarking as a technique for measuring and improving operational performance in underground mines, the underlying drivers of best practice in underground mining are identified.

Jan 1, 2005

By M Berry

Many mining companies routinely use benchmarking to review their operational activities and associated costs. The aim is to measure operational performance against industry norms, and identify areas where a company is performing better or worse than industry best practice. The goal is continuous improvement.In general, mine technical services, including mining geology activities, are not routinely benchmarked. There are exceptions, such as the cost of drilling per metre and the average discovery cost per unit of metal, but generally mining geology activities are only included indirectly in mining benchmarking studies.Aspects of benchmarking can play a critical role in assisting mining geologists to improve the efficiency and effectiveness of the services they provide. Industry norms for many generic mining geology functions have not been developed and measured, and therefore it is impossible to use external benchmarking to assess performance against other mines. But when used in parallel with quantifying the value of mining geology functions and establishing strategic goals for the team, key components of benchmarking methodology can provide essential feedback on how a team is performing against these strategic goals.CITATION:Berry, M, 2014. Benchmarking – does it have a role in improving the performance of mining geology?, in Proceedings Ninth International Mining Geology Conference 2014 , pp 361–366 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 18, 2014

The cost of production from truck and loader fleets is influenced by management development of the culture of the organisation, work practices, systems and procedures of the production and maintenance teams. Establishing if the cost of production is the best that can be achieved then requires the measurement of results against established standards of performance. This paper provides a series of discussion points of the factors that influence the cost of production from men and machines for large scale open pit mining operation and provides some suggested performance standards in the form of Benchmarks. Most of the references have been drawn from established large scale deep pit mines in USA, Canada and Australia which have had to implement and constantly fine tune cost efficiencies in order to survive. The discussion provides:ò a review of priorities or the relative importance of the various cost elements for a mining system;ò suggestions of systems and procedures for the operation and maintenance of machines which are considered to yield the best overall results;ò examples of operations that have developed and implemented management systems and controls that are achieving good results in specific functions; andò suggested benchmarks of performance.

Jan 1, 1992