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By S Paciornik

The traditional trading of iron ores is based on chemical specifications and particle size distribution. However, recent characterisation studies, that bring additional information like mineralogical composition and microstructural (textural) aspects, have become important. They contribute to determination of the iron ores downstream beneficiation operations and subsequent steelmaking processing, allowing improvements on both new and existing processes. Despite progress in commercial scanning electron microscope/energy dispersive spectrometer (SEM/EDS) automatic instruments in the last decade, these systems are not capable of performing the identification and discrimination of major iron ore minerals (haematite and magnetite) and the consequent description of its microstructure. On the other hand, reflected light microscopy (RLM) can easily distinguish the iron oxides by their reflectancies, but it cannot discriminate quartz and epoxy resin, which present similar colour on images. The present work proposes an innovative method to perform a quantitative mineralogy characterisation of iron ore based on RLM-SEM co-site microscopy. This technique combines images obtained by RLM and SEM through an automatic registration procedure that accurately aligns the two kinds of images of each field. In fact, it creates multi-dimensional images, which are then analysed using image processing and pattern recognition techniques. The case study is an itabiritic iron ore from Quadrilßtero Ferrffero (Brazil) which contains mainly quartz, goethite, magnetite and haematite. The discrimination of phases that are not distinguishable with either RLM (epoxy resin and quartz) or SEM (haematite and magnetite) can be performed through this multimodal approach, allowing the subsequent mineralogical quantification. The mineralogical quantification computed by image analysis was consistent with independently obtained results based on the Rietveld technique.

Jan 1, 2008

By G Harbort, C Sola

The rapid development of geometallurgy in the mining industry has occurred in relatively recent times. Its importance as an independent discipline in the mineral processing world has been emphasised and recognised. To a large degree, this is the result of a growing understanding of the ore type being processed and their application to provide better metallurgical responses in different mineral processing techniques. The development has matured from early progress through to geological knowledge and into the realm of the metallurgist and mining engineer. Working together, they have developed a powerful framework that will interpret a body of mineralisation into measurable properties.The integration of geometallurgy and operations has become of increasingly important due to improvement in understanding of an orebody as a natural system formed by a number of processes and with a definite fabric of mineralisation within different geological domain. These have to be taken into account when creating techniques that will enable operations to extract the valuable components from a distinct type of ore. Incorporation of such knowledge at an early stage of development, such as the feasibility stage significantly reduces the project risk.This paper is written from the unique perspective of a process engineer embedded within a geological team. It discusses issues such cross discipline communications and misconceptions and details the numerous tricks, traps and treasures of geometallurgy encountered during defining of the Seminco and Taysan resources.CITATION:Sola, C and Harbort, G, 2012. Geometallurgy - Tricks, traps and treasures, in Proceedings 11th AusIMM Mill OperatorsÆ Conference, pp 187-196 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Oct 29, 2012

In Australia we usually define "resource" in purely material terms, and rarely relate it to intellect and human capacity. We look at the sheer abundance of our natural resources and are satisfied with the feeling that we don't really need-to rely on using our brains. Certainly our country is fortunate to have the mineral resources it does, but in many ways Australia's worst enemy is its "lucky country" syndrome because we tend to underutilise the great resource we have in the capacities of our people. Raw material exports will undoubtedly continue to contribute a major share of our export revenue, but to harness the riches our country has to offer most effectively we need the vision and planning necessary to bring together our material and human resources. There is a need not only to find, exploit and process our minerals economically, but to turn as much of our mineral wealth as possible into high value products before it leaves the country. In particular we must use our brainpower if we want to maximise economic benefit from and political influence over the strategic minerals which leave our shores. In the past we have been successful in finding and exploiting minerals because our mining industry has been in the forefront of private sector research and development. But if Australia is to have an advantage over other mineral rich countries in insulating itself from the effects of cyclical swings in commodity prices, then the future of the industry must lie even more in technological sophistication rather than depending. on such considerations as size and location of mineral deposits. To survive, our mineral industry must have the foresight and resourcefulness to make its own luck. There are two keys to increased efficiency in exploration and production and in further processing methods: enhancement of the skills of the workforce and continual improvement of R&D.

Jan 1, 1986

A new lead refinery with a capacity of 230,000 tons per year commenced operation at Port Pirie in October, 1959. This plant superseded the refinery which had operated from 1933 with the advent of the continuous lead refining process. The incorporation of new equipment following local metallurgical developments, together with the overseas demand for lead of extremely low antimony content createddifficulties in operating the original plant. The new refinery project was undertaken to cover this disability and to gain the full advantage of the new processes.Desilverising and softening are carried out in units identical in size to those used previously. Metallic zinc is recovered from the entire output of desilverised bullion by vacuum distillation. Final refining is carried out by batch treatment with caustic soda yielding lead of purity previously unattainable at Port Pirie.These two processes replace continuous dezincing by oxidation, a high temperature process which caused large quantities of lead and antimony to be recirculated. The final stage is a batch process; therefore the product composition can be checked before casting. Individual batches can be adjusted to produce special alloys to consumer's specification.Improved casting equipment allows the quantity production of pigs of good physical characteristics either as 56 lb bars or 2000 lb pigs.This, together with the high purity of the lead, assures the Broken Hill Associated Smelters Pty. Ltd. (RH.A.S.) position in world markets.Automatic control systems are extensively employed, particularly on the vacuum dezincing unit.The anticipated financial benefits have been achieved mainly by a reduction in the tonnage of recirculated materials, a smaller labour force, and reduced maintenance requirements.INTRODUCTIONIn December 1956 a decision was made to build at Port Pirie a lead refinery on a completely new site, and in October 1959 the new refinery was brought into operation. This plant superseded the lead section of the old refinery which...

Jan 1, 1963

By J B. Holman, P A. Weber, P Lindsay

Underground and opencast coal mining has occurred since 1896 on the Stockton Plateau, West Coast, New Zealand. Acid Rock Drainage (ARD) from historic and current mine workings has had an adverse environmental impact on the surrounding aquatic environment. The two main catchments affected by ARD from historic and current mine workings are the Mangatini and St Patrick Stream catchments. Solid Energy New Zealand Ltd (SENZ) is using active (e.g. alkali dosing) and passive (e.g. engineered cover) technologies to mitigate the adverse environmental effects associated with ARD contaminated waterways. This paper discusses the passive technologies. Principal strategies include the capping of high capacity potentially acid-forming volumes of overburden. The mudstones were found to generally have the highest sulphur levels compared to other overburden lithologies. Areas with high mudstone volumes are prioritised to be encapsulated and 390 Ha is planned to be capped in the Mangatini catchment in the near future.   Monitoring beneath granite, cement kiln dust and coal combustion product covers show oxygen can be reduced to less than 10% of atmospheric levels. Laboratory column leach tests that were subjected to oxygen flux rates of 10 % showed reducing oxygen ingress into acid-forming material can result in significant acid load reductions.   The oxygen content below the cement kiln dust cover was generally lower than 5% and water quality measured in lysimeters beneath this cover improved after 50 weeks of emplacement. Column leach tests containing saturated samples were undertaken to determine the most appropriate water medium in preventing pyrite oxidation. The sample saturated with ARD (pH ~ 3) had a negligible acid production rate and leached very minor Al concentrations although Al is soluble at low pH. This indicated saturating waste rock dumps with ARD can be an effective method in mitigating ARD formation.

Jan 1, 2007

Rheology is the science which deals with the deformation and flow of matter. Thus rheology is concerned with the flow of any material. The mining industry is concerned with digging things out of the ground, extracting the good stuff and throwing away the bad stuff. In the upgrading processes associated with mining, ie mineral processing, wet techniques are used where the primary material being handled is a particulate fluid, ie a suspension. After the processing operation, with the concentrates extracted, what is left behind generally is a wet material in suspension form, which may or may not contain reagents harmful to the environment. The amount of waste generated in any of the mining processes is large, in fact, the mining industry is the largest generator of solid waste in Australia. In order to minimise the waste generated within the industry it has become of interest to handle the particulate fluid wastes, or suspensions, at high concentrations, thus removing water and some of the reagents which may be harmful to the environment. The resultant highly concentrated suspension is a non-Newtonian fluid. Rheology deals with the flow of non-Newtonian fluids; therefore a combination of rheological understanding of high density suspensions, in conjunction with an understanding of the environmental problems being faced by the mining industry, can and has led to improved methods of waste disposal in the industry, ie waste minimisation. This paper describes the progress that has been made in the development of dry disposal technology in the mining and minerals industry in Australia.

Jan 1, 1998

By N McKenzie, F Brodbeck

The North-South Bypass Tunnel is the first project to get underway as part of BrisbaneÆs transport plan, which aims to improve the urban road network. The total length to be excavated is 6.8 km, which includes 4.8 km of driven tunnel and associated road connections. Construction commenced in August 2006 with project completion targeted well before the contractual completion date of October 2010. Due to the local geology, in particular the hard Brisbane tuff and neranleigh-fernvale formation, a combination of tunnel excavation methods are used. The majority of the tunnel is excavated by two tunnel boring machines which have a rate of progress of 16 - 20 m per day in rock having a compressive strength of between 80 and 150 MPa. Ten roadheaders operate at a rate of up to 2 m per day excavating the remaining tunnels, such as ramps, access tunnels, cross passages and merges. The tunnel team are managing the challenges and complexities associated with tunnelling through the hard Brisbane rock. A major challenge arose during the planning of the initial mainline excavation underneath the Royal National Association Showground in Bowen Hills. This section contains low rock cover and historical maps indicate that the showground is located within a former topographic depression (alluvial valley), which a creek once flowed through.Due to traffic merge design requirements, both tunnel boring machine (TBM) and roadheader excavation methods were required to be used in this challenging geological profile. The answer was to stabilise the alluvium above both TBM section tunnels from the surface prior to excavation and to operate the TBM in single shield mode with immediate grouting of annular void from the tail shield. In addition, the roadheader section of tunnel required additional support by spiles and canopy tubes installed from the tunnel face.

Jan 1, 2008

By Sandvik

Fine grinding in an air-swept ball mill working in closed circuit with a forced vortex air classifier has been investigated first in continuous laboratory and then in industrial scale. Results from the laboratory circuit have shown significant influence of mill load (powder filling) on the capacity of the circuit. In laboratory scale the mill load was measured and controlled by a weighing platform placed under the complete mill set-up. The mill load of the industrial air-swept ball mill has till now been controlled by measuring the power consumption of the mill motor. Thus, it was necessary to operate far from the range of optimal mill filling. To improve the circuit performance, alternative ways of mill load measurement were investigated. An important factor was investment cost, as many fine grinding mills operate in relatively small circuits that do not wan-ant large investment. In this case the task was accomplished by using a piezoelectric strain transducer, which detected strain changes in the mill shell. It was installed in the midpoint of the shell, where the highest deformation was obtained. As the transducer was on the top position, it indicated compression, and on the bottom position it measured tension. By taking the difference between the readings, it was possible to calculate total strain variations, directly proportional to the mill load. The signal from the transducer was sent to a control room via a cordless infrared communication system, employing a microprocessor control card, which could further regulate other operating parameters of the circuit according to the software model. The installation required very low investment cost and provided simplicity of application as well as stability and reliability of characteristics under severe industrial condition. The measurement system made it possible to optimise the mill load and thus increase the production from 3.2 to 3.7 dh (15 per cent), and stabilise the circuit operation.

Jan 1, 1995

By P Duplancic and C R Lilley, R Hudson, D Beck

For deep block and panel caving mines, undercut or extraction level instability can have as much impact on overall recovery as underbreak or the premature ingress of waste. If the area of the mine affected by excessive convergence is small, recovery is usually possible. However, there are several examples of entire blocks that were abandoned prematurely due to footprint collapse. Clearly, such global instability has a major impact on recovery and must be avoided – this is one of the essential tasks for the design team.The design problem is complex. The planning engineer must ensure that the footprint has sufficient capacity to withstand the maturing loads in the cave, accounting for the effects of stress path, geological structures and the rock mass conditions. These are often uncertain and only sometimes quantified.The demand on the footprint will also be influenced by decisions and actions taken during production, especially related to draw, which can worsen a developing problem. Perhaps most importantly, the design decisions that favour stability and lead to lower deformation also negatively impact on idealised cave flow. Many engineers aim to minimise the size of extraction level pillars, to improve theoretical future resource recovery but in fact this can reduce recovery if widespread deformation ensues due to the undersized pillars.In 2014, PT Freeport Indonesia undertook detailed numerical analysis to quantify the effects of variability in rock mass conditions and geological structure on overall footprint performance. The analysis accounted for a range of stress paths and maturing cave loading scenarios sourced from a calibrated whole-of-cave deformation-flow model. The intent was to replicate some of the diversity and distribution of pillar deformation outcomes that may be seen in practice at Freeport.The discontinuum finite element analysis was able to replicate damage localisation around persistent structures, a realistic distribution of drive deformation and show how small areas of instability can evolve into major problems if poorly managed. The limits of pillar size and ground support as solutions to a number of different instability problems was also investigated, showing that pillar size alone was not a sufficient remedy for all adverse circumstances.In this paper, we describe the workflow for numerical analysis of footprint deformation. We discuss the compromises and considerations for balancing the sometimes competing needs for efficient extraction levels pillars, ground support and prudent draw strategy.CITATION:Beck, D, Hudson, R, Wilson, A D, Duplancic, P and Lilley, C R, 2016. An investigation of factors affecting the long-term reliability of extraction level pillars in deep block and panel caves, in Proceedings Seventh International Conference and Exhibition on Mass Mining (MassMin 2016), pp 295–304 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2016

By Singh BN, Chakravarty PK, Chatterjee LM

Indian blast furnaces operate with coke gener- ally containing 24 to 28% ash compared to 10-15% ash in coke in most other parts of the world. The operating problems are further aggravated by the high alumina content and the adverse alumina to silica ratio in the ore. The above factors not only increase the coke rate but, at the same time, increase the flush slag volume, make the bosh slag highly limey and thereby viscous, and produce a flush slag containing 24 to 26% alumina. Relative- ly low flame temperatures (RAFT) make conditions more difficult. The high basicity of the bosh slag limits the maximum flush slag basicity to around 1.0, beyond which the burden movement is adversely affected by the viscosity of the bosh slag: This effect is partly controlled by operating blast furnaces with high MgO in the flush slag (around.10%), which also improves the desulphurizing power of slag. Steps are underway in some plants to inject lime through theòtuyeres to control the bosh slag basicity and also to neutralise the large quantity of silica which is released at the tuyere level from the coke ash, so that the silicon content of the hot metal can also be controlled. High bosh slag basicity coupled with the characteristics of iron ore/aggolmerates, widens the softening-melting zone and alters the shape of the softening-melting zone. This leads to operat- ing difficulties and poor hot metal quality. This paper discusses the above aspects of Indian blast furnace operation and steps being taken to surmount some of the above difficulties.

Jan 1, 1981

By N J. Beukes, S T. Netshio, M O. de Kock

The Thabazimbi iron ore deposit comprises a series of stratabound orebodies, on average 18 - 25 m thick that are aligned along the faulted basal contact between the Penge Iron Formation and dolostones of the Malmani Subgroup, Transvaal Supergroup. Field geological relationships and petrographic observations suggest that the formation of high-grade iron ores took place after contact metamorphism related to the intrusion of the Bushveld Complex (2.06 Ga) but before the deposition of red beds of the Waterberg Group at ca 1.9 Ga. Hard, high-grade iron ores are predominantly composed of martite and microplaty hematite. Goethite is restricted to supergene-modified ores close to the Late Cretaceous û Early Cenozoic Old African land surface. At depth, the high-grade hematite ores interfinger with low-grade dolomite-hematite and calcite-hematite ores. Iron oxides (martite, microplaty hematite) present in these low-grade ores are texturally indistinguishable from those in the associated high-grade ores, ie ore formation is genetically associated with carbonate metasomatism. Microthermometric studies of fluid inclusions in sparitic carbonates and rare megaquartz reveal their hydrothermal origin. Two compositionally distinct aqueous fluids of shallow crustal origin are identified, namely a Ca-Na-rich high-salinity brine (26 wt per cent NaClequivalent, TH ~160¦C), and an aqueous Mg-K-bearing fluid of intermediate salinity (8.3 - 12.6 wt per cent NaClequivalent, TH~120 - 150¦C). The results confirm that high-grade hematite orebodies at the Thabazimbi deposit owe their origin to an event of extensive oxidative carbonate metasomatism (calcification), similar to that recognised at other important high-grade iron ore deposits in the world. Hydrothermal ore formation is both structurally and lithologically controlled. Size and quality of the orebodies was improved by Late Mesozoic-Cenozoic deep lateritic weathering as carbonate-hematite ores were enriched to friable high-grade ores, but this supergene modification is second in importance compared to the primary event of hydrothermal ore formation.

Jan 1, 2005

Since its commercial in Australia at Broken Hill in the early part of the 20th century, the flotation process has grown to become the single most important minerals separation method available to mineral processing engineers. Statistics on flotation are impressive both in terms of growth of tonnages treated and in terms of the variety of separations accomplished. Because of the steady decline in the grade of ores and because many of the ores remaining are finely disseminated mixtures of minerals (many of them in a highly oxidized state) mineral processing scientists and engineers are now con- fronted with the problem of improving and modifying conventional flotation techniques so as to be able to effic- iently process these more refractory types of-ores. The flotation process did not come into being as the result of an intensive fundamental research effort but, in a similar way to so many other methods used in the processing of raw materials, it was developed over the years by the continued application of empirical methods. As a result, most of the basic research in this field has long been concerned with the problem of explaining why the existing process works so well. We are now at the stage where any further substan- tial extension of the flotation process will demand a more profound understanding of its fundamental principles. Current knowledge of flotation fundamentals is still far from the stage where processes can be designed, optimized, and controlled from first principles. The extensive

Jan 1, 1984

The construction of mine headframes of reinforced concrete is not a new departure as many structures have been built of this, material particularly in Canada and South Africa. This type of construction has been satisfactorily tested in service and is now accepted by the mining fraternity.The two headframes at New Broken Hill Consolidated Limited are the first structures of this type to be built in Australia, and provide an interesting application of reinforced concrete design and construction.Reasons for Adoption of ConcreteDuring 1947 the writer visited D.S.A. and Canada and inspected three headframes, of reinforced concrete construction.Leading details are as follows:(i) Hollinger Gold Mines. (Timmins, Ontario) : Height of sheaves 110 ft. Shaft has provision for 4 skips each of 12,000 lb. capacity. Structure incorporates surface crushing plant.(ii) International Nickel Corporation-Murray Shaft (Sudbury): Height to sheaves 153 ft. 6 in. Shaft provides for 2-12 ton skips and 2 cages. Surface crushing plant built integrally with frame.(iii) Asbestos-Johns Manviae (Quebec): Height of sheaves 116 ft. Shaft provides for 2 skips 200 cu. ft.

Jan 1, 1956

By A Murphy, I Samsonova, N Eastwood, D Whittle

Part XI of the United Nations Convention on the Law of the Sea (UNCLOS or the Convention) (United Nations (UN) Division for Ocean Affairs and the Law of the Sea, 1982) establishes a comprehensive regulatory framework for the conduct of deep seabed mining (DSM) activities of mineral resources in the Area (defined in Article 1(1) of UNCLOS as ‘the seabed and ocean floor and subsoil thereof, beyond the limits of national jurisdiction’). Under that framework, DSM activities can only take place in the Area pursuant to an approved Plan of Work in the form of a contract with the International Seabed Authority (ISA) (the Authority), a 168-member international body created under UNCLOS to administer the Area. Private contractors can undertake DSM activities if they are sponsored by Member States of UNCLOS, providing a dual system of international and domestic regulatory control and oversight for activities in the Area.

Sep 1, 2024

By T A. Short, P L. Brown

Kestrel Mine co-disposes around 1.5 Mt of fine (2SO4/t and to date around 9 Mt has been deposited. The mine plans to co-dispose of approximately 39 Mt of material, creating a dump with a maximum height of 35 m and a disturbance footprint of 260 ha. Benign materials suitable for rehabilitation are severely limited and no successful rehabilitation strategy has yet been demonstrated. A rigorous measurement and modelling program is resolving outstanding issues associated with acid rock drainage (ARD). The objective of the program is to develop and validate a strategy for dump rehabilitation that will control ARD and allow for mine closure. The strategy includes using a soil cover to reduce water flux into the dump to control the overall oxidation rate and to control effluent release. Monitoring of the oxygen distribution and water flux in the uncovered material commenced in February 2001 and monitoring in waste under a trial cover commenced in February 2002. Carbonaceous and sulfidic oxidation rates have been measured. Initial modelling indicates that the carbonaceous material has the general effect of slowing the rate of pyrite oxidation, lowering the maximum sulfate production rate and extending the time to oxidise all the sulfides. The combined approach of measurement and modelling provides a sound basis for assessing the performance of the trial cover and predicting the long-term quality and quantity of effluent at the base of the rehabilitated waste dump.

Jan 1, 2003

During the lifetime of an open pit mining project, each stage from exploration activities to exploitation and mine closure produces disturbances on the mining region. Mined land reclamation plans establish constructive solutions to rehabilitate the disturbed areas. Open pit mining as an effective method for exploitation of a wide range of orebodies especially for massive reserves of shallow metallic substances has exhaustive and harmful environmental effects on the mining project region. Nowadays, closure and reclamation stage in a mining project is emphatically enforced by the relevant environmental protection regulations in many countries. It is therefore obvious that closure and reclamation costs of an open pit mining project, as costs of other stages of project, must be estimated to enter the planning and design processes in open pit mining. Post-mining land use is the most important factor to recognise closure and reclamation costs. Thus, using a model to define optimal land use in planning phase of an open pit mining project is necessary in this regard. In this project a model was developed to define optimal land use regarding different sections of open pit mines such as pit(s), waste dump(s), tailing pond(s), roads, areas for onsite facilities and free land zones which are not mined. TOPSIS and PROMETHE techniques were applied to create the developed model. Lumber production was recognised as the optimal post-mining land use for the pit area of the case study in this project.

Dec 6, 2010

By Russo S

Metals Refining Operations Pty Ltd (MRO) began refining gold in PNG in 1991 and has undergone continuing growth since then in servicing an everchanging and growing market. MRO's ownership combines PNG Government interests and Golden West Refining Corporation Limited as operator.Features include a very diverse range of suppliers, a full range of technical methods and challenges and the financing and marketing responses unique to a developing country. These areas are examined and documented with special emphasis upon the service needs for the gold industry and future trends and challenges are discussed.

Jan 1, 1997

By Chowdhury P. J R, Biswas S. K

Recovery of metallic values from lean-grade raw materials as well as from secondary/intermediate industrial products is of immense importance to a country like India which is not endowed with extensive sources of copper and nickel. The results of a few studies carried out in this area are described in Part-I and Part-II in this article. A novel anode casting system, specially designed for a small copper refinery which had been set up to produce copper wire bars/rods is described briefly in Part-III.

Jan 1, 1992

By K Myers

Since the mid-1990s, the Chino Mine Facility (Chino) located near Silver City, New Mexico has been developing a closure plan with financial assurance to protect water quality, as required by State regulations. In February 2002, Chino and the New Mexico Environment Department (NMED) reached agreement on a closure plan; a closure cost amount of approximately $US 394 million ($A 591 million) was finalised in April 2003. Both the New Mexico Water Quality Act Regulations (1977) and the New Mexico Mining Act Regulations (1993) guided development of the closure plan and financial assurance amount. The process incorporated many years of correspondence, studies, negotiations and administrative hearings. The major technical issues focused on regrading slopes of the leach ore stockpiles and waste rock piles; cover systems; water treatment systems; and abatement of ground water contamination. The proposed financial assurance amount covers all closure costs and provides for perpetual water treatment.

Jan 1, 2003

By C. P. BATES

In November 1969, New Zealand Steel Ltd pioneered the commercial use of the SL/RN solid fuel direct reduction process to make sponge iron as a feed material for electric arc furnaces. Serious process problems with the use of green balls and coal injection were progressively overcome. The process was developed by New Zealand Steel along a radical route, of feeding the fine grained raw ironsand concentrate and coal directly to the kiln. Contemporaneously with this development of direct reduction, steelmaking process innovations were made that enabled the arc furnaces to operate successfully with the high volumes of acid slag.

Jan 1, 1980