With sustainability and technological progress reshaping Australia’s mining industry, recent discussions at the Mill Operators Conference in Perth highlighted several key themes. For operations and processing managers on site, these developments have real, tangible implications. From rethinking waste management to embracing AI in mineral processing, this article explores how these trends could directly impact day-to-day operations across Australia’s mineral processing plants.
1. Engaging Stakeholders for Automation Success
Automation offers transformative potential for mineral processing, particularly in critical minerals production, which plays a vital role in Australia’s competitive standing. However, implementing automation solutions requires careful stakeholder engagement to ensure that these systems are designed with the unique demands of each site in mind. For processing and operations managers, this means:
For Australia’s critical minerals supply chain, automation offers a path to increased efficiency and sustainable production—provided it is implemented with thorough, inclusive stakeholder engagement.
- Increased Efficiency and Safety: Automation can streamline workflows, reduce costs, and mitigate risks.
- Effective Rollout through Stakeholder Buy-In: By involving operators, end-users, and technical staff early in the process, managers can ensure that automation tools meet the specific needs of the plant and that users feel confident using the new systems.
- Smoother Adoption of Technology: Stakeholder involvement helps reduce resistance to change and addresses any concerns around job security or operational disruptions, ultimately leading to long term adoption of automation solutions.
For Australia’s critical minerals supply chain, automation offers a path to increased efficiency and sustainable production—provided it is implemented with thorough, inclusive stakeholder engagement.
2. The New Age of Metallurgical Accounting
Metallurgical accounting is evolving, driven by a renewed focus on transparency, regulatory compliance, and performance optimisation. The recent release of AusIMM’s metallurgical accounting course has heightened awareness of the importance of accurate accounting across processing stages. For daily operations, robust metallurgical accounting means:
Processing managers who prioritise accurate metallurgical accounting practices not only safeguard operational compliance but also contribute to a transparent industry reputation, which is becoming increasingly important in today’s market.
- Enhanced Compliance and Transparency: Adopting the AMIRA P754 guidelines allows plants to standardise reporting practices, giving stakeholders a clear view of mineral recovery and processing efficiency.
- Informed Decision-Making: Accurate accounting ensures that processing managers have reliable data to optimise production and manage costs, particularly in response to market volatility.
- Digital Integration: As digital transformation accelerates in mining, digital accounting systems can help streamline data collection and reporting, supporting a more comprehensive approach to resource management and ESG (Environmental, Social, and Governance) metrics.
Processing managers who prioritise accurate metallurgical accounting practices not only safeguard operational compliance but also contribute to a transparent industry reputation, which is becoming increasingly important in today’s market.
3. Rethinking Waste: Turning Liabilities into Assets
Traditionally, mining waste—from tailings to stockpiles—was seen as an inevitable byproduct, often left idle or disposed of at a high cost. However, recent advances in waste reprocessing and the development of new uses for waste material are shifting this view. Cases presented at the conference included the reprocessing of a 12-year-old stockpile of ball mill remnants and using technologies like coarse particle flotation to reuse tailings sand for embankment construction. For site operations, this shift can mean:
Implementing these changes may require an initial investment in new technologies, but the long-term benefits to site productivity, safety, and regulatory compliance are substantial. For operations managers, considering waste as a potential asset rather than a liability may reshape resource allocation and waste management practices.
- Reduced Tailings Volume: By reprocessing tailings, plants can lower storage needs and associated environmental risks, which is especially critical for sites aiming to minimise their environmental footprint.
- Material Savings and Additional Revenue: Repurposing waste materials for construction or other industrial uses opens up new revenue streams and reduces disposal costs.
- Operational Efficiency: Moving toward a circular economy model—where waste is reintroduced as a usable resource—can help streamline waste handling and disposal activities on site, making processes more efficient and aligned with environmental standards.
Implementing these changes may require an initial investment in new technologies, but the long-term benefits to site productivity, safety, and regulatory compliance are substantial. For operations managers, considering waste as a potential asset rather than a liability may reshape resource allocation and waste management practices.
4. Australia's Competitive Edge in Critical Minerals
As global demand for critical minerals grows, Australia faces intense competition, particularly from China, which has heavily invested in the vertical integration of its critical minerals supply chain. This competitive landscape was a recurring theme at the conference, underscoring the need for Australia to leverage its unique advantages. In practice, this competitive push can influence site-level priorities:
The implications for processing managers are clear: by optimising production efficiency and adopting sustainable practices, plants can align with Australia’s national goals, contributing to a resilient critical minerals sector capable of competing on the world stage.
- Focus on Value-Adding Processesrther up the value chain, enhancing the economic impact of their operations.
- Prioritise Sustainable Processing: With stricter environmental regulations and a social license to operate, Australian operations that adopt sustainable practices will be better positioned to compete globally.
- Technological Investments: Advanced processing technologies, supported by government and industry, could help plants lower costs and increase efficiency, improving Australia’s competitive edge.
The implications for processing managers are clear: by optimising production efficiency and adopting sustainable practices, plants can align with Australia’s national goals, contributing to a resilient critical minerals sector capable of competing on the world stage.
5. AI in Mineral Processing: Unlocking New Levels of Efficiency
AI in mineral processing is an emerging area, yet it holds immense potential for optimising operations, predicting maintenance needs, and enhancing safety. The potential of AI lies in its ability to analyse data across the entire processing flow, providing actionable insights to improve efficiency and reduce downtime. For site operations, the benefits include:
- Optimised Processes: AI can analyse large datasets to identify ideal processing parameters, leading to higher resource recovery rates and lower energy usage.
- Predictive Maintenance: By detecting early signs of wear or failure in equipment, AI systems help minimise unplanned downtime, allowing for proactive maintenance planning.
- Safety Enhancements: AI can monitor hazardous environments, providing insights that help avoid potential risks and reduce human exposure to dangerous tasks.
Conclusion: Embracing a Future-Ready Mindset
The themes depicted at the conference illustrate that Australia’s mineral processing industry stands on the edge of a fundamental transformation. Through advancements in waste management, bringing stakeholders into automation, bolstering our position in critical minerals, and investing in metallurgical accounting and AI, processing operations managers can transform their sites into more efficient, sustainable, and competitive enterprises.
Whilst considerable obstacles do exist – particularly in the acceptance of technology
and in cost – an optimistic and pragmatic perspective will pay off for Australian mineral processing sites as they cope with change and take advantage of opportunities that emerge in the global market.
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