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By S-C Shim, H-R Lee, Y Kang, H Shin

Since iron oxide and silicon oxide are major gangue components in various types of ore, FeO-SiO2 base slag, ie fayalite slag, has been often encountered in pyrometallurgical processes of non-ferrous metals. During most matte production processes such as the smelting of Cu, Pb, and Ni, the FeOSiO2 based slag is inevitably formed and plays an important role in refining crude metal as well as engineering aspects. Recently, similar pyrometallurgical approaches have been attempted in the recovery of valuable metals (Ni, Co, Cr) from wasted secondary batteries. Thus, the viscosity of the FeO-SiO2 based slag has great significance in properly controlling smelting processes. However, when molten metal or matte does not coexist with the slag during the measurement, there has been a serious difficulty in maintaining Fe valance and consequently, the slag composition. In the present research, the viscosity of molten FeO-SiO2 slag was measured in 1573~1673 K using a rotational viscometer. In order to keep the state of iron oxides, the oxygen partial pressure was controlled using CO/CO2 gas mixture. The optimised ratio of CO/CO2 could be calculated using Fe/Fe2+ and Fe2+/Fe3+ equilibria at each temperature. The composition of the slag, particularly Fe valance, after the measurement was analysed with the aid of an inductively coupled plasma – optical emission spectroscopy (ICP-OES) and an automatic potentiometric titrator. The measurement showed that the FeO-SiO2 slag has considerably low viscosity values in the molten state, and it sharply increases as the temperature decreases. In spite of the careful oxygen partial pressure control, a part of Fe2+ was found to be oxidised to Fe3+, with a maximal case reaching about 20 per cent. The increase in viscosity of FeO-SiO2 at low temperatures can be attributed to the composition change due to an unavoidable Fe2+ oxidation. In addition, the relationship between the change in the viscosity and the liquidus temperature of FeO-SiO2 based slag was discussed to understand the composition dependence of viscosity.

Jun 19, 2024

By R S. Sing, M D. Yadav, G Udaybhanu

This paper presents the results of the first part of a research project to study the effect of various inhibitors to reduce the spontaneous heating susceptibility of some highly susceptible Indian coal seams. In this investigation 11 inhibitors were chosen and applied at three, five and ten per cent of their concentrations in an aqueous solution for four coal samples collected from four different seams. The susceptibility of coal samples, before and after application of these inhibitors, was determined by carrying out crossing point temperature (CPT) analysis. The findings of this study have indicated that it is possible to retard the tendency of spontaneous heating of Indian coals to a considerable extent by the application of six of the inhibitors studied. Further, these inhibitors were tested in 1:1 combination to study their synergistic effect. Finally the economics of the application of these inhibitors has been analysed and four inhibitors are recommended for field use. These results have direct application to control fire and improve productivity and safety in coal mines.

Jan 1, 2005

The use of coal as a fuel for heat and power generation has a long history. During the nineteenth century most of the present combus- tion technologies were pioneered, as shown in Table 1, This period was associated with the "golden age" of coal and its contribution of almost 80% of the world's energy demands in the early,1900s . The decline in the use of coal has been due to the transfer of the heavy transportation area to diesel power, the elimination of coal as a household fuel and the substitution of oil for coal in power plants. Coal remains the major fuel for the electric utility industry and the present paper will be concerned primarily with that application. Table 1 outlines the development of coal tech- nology with the parallel understanding of coal as a material and its behaviour during combus- tion. Clearly many developments in combustion technology have occurred in this century, although most of the processes had been invented in the nineteenth century. Also, the great expanse in coal research of the past few decades has led to a greater understanding of the coal combustion process.

Jan 1, 1987

The role of a project metallurgist is diverse and covers input into the resource definition, mining studies, metallurgical test program development, process engineering and plant design, cost estimate preparation and financial analysis aspects of project feasibility studies. Mining project schedule and cost overruns can often be attributed to cutting short metallurgical test work, engineering and cost estimating leading up to commitment to development. In a significant number of cases this may result from the lack of understanding and commitment by the project proponent to the requisite metallurgical and processing studies required during the various pre-commitment stages of a mining project. Metallurgical test work, process development, engineering and cost estimating requirements for each stage of pre-commitment development are described together with a summary of the ongoing role of the project metallurgist during detailed engineering and commissioning of a process plant.

Jan 1, 2008

The Northland region of New Zealand has a complex geological history which has long been the subject of considerable controversy. Small mineral deposits have been discovered in the past, and some have been mined. Except for aggregates and very high quality china clay, mining is virtually nonexistent at present. Mercury mining is proposed from small deposits in the Kaeo area. Intensive exploration for epithermal precious metals deposits in the past seven years, combined with some recent geological mapping undertaken by the Geological Survey and University thesis students has added greatly to an understanding of Northland's geology. Mapping of the Whangaroa-Kaikohe map sheet at a scale of 1:100 000 by Brown and Laurenson Limited has enabled new geological information to be collated for the first time since 1961, when the last geological map was published. The 'Northland Allochthon' is now observed to be a series of four or more thrust sheets each containing predictable formations. High angle faulting contemporaneous with overthrusting has modified the thrust sheets, and established a series of horsts and grabens. The Pirau Fault is considered to be a major earth fracture.

Jan 1, 1987

By N N. Viswanathan, D Kumar, S Kumar

In secondary steelmaking, calcium treatment is practised to modify the solid alumina or spinel inclusions into liquid or partially liquid calcium aluminates. It has been seen that the dissolved calcium reacts with sulfur or oxygen present in the steel to form CaS or CaO type of transient inclusions. Post-calcium treatment these transient inclusions further react with pre-existing alumina or spinel inclusions and modify them. In addition, direct modification of pre-existing inclusions is also reported in the literature. In the present study, laboratory-scale induction furnace-based experiments are carried out to melt electrolytic iron in an alumina crucible followed by deoxidation with aluminium. The CaS-based composite material, prepared in-house, is added after the aluminium deoxidation to study the stability of CaS at the steelmaking temperature. Multiple steel samples were also taken to track the dissociation of CaS by means of sulfur pick-up in steel. Additionally, inclusion analysis of these steel samples was also performed to track changes in the chemical composition of inclusions in response to CaS addition. It has been seen that the CaS dissociates leading to a gradual pick-up of sulfur in steel. The scanning electron microscope – energy dispersive X-ray spectroscopy (SEM-EDS) analysis reveals that the alumina crucible and floated alumina inclusions are modified into calcium aluminates and the extent of modification depends on the contact time of CaS with the two sources of alumina mentioned earlier. However, the modification of alumina inclusions in the bulk steel did not occur during these experiments.

Jun 19, 2024

MIM Holdings Limited has acquired a reputation for the successful application of R&D to develop break-through technologies for the mining industry. The Isa Process tank-house technology has been licensed to copper refineries throughout the world, and almost 40 per cent of the worldÆs copper is refined using this technology. Isasmelt copper and lead smelting technology is either in use, or is currently being installed, by eight companies in eight countries around the world. Jameson Cell technology is widely used in the coal mining industry and increasingly in the base-metal industry. The IsaMills developed at Mount Isa and McArthur River made it possible to develop the McArthur River and George Fisher orebodies. This paper will address the need for innovation and then discuss the development of the IsaMill and Isasmelt technologies. It will conclude with some comments about why MIM has been so successful in developing such technologies.

Jan 1, 2002

Some design and feasibility studies have been made into possible methods of economic recovery of sulphur from smelter gases emitted at Western Mining Corporation's Nickel smelter at KalgoorIie in Western Australia. The smelter discharges some 330 000 tonne/yr of sulphur dioxide in a stream of approximately 6 per cent by volume of S02.Three possible recovery methods have been considered:1. The manufacture of sulphuric acid using the contact process.2. The concentration of sulphur dioxide to a pure form using dimethyl aniline as an absorbing medium.3. The reduction to elemental sulphur using natural gas as the reducing agent.Design studies were carried out by final year chemical engineering undergraduate students at Royal Melbourne Institute of Technology (RMIT) in 1981 under the supervision of the author and other teaching staff of the chemical engineering department. These studies indicate that sulphuric acid manufacture is the economically preferred recovery route.Markets for sulphuric acid include several potential mineral processing applications and the established fertiliser industry.Sulphuric acid is currently manufactured in a number of plants located at coastal regions of Western Australia using imported sulphur. The sulphuric acid is then used for superphosphate or titanium dioxide pigment manufacture at adjacent plants.The possibility is considered of manufacturing superphosphate at Kalgoorlie from locally produced acid obtained from the smelter gases and from phosphate rock railed to the site from the coast. The advantages of such a scheme include improved scale and technology of operation compared with some existing coastal operations, use of a waste material to replace imported sulphur, and avoidance of costs and hazards associated with railing large quantities of sulphuric acid.

Jan 1, 1983

By Beardsmore G. R

Geothermal gradients in the Gippsland Basin commonly exceed 35¦ C/km. Consequently models of thermal maturation may indicate exploration targets with an anomalous age/depth distribution. However regional geothermal models are constrained primarily by observations of surface heat flow. High geothermal gradients may simply reflect the presence of low conductivity coal beds within the basin. Heat flow data are not readily available for the Gippsland Basin. Normally special purpose drill holes are required to provide direct determinations of surface heat flow. These provide core samples for thermal conductivity and allow measurements of a stable geothermal gradient at least one year after drilling. Different indirect procedures are now required to provide estimates for the Gippsland Basin. Bottom hole temperatures can be used with suitable corrections to provide an indication of the regional geothermal gradient. However the corresponding thermal conductivities are more difficult to determine. Geophysical logs can be used to detect the major lithologies but detailed statistical analysis is required for numerical estimates. Complex mixing models are now suggested for geothermal surveys linking physical properties to variations in the mineralogy of each well. Allowing for low conductivity coal measures the data in the Gippsland Basin suggest values for heat flow consistent with regional trends in Australia. Interpretation is complicated by overprinting of transient thermal events with different time scales. Apart from the tectonics of basin evolution geothermal signatures may be complicated by regional ground water migration, the 'hot spot' trace associated with southward younging of Cainozoic volcanism, diagenesis, and basin refraction.

Jan 1, 1992

By N Power, A D. Costar

There has been significant growth in mining and energy exploration in South Australia, which has identified new major potential opportunities. This sector generates significant economic value to the state and their support remains a priority for the state government. The delivery of this economic and associated community value to the state is dependent on the mining and energy sector being able to access reliable water supplies.The vast majority of priority areas for the mining and energy sectors are located in areas that have traditionally been of low priority from a water-use perspective and hence, data and knowledge levels are generally low.Recent studies have identified a potential increase in demand for water in the mining and energy sector for potential developments from approximately 40 GL to over 170 GL over the next ten years. The studies found that water and water infrastructure is the second highest proportion of planned infrastructure capital investment by resource companies. The South Australian GovernmentÆs Plan for Accelerating Exploration (PACE) initiative (PACE 2020), also identifies addressing the issues of location, use and management of South AustraliaÆs water resources as a key priority for the growth of the mining and energy sector.The Department of Environment, Water and Natural Resources (DEWNR) has developed the facilitating long-term outback water solution (FLOWS) initiative. DEWNR is currently undertaking a suite of programs to provide groundwater information at the regional scale to better target water supply options for mining and energy developments and community water supplies.The Goyder Institute for Water Research has leveraged significant research investment of $3 M to develop methodologies to interpret airborne geophysics to map groundwater sources.The FLOWS Initiative will provide key content for the PACE Water Program and will also assist in the development of water supplies for remote far north communities by identifying alternate groundwater sources to improve water supply security.This paper will discuss how developing an appropriate science and knowledge base will encourage and secure development where appropriate, enable prudent decision-making and policies regarding water allocation, accounting and licensing, whilst ensuring the protection of environmental assets.CITATION:Power, N and Costar, A D, 2013. Finding long-term outback water solutions, in Proceedings Water in Mining 2013 , pp 191-196 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 26, 2013

Owing to the 'creeps' and consequent movements in the mines, followed by the recent fire in the southern workings, the whole of the orebody above the 800 ft. level is now very much crushed and broken. The same applies to the hanging wall or overwall coutrny, which has subsided towards the workings, so that for some years past all development work within the lode has had to be carried out with extreme care.The continual but slow subsidence of the overburden into the stopes necessitates a periodical renewal of all gangways in the lode, and, as the subsidence amounts to as much as 60 ft. in places, these new gangways must necessarily pass through the mullock-filling of old stopes in addition to broken ore. They at times pass into the broken ground of the hanging-wall for some distance, where the orebody has widened underneath by the original folding and puckering.

Jan 1, 1932

By R Wynn, R A. Pax, S Mann, B Cornish

The semi-autogenous grinding (SAG) mill at the MMG Century operation has failing load cells that are essential to the control strategy used to stabilise the mill. Currently, mill-bearing pressure is used as a proxy for the load cells, but it has been found to be a noisy signal and lacking in useful sensitivity. It is also prone to variations and drift due to temperature. After consideration of a number of options, a non-contact acoustic array has been installed around the SAG mill to provide a more stable proxy load signal as well as other information about the internal operation of the?mill.The installation consists of 12 microphones to provide some detail into the operational differences that occur during normal operations at the MMG Century SAG mill. This acoustic approach acknowledges that operational grinding mills emit significant acoustic emissions that are a consequence of the dynamic environment prevailing inside them.Previous studies have attributed the acoustic noise to a range of events that occur inside these mills (Pax, 2011; 2012). Consequently, non-contact acoustic determinations of in-mill behaviour can provide powerful insights into the operation of the primary comminution tumbling mills. By measuring key microphone signal attributes at different positions around a mill, a holistic picture of mill internal operation can be developed.This paper will describe the installation of the 12 microphones and discuss the use of the acoustic load signals as a proxy for failing load cells. It will also present data from new observations of internal mill dynamics and the results of implementation of control using these acoustic signals. Key to the control approach has been the development of a logically coherent picture of the processes inside the mill.CITATION:Pax, R A, Wynn, R, Mann, S and Cornish, B, 2014. Implementation of acoustic arrays for semi-autogenous grinding mill?operation, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 273–282 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

By K J ROSENGREN

Underground rock mechanics was initiated as a formal discipline in Australia by early studies for underground structures for the Snowy Mountains Scheme in the 1950s. These techniques were quickly embraced by underground mining and there has been steady development to the present time. The paper reviews the status of current techniques for rock mechanics studies and discusses some important issues such as ground support, mine filling and caving. It concludes that a considerable degree of engineering judgement is still required for the practical application of rock mechanics to underground mine design.

Jan 1, 1992

In, one stage of the purification sequence of the zinc sulphate electrolyte used at Risdon, cobalt is, precipitated as cobalt nitroso-,B-naphtholate, which is separated from the solution by filtration. Owing to the method of conducting the purification the filter cake contains much gypsum, unconsumed calcium hydroxide, basic zinc sulphate, and entrained zinc sulphate solution, Small amounts of iron and copper that have escaped previous purification steps are also precipitated with the cobalt as nitroso-,B-naphtholate. Thisprecipitate, normally carrying about 18% cobalt, is the raw material for the production of cobalt oxide, cobalt sulphate and cobalt metal.COBALT OXIDEThe main problem in the preparation of a reasonable grade of cobalt oxide from the filter cake is the economic separation ,of the cobalt nitroso-,B-naphtholate from the gypsum. This was solved by the application of flotation. It was discovered that the cobalt nitroso-,B-naphtholate, under correct conditions, would float without any addition agent, giving a relatively high grade concentrate. A plant, was built and has been in operation since 1936. The filter cake is pulped with water and pumped to one of two mechanically agitated tanks, eath capable of holding one day's output. Sulphuric acid is added until the free acid concentration reaches about 3 gm. per litre. Basic zinc sulphate is dissolved and calcium hydroxide converted to gypsum. The pulp, carrying about 2t lb. of solids per gallon, is pumped at a suitable rate to the first of a series of 10 flotation, boxes.. Each box is 3 ft. by 2 ft. 9 in. by 5 ft. deep, and, all have a common, pulp level, since the...

Jan 1, 1949

By A J. Cornah

Critical decisions in iron ore project evaluation and production are based on global and local spatial estimates of primary mineral deposit properties (such as in situ geochemical grades) and geometallurgical responses (such as screened, washed or concentrated product yields and grades), which are derived from limited sample data. These spatial estimates are typically made using classical geostatistical techniques, which fundamentally assume that the attributes of interest behave additively. This assumption is generally appropriate for æprimaryÆ variables but æresponseÆ variables may behave non-additively and therefore their direct linear estimates may be biased.In this paper an existing additivity testing mechanism is used to quantify the bias resulting from direct linear estimation of a non-additive iron ore attribute. Data from a magnetite project are used to determine the circumstances under which such biases may be of material impact. The implications for iron ore resource estimation, geometallurgical modelling and grade control are outlined and discussed.CITATION:Cornah, A J, 2013. Assessment of the impact of non-additivity in the estimation of iron ore attributes, in Proceedings Iron Ore 2013 , pp 129-136 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 12, 2013

By G P. S Resende, D E. G Oliveira, E A. S Baeta, T F. Bravin

There is currently in the mining industry, as well as in other industries, a movement seeking to increase investments in decarbonisation processes to help combat global warming. Among some initiatives taken is replacing diesel-powered mobile equipment in the mines with electricity-powered equipment, such as electric off-highway trucks or even belt conveyors in the mining operation. Samarco is a Brazilian mining company that since its conception has used a conveyor belt mining system in its mining operation, using only a small number of trucks to complement the mining process. This mining process that combines conveyor belts and trucks has brought environmental gains for the company since the environmental impact of conventional truck-only mining is greater than that of the combined system. To measure these gains, a medium-term mining plan was developed in which two fleet scenarios were detailed. One scenario contemplated a high level of detail of belt mining seeking its maximisation, while the other considered the operation performed 100 per cent by trucks, eliminating the use of conveyor belts. Through the comparison of these two scenarios, it was possible to make an inventory of atmospheric emissions and greenhouse gases for each one of them considering data such as types of equipment, diesel consumption, total distance travelled and energy consumption. The results showed that the fleet scenario with conveyor belts results in periods with up to 15 per cent less greenhouse gas emissions and 37 per cent less total particulates compared with the truck-only scenario. Therefore, the results confirm the environmental benefits of the method and the need to look for ways to even expand it in future operations through a study to identify the potential areas in the long-term mining plan.

Sep 18, 2023

This paper suggests the models for determination the optimum life of machines on the basis of sum and difference of investment and maintenance costs. The economic-mathematical models are based on complex percentage method taking into account the time factor of referring cost. The following strategies of maintenance policy have been considered in machines repair: a strategy without investment, a strategy with continuous investment and a strategy with step-like investment. The effect of value of investment in repairing and time interval of investment on optimum machine exploitation life has also been considered. An illustrative example is presented.

Jan 1, 2003

Estimation of the semi-variogram is basic to the geostatistical processing of data. The most widely used arithmetic average estimator is here employed with various sampling patterns to calculate experimental semi-variograms in a deposit which is simulated to have a defined semi-variogram. Percentage differences between theoretical and experimental semi-variograms are reported.

Jan 1, 1984

By Wood W, Bell A

Brown coal production in Victoria's Latrobe Valley Region (Figure 1) continues to rise and currently stands at around 50 Mt per annum. With the exception of around 2 Mt used to produce some 700 Kt of brown coal briquettes, this coal is mined by the State Electricity Commission to fuel large thermal power stations with a total installed capacity of just over 5 000 Megawatts. The moisture content of the coal as mined typically exceeds 60 per cent, making Latrobe Valley coal a markedly low rank fuel. The lack of heating value is, however, compensated for through power station design and by the fact that ash yield is very low, usually within the range of one per cent to four per cent on a dry basis. This means that compared with most other coals, the burning of Latrobe Valley brown coal produces relatively small quantities of waste products and discharges a minimal level of pollutants into the atmosphere. Even so, the inherent quality of Latrobe Valley coal does vary significantly from one area to another (Gloe, 1991; Barton et al, 1992) both on a local and a regional scale. Such variations need to be recognised and understood in order to not only realise efficiency gains in existing power stations but to properly assess resource potential for future utilisation and the application of new technologies. The principal aim of this paper is not to describe coal quality variation in detail or to speculate on the nature of and reasons for such variation. Rather, it is to simply underscore that significant differences do occur and that this is clearly a factor which needs to be considered in any evaluation of Latrobe Valley brown coal as a resource for the future.

Jan 1, 1992

By R Smart

This paper examines the longer-term predictive capacity of the GAMSPATH computer program (developed by the Alberta Research Council) for a waste rock (sample MS) obtained from the Kaltim Prima Coal (KPC) mine, Kalimantan that contained significant framboidal pyrite. The model was refined by comparison with the net acid generation (NAG) and column leach tests to provide a basis for calibration of the model for both short term and longer-term reaction trends. The oxidation of pyrite during the kinetic NAG test using H2O2 provides oxygen directly at the mineral surface, generating a measured oxidation rate for pyrite of 1.16 + 10-6 mol m-2 s-1, whereas the oxygen diffusion limited rate in the leach column air equilibrated reaction was of the order 10-8 mol m-2 s-1 as calculated from the GAMSPATH thermodynamic database. Results indicated that the oxygen derived from hydrogen peroxide had to be included as a reactant (eg a reacting mineral) in the simulation to account for the direct availability of oxygen at the sulfide mineral surfaces. Optical investigations identified the proportion, particle size, and surface area, of framboidal and euhedral pyrite in sample MS. The reactive surface areas of the two morphologies were very different (eg ratio: 5:1). To manage these two different pyrite morphologies the GAMSPATH thermodynamic database was updated to include framboidal pyrite, with similar thermodynamic properties and oxidation rate to euhedral pyrite but with a particle size based on the size of the individual internal framboid microcrysts. This modification, with framboidal pyrite reaction based on the size of its microcrysts produced results that correlated well with the kinetic NAG and column leach test results when the measured (kinetic NAG test rate) and calculated (column test rate) pyrite oxidation rates were employed. This provided some confidence that the model could be extrapolated to indicate longer-term geochemical reaction trends.

Jan 1, 2003