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By W Valery, S Morrell

In the mining industry blasts are usually designed to fracture the in situ rock mass and prepare it for excavation and subsequent transport. The run of mine (ROM) fragmentation is considered good when it is fine enough and loose enough to ensure efficient digging and loading operations. Mining optimisation strategy is hence usually focussed on minimising total mining costs and maintaining these ROM fragmentation characteristics. Although this approach ensures an efficient mining operation it ignores the potential impact on crushing and grinding. Investigations by several researchers have shown that designing blasts to produce ROM fragmentation to optimise crushing and grinding performance enhances the overall efficiency and profitability (Eloranta, 1995; Kojovic et al, 1995; Bulow et al, 1998; Kanchibotla et al, 1998; Scott et al, 1998; Simkus and Dance, 1998). Field experimentation in this area is often found to be difficult because of high implementation costs and insufficient understanding about the effect of fragmentation at different stages in a comminution circuit. Modelling and simulation of blasting and comminution processes provide a more economic alternative to explore the impact of blast design changes on the down stream operations (Kanchibotla et al, 1998; Kojovic et al, 1998; Adam and Siddall, 1998; Bulow et al, 1998). However, the reliability of such simulations depends on:the ability of the models to reproduce the physical processes that take place; characterisation of rock mass in terms of its blastability and comminution characteristics; and in the case of blast modelling the ability to predict fines (-10 mm) has been found to be particularly important as this fraction has a significant effect on mill throughput.

Jan 1, 1999

Ore deposit modelling is becoming an increasingly accepted tool in mineral exploration. Successful models have already been proposed for several ore deposits of base metals and gold, but tin has so far received comparatively little attention, perhaps because of an excessive preoccupatioi with alluvial operations. This situation is rapidly changing and some of the world's most profitable and newly commissioned tin mines are large, primary tin deposits. Some basic principles of ore deposit modelling are briefly reviewed and the fallacy of an excessive reliance on grade tonnage diagrams based on the tin industry worldwide is discussed. The four proposed models and submodels of large, hard-rock, tin deposits focus on basic concepts such as the spatial relationship with "tin granites", depth of emplacement and the level of erosion. General concepts are drawn. The modelling of large primary tin deposits is reviewed not only in its geological and exploration aspects but also in its mining and economic implications.

Jan 1, 1986

By A Tawadrous, B Wheeler, D S. Preece, S A. Silling

The two key results of rock blasting are fragmentation and movement of geomaterials. Movement/flow of the blasted rock is often referred to as heave. Moving rock with explosives rather than mechanical equipment can improve mining efficiency. Such is the case with coalmine cast blasting. Controlling and directing rock movement through explosive deck delay timing can greatly improve ore recovery by segregating ore and waste. In both cases, understanding, predicting and controlling heave is an important element of successful blasting.Computer programs for predicting 2D blasting-induced heave have been used in mining for decades, helping to drive the innovation of new and more efficient mining methods, ie cast blasting. The past few years have seen the advent of 3D distinct element modelling of blast-induced heave. This is an important advancement because most blasting situations are three-dimensional in nature, especially when controlling the direction and intensity of rock movement through explosive deck delay timing.This paper documents the first full-scale blasting simulations in 3D with distinct element models that include hundreds of blastholes and in excess of a million particles, made possible with parallel processing. Surface mineral blasting is the focus of this study which treats the effect of blasthole delay timing on ore recovery. Ore waste and dilution resulting from typical row-on-row delay timing will be demonstrated. Also demonstrated will be the ore recovery possible with delay timing designs that significantly enhance ore/waste segregation. This type of high fidelity modelling and the use of electronic detonators makes possible the sculpting of rock blasting muck into separate piles of ore and waste.CITATION:Preece, D S, Tawadrous, A, Silling, S A and Wheeler, B, 2015. Modelling full-scale blast heave with three-dimensional distinct elements and parallel processing, in Proceedings 11th International Symposium on Rock Fragmentation by Blasting, pp 127–136 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 24, 2015

By S Khosrowshahi, A Weeks, W J. Shaw

"To provide an indication of expected performance of the mine and mill, feasibility studies should include an assessment of the expected day-to-day variability in process plant feed. Attempts to do this based on conventional resource models will be flawed as such studies fail to consider and account for the in-built smoothing (averaging) of input data.This can lead to one of two situations: an expensive, over-engineered process plant that can cope with every possible situation, or operational strategies that fail to manage the natural variability within the orebody and the impact of day-to-day operational decision-making.In both cases the value of the project diminishes through excessive capital costs or reduced throughput or recovery during operations.Unlike conventional estimation techniques, the geostatistical method of conditional simulation can reproduce the inherent variability of the deposit. Once a valid model has been developed, it is possible to analyse the model using a transfer function that simulates the proposed mining processes and provides a representation of the likely variation of mill feed characteristics at any time scale.The case study demonstrates how the proposed mining strategy would result in mill feed being considerably more variable than expected, resulting in poor recovery, low throughput and potential breaches of environmental conditions. Mitigation measures included budgeting for additional mining equipment to enable greater flexibility during mining and revised stockpiling and crusher feed strategies.Awareness of the benefits of modelling the variability of geometallurgical parameters will increase the use of this approach in producing more realistic financial models of expected mine performance at the design stage.CITATION:Shaw, W J, Khosrowshahi, S and Weeks, A, 2013. Modelling geometallurgical variability - a case study in managing risk, in Proceedings The Second AusIMM International Geometallurgy Conference (GeoMet) 2013, pp 247-252 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Sep 29, 2013

Metsim is proving to be a powerful tool when designing a heap leach operation. The most useful outputs arc determining the fluctuations in pregnant solution recovery rate, make-up water rate, gold recovery rate. and pond levels. Detailed data are needed for input: a pad loading schedule, a mining rate schedule for each ore type, column leach test data for each ore type, column tests on water dynamics (ie hourly flow-out versus-in during saturation and drain-down), monthly rainfall and evaporation data, and proposed pond dimensions. These data allow 'what if' studies on application rates, leach rates, loading rates and other variables of interest. Examples will he given of modelling both a rectangular pad and a valley fill operation.

Jan 1, 1994

By M Campbell, A Jeffcoate, J-C Vannay, B Perriaux

Phyllite waste rock at the Simandou Pic de Fon and Oueleba Iron Ore deposits (Guinea, West Africa) variably weather to form clay-rich rocks. This weathering modifies the mineralogical, geochemical and mechanical properties of the phyllites. Final pit walls will largely be formed in phyllite, so it is critical that the slope design takes account of the distribution and variability of weathering within this material. Phyllite intact material strength has been correlated with geochemistry (ie mineralogy) facilitating the establishment of domains of intact rock strength (IRS). In order to calibrate this geochemically-based strength model, core from diamond drilling (DD), comprising a variety of phyllite material types (from soft clay to moderate strength rock), was geotechnically logged to assess intact strength; further validation was achieved by uniaxial compression (UCS) testing and point load tests (PLT). The correlation between geochemistry and strength offers a potentially powerful tool for differentiating basic mechanical properties of the rock mass, especially at Simandou where a significant proportion of the resource drilling is done by reverse circulation (RC). Unlike DD, reliable measurements of material strength from RC samples can prove difficult, especially in clay-rich material. Therefore, gaining information from routine geochemical assay results, independent of the sampleÆs physical integrity, is a valuable and cost-effective source of reliable empirical data. Data acquired using this approach provides an opportunity to develop strength domains, which are integrated into mine planning block models. In combination with other geotechnical characteristics, this can be a valuable input to the development of geotechnical models. This technique has allowed spatially representative rock strength data to be derived and offers the potential for optimising pit slope angles in areas where hitherto conservative design criteria had been assumed.CITATION:Jeffcoate, A, Campbell, M, Vannay, J-C and Perriaux, B, 2013. Modelling intact rock strength of clay-rich rocks with geochemistry at the Simandou iron ore deposit, Guinea, West Africa, in Proceedings Iron Ore 2013 , pp 193-202 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 12, 2013

By P Dowd, A Adeli, C Xu, X Emery

Geometallurgical modelling is increasingly being incorporated into mineral resource modelling and estimation as a means of increasing efficiency, decreasing operating costs and reducing risk in mining operations. Traditional geostatistical workflows for geometallurgical modelling face several difficulties, in particular, related to the non-additivity of process response variables, to highly heterotopic data sets and/or to preferential sampling designs, all of which may explain why most attempts to estimate geometallurgical response variables from assay data and mineralogy are still based on statistics and machine learning. The aim of the work presented here is to demonstrate the applicability of geostatistics to estimate copper recovery from copper sulfide ores at the Prominent Hill Iron Oxide Copper-Gold (IOCG) deposit in Australia. As recovery is non-additive, the preferred workflow is the joint estimation of the masses of metal in the feed and in the concentrate, both of which are additive variables. While the mass of metal in the feed can be estimated from abundant online assay analyses, the mass of metal in the concentrate can only be estimated from a very limited number of laboratory-scale batch flotation tests. Traditional approaches to estimating the masses of metal in the feed and in the concentrate, such as simple and ordinary co-kriging, are described and discussed. A modified version of co-kriging is introduced, which incorporates linear relationships between the mean values of the input variables, in addition to a spatial correlation model. Co-kriging with related means is shown to outperform traditional simple and ordinary co-kriging in terms of precision, accuracy and consistency of the estimates, and offers a practical and efficient tool to deal with highly heterotopic and preferential sampling designs.

May 24, 2023

By A Lyon

The minerals industry, as many other industries, has a wealth of indicators and a thriving æindustryÆ in their development, measurement and reporting. It is natural for this to occur for a new endeavour. However, perhaps it is time for the community concerned with minerals industry indicators to ask whether we have achieved a certain maturation whereby proliferation of indicators may be replaced by a more disciplined and constrained approach. In many natural and engineered systems, thermodynamics provides well-understood and tested constraints. Indicators that are uninterpretable in this framework are not considered acceptable. This paper provides initial evidence that such a formalism may be possible for mine sustainability. The formalism developed does not claim to have the rigour of thermodynamics. However, it does provide a first step towards formalising selection of indicators on the basis of their true comprehensibility. A set of simple equations is developed that represent the conventional five capitals (actually we use six because we separate renewable and non-renewable natural capital) and how they are linked. This is coded into a simulation model. The base equations are then used to develop a system level indicator of sustainability performance, which is asserted to be a reflection of the mineÆs reputation. We define a least sustainable state, termed æmaximum revenue mining (MRM)Æ in the system and define the degree of system sustainability as how far the system is from the MRM. We then introduce a simple mechanism whereby different actors can express differing views on the emphasis for the distance from MRM. Sustainability thereby becomes a non-unique thing that is defined by a distance from MRM and a set of preferences across the capitals.

Jan 1, 2009

By A Lines

This paper addresses a gap in longwall multi-seam interactions and their predictions, providing a case study for future multi-seam operations for both anticipated conditions and a method for understanding the changes in stress regime. Multiple panels were modelled with the results analysed and compared to panel experiences to validate the parameters and properties. The software chosen (LaModel) is a numerical modelling package designed to model stresses and displacements on thin deposits. It utilises a displacement-discontinuity variation of the boundary-element method and has been used extensively throughout both the United States and Australia in multi-seam operations. Analysis of the results demonstrates a clear correlation with the above workings and regions of significant strata instability. This provides the opportunity going forward to analyse new models and incorporate into mine planning and geotechnical designs. Continuous site-based assessment should be undertaken at multi-seam operations to better understand and quantify likely vertical stress levels within the workings. With a detailed analysis of models prior to extraction and a review of models post extraction. Further research is required as LaModel is limited to vertical stress and it is likely that interactions impact both the horizontal and shear stress regime. 3-dimensional modelling could further assist in this understanding, combined with a thorough stress monitoring regime. CITATION:Lines, A, 2018. Modelling multi-seam interactions for longwall mining, in Proceedings The Fourth Australasian Ground Control in Mining Conference (AusRock), pp 185–195 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 30, 2018

By R Steinhaus, D M. Frantois-Bongarton, P W. Cleary, G K. Robinson, M D. Sinnott

Multotec Process Equipment and Dominique Frantois-Bongarton have a patent for a mineral sampling device, which they call a æTrue-Belt SamplerÆ. This uses a plough, which is rotated about an axis parallel to a conveyor belt to throw material off the belt. A fixed sample cutter takes a sample from the material thrown off the belt.Discrete element modelling has been used to consider a range of plough designs, plough speeds, positions for the cutter relative to the plough, cutter apertures, cutter designs and frictional properties, prior to the building of a physical prototype. This modelling work will be discussed, both as an illustration of the role of modelling in the development of new materials-handling devices and in order to explain the likely strengths and weaknesses of this new type of sampling device.CITATION:Robinson, G K, Sinnott, M D, Cleary, P W, Steinhaus, R and Frantois-Bongarton, D M, 2012. Modelling of a ætrue-belt samplerÆ - A new device for sampling from a conveyor belt, in Proceedings Sampling 2012 , pp 33-40 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 21, 2012

By P Edmondson, S Narendranathan, S Setchell

The complexities of mining in current economic conditions, where ore extraction schedules are varied on a weekly basis so as to ensure constant supply to the process plant, can result in a number of scenarios that pose geotechnical challenges. This paper presents a case study where alterations in the mining schedule of a particular mine resulted in the necessity to mine under a large uncompacted embankment, ie integrated tailings and mine waste landform. To effectively ensure that ore recovery was maximised, a well-designed slope monitoring system to evaluate design performance and to provide timely warning of impending failures was imperative. In order for an appropriate slope monitoring strategy to be developed, a thorough understanding of the potential slope failure mechanisms, capabilities and limitations of available monitoring techniques is required. Communication of the monitoring results and response strategy to alarms generated by monitoring systems must also be carefully considered to maximise effectiveness. The results of preliminary stability modelling can be used to guide the design of a monitoring system, which in turn can then generate data which can be used to iteratively refine the geotechnical model. This paper illustrates the development and implementation of a slope monitoring system and associated communication system, using a case study developed at a large iron ore open pit mine in the Pilbara region of Western Australia.CITATION:Narendranathan, S, Lee, E C, Setchell, S and Edmondson, P, 2015. Modelling of an integrated waste storage facility, in Proceedings Tailings and Mine Waste Management for the 21st Century , pp 183–190 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 27, 2015

By Mckenzie CK, Leach KR, Bateman KW

Modelling of industrial coal flotation based on data collected in several Central Queensland flotation plants and supplemented by laboratory data is discussed. The model is kinetic in form and provides the basis of an automatic control system. The important features of the model are, 1. a distribution of flotation rates for each species of particles corresponding to the range of particle sizes, 2. a physical restriction on the removal rate of solids in cells where froth 'overloading' occurs. In this condition the removal rate of solids is proportional to the removal rate of water, 3. enhanced particle floatability due to increasing collector addition where froth overloading does not occur, 4. a second mechanism of recovery of all particles by mechanical associ- ation with water. This mechanism is particularly important in the recovery of fine high-ash species.

Jan 1, 1978

By B Yeganeh, A Sam, A Kohsari

The base of separation at Gol-e-Gohar iron ore plant (Sirjan in the south of Iran) is magnetic separation after milling. Magnetic separation in the plant is divided into two parts: dry magnetic separation and wet magnetic separation. Sixty-five per cent of the plant production belongs to the dry magnetic separator section. Therefore, investigation of this part of the plant is necessary. Prediction of plant production is one of the most important subjects in mineral processing plants. That means, before feed enters the plant, specification of production has been calculated with laboratory methods. The purpose of this paper is the prediction concentrate quality has achieved from the dry magnetic separator. The content of iron in the final dry concentrate will be predicted, with laboratory, pilot and modelling methods, before feed enters the plant. Different variables are used in this approach, which consist of: speed of the first dry magnetic separator (rougher), speed of the third dry magnetic separator (cleaner), iron content in plant feed, size of 80 per cent passing of feed, size of 20 per cent passing of feed and iron content in pilot dry magnetic separation concentrate that performs in a standard manner. The artificial neural network is used for modelling and one of its branches is the radial basis network (RBN). Iron content in magnetic separating concentrate in plant will be introduced as the target and will be calculated with the RBN method. In the RBN method, a set of data enters to neural network and they will be trained and simulated. Finally, the target will be predicted. Ultimately, the original target (actual iron content) and the predicted target (predicted iron content) compare and error of them will be calculated. The obtained result is acceptable and satisfactory.

Jan 1, 2007

By J-P Franzidis, E V. Manlap

Froth transportation characteristics have a significant impact on the flotation recovery especially in large flotation cells. The probability of an attached particle being recovered into the concentrate depends strongly on the location where it enters the froth phase. A mathematical model for froth transportation in industrial flotation cells was proposed (Zheng et al, 2004). The model has been tested on the experimental data obtained from testwork conducted at the Western Metals Hellyer lead/zinc concentrator. The results show that the model fits the experimental data well, especially when the froth is well developed (ie for a deep froth). The model fitting can be significantly improved by incorporating an air dispersion factor. However, the models encounter some limitation, ie inconsistent prediction at different froth heights, due to change in froth viscosity which cannot be modelled at the present time.

Jan 1, 2005

By B J. Monaghan, P Zulli, X F. Dong

In the lower zone of blast furnace (BF), slag trickles down through a packed bed of carbonaceous particles in the form of films, rivulets or droplets. During its downward flow, there are significant interactions occurring between slag and other phases, ie gas and packing particles. In particular, the interaction between gas and slag is closely associated with the key flow phenomena such as loading, flooding or channelling in the lower zone of the BF. With gas introduced laterally through tuyeres and slag flowing downward from the cohesive zone to the hearth, this interaction varies throughout the lower zone and in the cohesive zone:  strong cross-flow of gas relative to the slag occurs in front of the raceway  counter-current flow of gas and slag occurs in the upper parts of the lower zone  both strong cross- and counter-current flow of gas and slag around and within the cohesive zone. These interactions can be linked to furnace irregularities, affecting smooth operation and limiting production. Therefore, understanding the gas-slag interaction and its influencing factors remains critical for BF process control. In the current review, the physical behaviour and key influencing factors of gas and slag flow are initially examined. Numerical models describing gas and slag flows in a packed bed at micro-, mesoand macro-scopic levels, are reviewed. Each simulation approach has its advantages and limitations, as well as unique assumptions when used in BF process modelling. Applications of these approaches to gas-slag flow in key identified functional zones will highlight the differences between approaches and modelling outcomes. As no single approach can fully address all aspects of gasslag interactions, an integration of different approaches is considered an effective and beneficial method in providing a more complete understanding of gas-slag flow in the BF process.

Jun 19, 2024

By D Adhikary, M Khanal, B Poulsen, H Guo

During longwall mining, the ability to reliably estimate the height of longwall mining-induced fractures is critically important in order to effectively manage mining-induced water inflows and aquifer interference. The extent of mining-induced subsurface deformation, fracture, surface subsidence and aquifer interference is largely controlled by local lithological conditions, mining methods and mine layouts. Therefore for the purpose of quantifying mining impacts it is imperative to incorporate the local geology and mine plan parameters in a mine scale model. Two different numerical models based on 3D continuum (Finite Element Method) and 2D discrete (Discrete element method) domains, respectively, are developed to incorporate the mine site parameters of a study site in Australia. Both the models are calibrated and validated with measured mine data. The continuum numerical modelling method is used to investigate the change in permeability of the overburden strata due to underground extraction considering the full 3D nature of geology and mine layout. The discrete element modelling method is used to simulate the initiation and propagation of fractures, allowing the caving of overburden strata to be represented in a realistic manner, and the permeability enhancement of the strata overlying the goaf to be calculated from first principles. Permeability enhancement in the discrete element model is a direct function of the fractures induced in the deformation/caving process; fracture location, extent, aperture and connectedness. From the numerical modelling under the simulated condition for the mine studied here, it is predicted that the permeability of the caving zone from the goaf to five times the mining height increases by almost six orders of magnitude. In the fracture zone to approximately ten times the mining height, the change in permeability is predicted to be around two to three orders of magnitude. At the height of more than ten times the mining height the magnitude of permeability increased is predicted to be one to two orders of magnitude. CITATION:Khanal, M, Poulsen, B, Adhikary, D and Guo, H, 2018. Modelling of height of connective fractures during longwall mining, in Proceedings The Fourth Australasian Ground Control in Mining Conference (AusRock), pp 254–265 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 30, 2018

By T Krull, T J. Donohue, D Ilic

"Problematic issues in materials handling applications are often amplified in the iron ore industry due to the relatively high density of the ore as well as the abrasive nature of the product. One of the main issues arising from the handling of iron ore is excessive wear, with two applications typically suffering accelerated wear issues being transfer chutes and conveyor belts. These wear issues are problematic due to additional capital costs, but mainly due to the associated downtimes resulting in the accelerated wear. This study will focus on the modelling of iron ore in practical applications where design work was undertaken in order to reduce the wear rates of different materials handling equipment.CITATION:Donohue, T J, Ilic, D and Krull, T, 2013. Modelling of iron ore in materials handling applications with a focus on wear, in Proceedings Iron Ore 2013, pp 355-362 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Aug 12, 2013

By Y Chung, B Choi, H Lee

Numerous studies have explored refractory corrosion in the presence of slag and/or metal, utilising the Finger Rotating Test (FRT). Recent experimental results revealed that corrosion initially increased with rising rotation velocity but was then suppressed above a critical rotating speed, under conditions involving a two-liquid solution of slag and molten steel. This phenomenon indicated that the liquid/liquid interface movement occurred during spindle rotor. However, understanding of the phenomenon, known as the rod climbing effect, remains inadequate in the case involving slag, molten steel and refractories. To gain deeper insights, a simulation experiment was conducted on the phenomenon using silicon oil/water and the phenomenon was analysed using computerised simulation software (Ansys Fluent). Experimental modelling demonstrated that interfacial movement occurs even at low rotation velocity, as low as 200 rev/min, when the viscosity of silicone oil is at 100 cP. Computational analysis utilising the Volume of Fluid (VOF) method and a realisable k-ε turbulence model elucidated that interface elevation during rotor rotation arises due to viscosity disparities between the two fluids. Furthermore, this movement is more pronounced when the viscosity difference is lower. Additionally, the study findings suggest that higher density differences between two liquids suppress the phenomenon of interface movement.

Jun 19, 2024

Modelling of Magnetic Carrier Separation Process Using Computational Fluid Dynamics

Sep 13, 2010

By E Werner, J J. Donovan, A J. Morris

Coal mining in the Pittsburgh coal seam, in the eastern United States, began in the late-1700s. Since that time numerous mining technologies have been used throughout the basin. Environmental concerns, particularly mine discharge quality, have only been considered since the early-1970s. During the last 20 years, many of the larger underground mines have closed and are now either flooding or already flooded. In order to understand the consequences and potential future effects of this flooding, mine mapping of the basin has been compiled utilising a geographic information system (GIS) with an emphasis on locating barrier pillars between mines. Mine flooding has been monitored at numerous sites utilising pressure transducers and data loggers. These data have been combined with historical data from mining companies and structure contour maps to yield chronological flooding maps of the basin from 1980 to present. Utilising these maps and the indicated flooding rates, future discharge locations have been identified along with estimates of when these discharges are likely to occur. Related work has identified barrier pillar hydraulic conductivities and vertical infiltration rates as a function of overburden thickness. All of this information has been integrated into a groundwater flow model that simulates mine flooding. This model is useful in defining mine to mine interactions as the various mines fill with water, and the testing of various flooding scenarios. The model will be used in evaluating mine discharge rates and evaluating the options for regional mine drainage treatment.

Jan 1, 2003