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By L Smith, R Beckie

An intermediate scale (8 m + 8 m + 5 m high) constructed waste rock pile experiment was built upon a contiguous grid of 16 gravity drainage lysimeters to investigate the flow of water in unsaturated waste rock. Average net infiltration to the uncovered waste rock pile is 55 per cent of precipitation. Large rainfall events have net infiltration of 55 per cent to 85 per cent. Net infiltration estimates range from 23 to 120 per cent of precipitation between lysimeters. Small-scale lysimeters of less than 4 m2 area are shown to be poor predictors of net infiltration for uncovered waste rock. The appropriate size for lysimeters increases with increasing flow rate. The residence time distribution has an estimated median value of 3.0 to 3.9 years under average infiltration conditions. Water flows within the fine grained matrix, within larger pores (macropores), and in matrix free areas of the pile. In situ tracer concentrations vary between pore sizes, and between spatially distinct areas of the pile, indicating water geochemistry may also be variable. Water samples collected from in situ soil water samplers are dominated by the most mobile water fractions. In situ measurements of water content and matric suction are compared to the measured outflow. The data indicate the focusing of flow in spatially distinct areas can make in situ instrumentation a poor (non-conservative) predictor of volumetric water flow.

Jan 1, 2003

By R Urie

Dilution and loss of ore during the mining process invariably occur in all underground mining operations. This dilution and ore loss can have a significant effect on the performance and value generated from a mining operation. Further, excessive dilution or greater than anticipated ore loss during mining is often one of the key reasons for the underperformance of a mining project when compared to a feasibility study or annual budget. Mining professionals often go to great lengths preparing detailed mine plans, schedules and economic models only to then apply high-level estimates or rule of thumb values for dilution and mining recovery that can ultimately lead to inaccurate forecasts for the performance of a mine with the resultant loss of value due to the mining of uneconomic material or the loss of potentially valuable ore. This paper discusses processes and practices that can be practically used to manage dilution and mining recovery in an underground mining operation with a focus on understanding and then maximising value. The processes cover items such as the definition and measurement of dilution and mining recovery, techniques for the estimation of dilution and mining recovery, consideration of the economic implications, management of dilution and mining recovery through the stages of the planning cycle, and practices to reduce dilution and improve mining recovery. Common misconceptions and omissions are also discussed.

Mar 29, 2023

By C M. W Boyle, E K. C Phuak, A Lewan, E Ryan, M D. Paine, P H. Mackenzie

"Rio Tinto Iron Ore (RTIO) has an extensive history in the application of geometallurgy to the iron ore value chain. Fundamental to this has been the geological logging of material types which are assigned processing attributes such as lump per cent and density. Initially these were used for product (lump and fines) grade predictions in relation to grade blocks to be used within short-term planning horizons.More recently the predictive reach of the material types and their associated processing attributes has been extended due to their inclusion into geological block models. These predictions can now be used to influence mine plans across multiple planning horizons in such a way that the extremes of geometallurgical properties can be pre-empted and managed thus improving efficiency. Spatial material type domains are also used in the planning of metallurgical drill holes to ensure greater representivity of material than was typically obtained by chemical and/or stratigraphic criteria alone.Material type logging has also been enhanced by the introduction of modern, rapid mineralogical techniques that have complemented visual logging. This has enabled the identification and quantification of contaminant minerals and their relationships with host ore types to be established. This data is used to better manage product grade predictions and identify risks to the short-term plan.Work is ongoing in RTIO to further refine logging based predictions and in addition apply them to new areas of the business. This work requires collaborative and multidisciplinary teams working on an integrated approach combining geology, metallurgy, technology and innovation, mine planning and technical marketing.CITATION:Paine, M D, Boyle, C M W, Lewan, A, Phuak, E K C, Mackenzie, P H and Ryan, E, 2016. Geometallurgy at Rio Tinto Iron Ore – a New Angle on an Old Concept, in Proceedings The Third AusIMM International Geometallurgy Conference (GeoMet) 2016, pp 55–62 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Jun 15, 2016

The Newcrest Mining Limited Telfer Gold Mine consists of an underground sublevel cave (SLC) operation located 734 m directly below active open pit operations. Open pit and underground current production rates are 50 million and 5.7 million tonnes per anum (Mt/a) respectively. The SLC was initiated in late 2006 with breakthrough planned to occur on the 5484 bench of the west wall in late 2009. Risk to the south ramp was identified during this time, resulting in the construction of the north ramp. The SLC was continually tracked from initiation with a suite of monitoring systems and managed with a Major Hazard Management Plan (MHMP) and associated Trigger Action and Response Plans (TARP). At breakthrough the eastern limb of the cave was located within a 70 m horizontal distance from the south ramp. The south ramp was closed in October 2009 due to significant slope deformation, extensive cracking in the berms and batters between the ramp and breakthrough bench and a major failure 250 m to the north of the cave breakthrough. Wall response was first identified from slope deformation measurements taken by the wall monitoring radar in May 2009, at which point the SLC was 160 m from breakthrough. The impact of the SLC on the slope is a unique case with the monitoring systems in place able to provide data on the slope reaction to the SLC progression. This paper will discuss the management of the south ramp such as the early interpretation of risk associated with cave breakthrough, monitoring systems implemented to track the cave progression and wall deformation, data integration and interpretation and risk management. Following the closure of the south ramp further instrumentation programs and risk assessments were conducted to determine the risk of re-opening this haulage route. The outcomes of this program will also be presented.

Nov 25, 2010

By I Zh Bunin, V A. Chanturia, V G. Minenko, M V. Ryazantseva, A L. Samusev

A promising source for the extraction of rare metals and REEs in Russia is the eudialyte ores of the Lovozero deposit, which do not contain active uranium components. The eudialyte ore reserves of the Lovozero Massif are considered virtually unlimited and therefore have the potential to become a primary source of a number of rare and rare earth metals. The goal of this study was to comprehensively examine the effect of the parameters of high-power nanosecond electromagnetic pulses (HPEMP) and dielectric barrier discharge (DBD) on the leaching performance of eudialyte concentrate and the selective separation of zirconium and REEs from productive solutions. Using scanning electron microscopy and infrared spectroscopy, the mechanism behind the intensification of acidic dissolution of eudialyte as a result of pretreatment with energy impacts was described. During the HPEMP treatment, weakening and destruction of the eudialyte surface was observed, which at the substructural level is expressed in the deformation and local destruction of Si10O27, Si9MO30 resulting in formation of microcracks. During the DBD treatment, the formation of characteristic defects was observed in the form of imprints of dielectric breakdown microchannels and individual mineral fragments. Pretreatment of eudialyte concentrate using HPEMP made it possible to increase the recovery of zirconium into the pregnant solution of leaching by 3.4–4.3 per cent (from 86.6 per cent to 90.9 per cent) and by 4.1 per cent (from 86.6 per cent to 90.6 per cent) when using DBD. The increase in the total recovery of REEs was 1.2–1.8 per cent (from 87.7 per cent to 89.2 per cent). The effect of pH values, solution temperature, initial concentrations of valuable components on the successive recovery performance of zirconium and REEs from the pregnant solutions nitric from the acid leaching of eudialyte concentrate by chemical precipitation was examined. The possibility of selective separation of the zirconium product and rare earth elements with a zirconium recovery of 99.95 per cent and a REE recovery of 87.5 per cent was established. REE loss with the zirconium product was 8.0 per cent and 4.5 per cent with the spent pregnant solution.

Aug 24, 2022

By G Corder

Even though most major operating companies in the minerals industry have Board-level endorsed sustainability principles and objectives, design engineers typically have no mechanism that allows them to implement those objectives in their work. In addition, the existing project management systems do not readily deliver the innovative solutions needed to address key sustainability issues, such as those related to significantly reduced carbon emissions, minimal environmental impacts, and maintaining the societal ‘licence to operate’. SUSOP® (SUStainable OPerations) is an approach for the integration of sustainable development principles into the design of mineral processes, which has been developed through the Co-operative Research Centre for Sustainable Resource Processing (CSRP). Somewhat analogous to the well entrenched HAZOP (Hazard and Operability) studies, SUSOP® is a holistic, systematic and rigorous mechanism for identifying and assessing sustainability opportunities and risks at each stage of project development - from corporate planning, through design and operation, to decommissioning and rehabilitation – without compromising financial rigour. SUSOP® was developed, tested and enhanced through its application to real case studies in the minerals industry. This development path provided significant insights into the process of identifying and evaluating opportunities for improving an operation’s contribution to sustainability and its long-term business case.This paper will discuss the need for a methodical approach for integrating sustainability principles into mineral processing plant design, present the key elements of SUSOP®, and outline its development path through real case studies. In addition, the reasons why such an approach will have growing importance into the future will be raised.

Aug 8, 2011

By T Peters

The Kibali Gold Mine is currently comprised of several open pits, a 3.5 Mtpa underground mine and a 7.5 Mtpa processing plant. Development of the underground operation commenced in December 2012, with initial access established through twin surface declines, followed by the commencement of a blind sink 8 m diameter rock hoist shaft in March 2013. Stope production started in December 2014 with ore and waste trucked to surface. The 755 m deep blind shaft sink was completed in August 2015 together with the cutting and equipping of three main station levels. Two of these levels provide access for the establishment of the underground materials handling system as well as the main dewatering system for the mine. This paper covers the process of determining the optimal location of the Kibali hoisting shaft relative to project-specific critical factors, and then focuses on the design and implementation journey associated with the off-shaft development that essentially encompasses the Material Handling System (MHS) for the mine. The journey starts from the findings of the previous owners Feasibility Study (FS), a subsequent Optimised FS, followed by detailed engineering through to implementation. It was identified during implementation that a significant change in the designed off-shaft layout was required following detailed underground geotechnical and hydrogeological investigations. In addition, the paper provides details on the MHS performance since commissioning to steady state, and on key learnings relating to the overall project process.

Mar 29, 2023

Upgrading of Indonesia's Bauxite by Washing Method There were eight bauxite samples used in this research, three samples from Kijang contain total SiO2 18.36 - 29.16 per cent, Al2O3 40.12 - 48.36 per cent, Fe2O3 4.27 - 5.13 per cent, one sample from Tayan, contains total SiO2 4.69 per cent, Al2O3 38.95 per cent, and Fe2O3 19.67 per cent, and four samples from Mempawah contain total SiO2 33.5 - 44.8 per cent, Al2O3 29.8 - 35.9 per cent, Fe2O3 7.29 - 9.88 per cent. All of those bauxite ores have not fulfilled the requirement for Bayer process yet; therefore simple up-grading using a rotary drum scrubber is needed. The scrubbing process was carried out with time variable up to 60 minutes with solid percentage applied was 50 per cent and rotary speed was set up 30 rev/min. The bauxite was washed by following steps: scrubbing, screening, drying, and finally it was analysed to show chemical content. The washed bauxite produced has size fraction that is retained on the 1.7 mm of screen opening. The result of the research shows that the higher alumina content of the raw bauxite, the longer washing time is needed moreover the higher quality of the washed bauxite is produced. The highest alumina content of the washed bauxite was 53.67 per cent with the alumina recovery was 89.66 per cent and the concentration ratio of 84.80 per cent was achieved within 20 minutes of washing time of the raw bauxite (Al2O3 48.36 per cent). The washed bauxite resulted from this research is suitable as a raw material for Bayer process.

Sep 13, 2010

By M Uceda, E Guerra, Y Choi, J L. Shepherd

In this paper we describe the leaching characteristics of pure gold in thiosulfate solutions that contain a known chelator; meso-2,3-dimercaptosuccinic acid (DMSA). The interfacial and chemical characterisation of the system was accomplished using both electrochemical methods and inductively coupled plasma mass spectrometry (ICP-MS) analysis after pure gold samples were exposed to solutions composed of 65 mM Na2S2O3, 1 mM NaOH and a range of DMSA concentrations. In the absence of DMSA, cyclic voltammetry revealed the onset of thiosulfate mediated gold dissolution, the degree of which was reduced at more positive potentials due to the formation of oxidised thiosulfate products on the gold surface. The addition of small amounts of DMSA (<10 ¦M) to the electrolyte resulted in minor changes to the voltammograms indicating a subtle interaction of the additive with the gold surface that may improve leaching. However, at higher concentrations of DMSA (up to 100 ¦M), electrochemical evidence suggests the formation of new oxidation products in solution as well as the formation of more compact monolayers of DMSA on the surface, which contribute to partial repassivation of the surface. The influence of DMSA on thiosulfate leaching of pure gold electrodes at the open circuit potential for a period of 90 minutes was tested and the corresponding gold leaching performance evaluated with ICP-MS analysis. Our data shows that small amounts of DMSA (1 ¦M) doubled the amount of total gold in solution when compared to the same study in the absence of the additive. However, higher concentrations (5 ¦M DMSA) reduced the overall amount of dissolved gold. These results may point to a mechanism where small amounts of DMSA improve leaching by adsorbing onto the surface in a highly defective monolayer that partially blocks or disrupts the formation of passivation products caused by thiosulfate oxidation, but excess DMSA can limit the leaching process itself by forming too coherent a monolayer on the gold surface.CITATION:Uceda, M, Choi, Y, Shepherd, J L and Guerra, E, 2013. Investigating the influence of meso-2,3-dimercaptosuccinic acid on thiosulfate leaching of bulk gold electrodes, in Proceedings World Gold 2013 , pp 207-214 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 26, 2013

During 2009 the technical services staff at Barrick Gold Corporation's Australian Business Unit conducted a review of their five underground mines that utilise pastefill as the backfill component for these operations. Of the five mines reviewed three use dry tailings and two use wet tailings plants. The primary aim for these reviews was to determine whether pastefill was the right option to be used, and if not, what where the alternatives. The reviews undertaken focus on several areas including, paste plant operation, reticulation and barricade techniques, the geotechnical requirements for pastefill in regards to the current mining methods, the consideration of alternative methods, capital and operating cost histories compared to initial estimates, and a cost benefit analysis of pastefill against other mining methods. The main benefits from the use of pastefill is increasing the extraction of the resource, reducing or eliminating the need to leave pillars. In some mines the use of pastefill is geotechnically driven, to manage high stress environments or mining induced seismicity. A third benefit of using pastefill in some circumstances is that it reduces dilution, however it is considered that this is not a valid argument for most of the mines reviewed. At two mines no alternative to pastefill was determined, whilst differing extraction and filling strategies were potentially identified at the other three mines. The reviews developed cost benefit curves for those sites that had alternative mining methods to assist in determining whether pastefill is the right option to use for any particular stope. At the grades typically mined in each operation, pastefill was the preferred option to use. In all mines, pastefill was determined to be the best option at this time.

Nov 25, 2010

By B Jones, M Chappell

Installing ground support correctly is not an easy task, whether lack of operator training, poor ground conditions or underperforming equipment. Confirming the quality of installation can help with planning and remedial works and help to maintain a safe working environment. A 2?m bolt with 700?mm of encapsulation will pass a 10?t pull test (assuming ground conditions permit); however, it will not provide any data of the unencapsulated length and thus the ability to withstand corrosion. Complimentary testing in the form of non-destructive testing (NDT) can provide factual data that leads to the assessment of the quality of the encapsulation. By improving the quality of the encapsulation, the risk of corrosion is reduced, the ground support durability is improved and hence the asset life is enhanced.This paper presents a case study of a trial using the NDT system RokTel™. Installations of varying quality were installed and tested. The characteristics tested were corrosion, load and free length. These characteristics can be tested and assessed for cable bolts, thread bar bolts and split sets. The aim of this paper is to present NDT testing as a viable method for assessing installation quality and ongoing performance of the ground support.CITATION:Jones, B and Chappell, M, 2014. A non-destructive testing method for measuring bolt condition, in Proceedings AusRock 2014: Third Australasian Ground Control in Mining Conference , pp 307–314 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 5, 2014

By I Auranen, J Raatikainen

IMA Engineering (IMA) and Mine On-Line Service (MOLS) companies have used on-line sensors for analysing ore and waste rock in mining for more than 25 years. Today IMA on-line sensors are used in various stages of the mining process including on-line analysis of drill cores, drill chips, ore and waste in loader bucket, ROM ore analysis on belt conveyor belt and in bulk ore sorting and in slurry analysis in concentrators. During years of extensive field experience and testing we have found that the waste rock dilution and ore losses create much larger economic and environmental losses than has been previously recognized. According to our studies the main reason is limited number of analysis already in exploration when drill cores or drill cuttings are used in block modelling. The same happens in production because too few and biased samples from benches are used to estimate the ore grade. Much more than today estimated amount of waste enters the mill and considerable volumes of ore losses happen at the same time. The ore grade on the benches and in muck piles is averaged and “homogenized” with averaged and biased samples. These are the main root causes of waste rock dilution and ore losses. Sensor based preconcentration can be the remedy to waste rock dilution and ore losses. This presentation will show examples of the use of on-line sensors in preconcentration when analysing ore and waste rock in drill cores, drill cuttings, on conveyor belt and in bulk ore sorting. Waste rock removal in preconcentration has direct effect on energy consumption in crushing and grinding and chemicals in concentrator. In concentrator waste is separated and goes to tailings pond, however, preconcentration directly reduces the volume of the tailings. In our presentation we will cover cases in base metals and in gold mines.

Nov 10, 2020

The words ""Uncertainty"" and ""Risk"" pervade every discussion about mining exploration and investment. Perhaps these terms are subjectively understood by industry professionals, but objective portrayal of these concepts outside the industry is a woefully undeveloped science. This paper addresses current industry understanding and practice regarding quantitative risk assessment techniques, and provides examples of the application of three of these techniques. Probabilistic techniques for financial risk assessment are valuable adjuncts to conventional financial analysis, and address a range of issues not assessable by any other means. The value of whole-of-project probabilistic risk assessment is currently debatable for decision-making purposes, but is seen as important as a mechanism to focus attention to the critical issues that ultimately impact on project success. The dissection of project capital into risk and non-risk components provides valuable insights into risk characteristics not readily quantifiable in any other way. This technique also provides a framework for more objective ""what if?"" scenario evaluation and for the capital structure of resource projects. Finally, mechanisms for the valuation of undeveloped reserves are examined, and guidelines suggested. The importance of reliability in production cost estimates is highlighted and the impact of early development on reserve valuations is discussed. The importance of economics throughout all stages of the evaluation process is fundamental.

Jan 1, 1994

BHP-Utah Coal Limited operates 33 draglines of varying sizes in the Bowen Basin of Central Queensland. The group's operations with draglines commenced in 1963 with the establishment of opencut operations at the then TPM Moura Mine and continued through expansion of that mine, the commissioning of the Utah Development Company Blackwater Mine in 1968, and the subsequent establishment of six (6) other large opencut mines, all in the general area over the next fourteen years. These operations generally commenced with boxcuts on the sub-crop at depths of 15 to 25 metres. Over the years, depths have increased so that average depths now are in the 45 to 50m range. It was soon realised that dragline operations would have to be supplemented with additional stripping equipment. In 1981, a symposium "45m and Beyond" was held in Rockhampton to assess the problems associated with such "deep" stripping. Subsequently, dragline operations have continued and although addi- tional stripping capacity has been added, in many instances, draglines have been used and are being used to dig depths greater than 45m, some- times as much as 65 to 70m.

Jan 1, 1989

By M L, G Maddocks, A Ferrier, ers, A Forbes

Evolution’s Mount Rawdon Operation (MRO) produces gold and silver through open pit mining methods. The mining operations are scheduled to be completed in FY24 (Financial Year 2024), after which low-grade stockpiles will be processed until the end of FY27. As part of MRO’s Progressive Rehabilitation and Closure Plan (PRCP), RGS Environmental Consultants (RGS) and Deswik were engaged to develop the final landform surface and a whole of site probabilistic water balance/water quality (WB/WQ) model to evaluate the viability of several closure options with respect to water quality in the various site water storages, particularly the final void which will form a pit lake. This case study details the closure option which included (amongst other things) covering the final landforms and directing water toward or away from the final void post closure. Closure and rehabilitation for MRO had previously been planned and evaluated on a ‘domain’ basis. Furthermore, the rehabilitation plans and final water management plans for the Tailings Storage Facility (TSF), Waste Rock Storage Facility (WRSF) and other domains were not coordinated, possibly resulting in competitive rehabilitation material requirements at the commencement of closure activities. An assumption was that a legacy non-acid forming (NAF) stockpile would provide sufficient material to both supplement ex-pit material for the construction of the TSF embankment raises and to complete all closure activities, but the volumes available and the volumes required to complete the closure activities had not been quantified.

Aug 2, 2023

By R Wei, Y Peng, D Seaman

This study addresses a widespread problem confronting the mining industry: the deleterious effect of clay minerals in flotation. This problem is seemingly exacerbated by the presence of iron contamination from grinding media. The interaction of clay minerals and grinding media in copper and gold flotation was investigated in this study. A low-clay ore and a high-clay ore were obtained from Telfer to represent different contents of clay minerals, while stainless steel and mild steel grinding rods were used to produce different grinding chemistry, in particular, iron contamination. Flotation tests on an unsized and sized basis were conducted to reveal how clay minerals and grinding media affect copper and gold flotation. Iron contamination and the oxidation of copper minerals were quantified by ethylene diamine-tetra acetic acid (EDTA) extraction. It is interesting to find that both clay minerals and iron contamination depressed the flotation primarily in fine particles smaller than 33 ¦m, and clay minerals played a dominant role. Although flotation of coarser particles greater than 33 ¦m was less affected by clay minerals and iron contamination, coarser grinding to increase P80 was not an effective way to improve copper and gold flotation for the high-clay ore. This study suggests that to improve copper and gold flotation from clay ores, clay dispersion in conjunction with the minimisation of iron contamination may be required.CITATION:Wei, R, Peng, Y and Seaman, D, 2013. The effect of grinding media on copper and gold flotation in the presence of clay minerals, in Proceedings World Gold 2013 , pp 283-288 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 26, 2013

Mobile mining equipment presents only a small portion (ten per cent mining project costs but the selected technology will determine to a large extent the mining performance and mine profitability. The actual performance of the selected mobile equipment technology will rely on the support functions, infrastructure, user interface and user acceptance. Optimising the technology to match the circumstances is an increasingly important phase in a mine feasibility study. Smartly done feasibility studies include the possible future needs of changing or building-up of the selected technology. In massive mining applications the machinery faces quite different challenges than in selective or small-scale mining applications. In massive mining applications the efficient and continuous move of large amounts of material has led to the use of increasing degree of automation. This higher degree of automation in a mining application, on the other hand, will be best applied to a smooth and streamlined mining process and operation. Mining methods like block caving support automated operation. Automated mobile equipment needs supportive infrastructure, monitoring and information transfer systems as well as well established working procedures. Too often the user interface and human factor is disregarded during the consideration of automation. Through the available supplier programming tools it is possible to see how much the selected technology provides flexibility in changing production or economical situations, when major rebuilds or replacements are necessary, and view the effects of all these on the mine economy. When adequate technology is available from various sources, the difference becomes from preparing for the future, managing costs and combining the best layout with the most suitable technological solutions.

Jan 1, 2000

By L Neems

In conjunction with Orica Explosives, Worsley Alumina have managed a program of continuous improvement to their cap rock blasting over the last two years. Blasting conditions are challenging because of the hard and shallow nature of the material. Blasting costs must be controlled and the environmental consideration of noise and dust is critical. Worsley have sought to determine the optimum balance between drilling and blasting costs and fragmentation. As the cap rock has few inherent weaknesses, loader productivity is strongly controlled by the degree of fragmentation from blasting. The optimum blasting solution is also constrained by maintaining airblast levels at the surrounding residences below 115 dBL . The major blast design parameters optimised during the program were stemming type, stemming length, powder factor and blasthole diameter. A series of carefully managed trial blasts were fired during 1997 and 1998 to quantify the effect of these parameters. Fragmentation was digitally measured using OricaÆs Powerseive G technique. Shovel productivity, airblast levels and blasting costs were also quantified. As a result of the project, Worsley now have an increased knowledge of the key parameters driving blast performance, and their consequent impact on downstream processes, the environment and total mining cost.

Jan 1, 1999

By A Roudnev, P Loderer

Mineral froth pumping utilising centrifugal slurry pumps is a major engineering challenge for both the end users and pump manufacturers. The traditional approach has been to oversize the pump for pumping mineral froth. New horizontal slurry froth pump designs offer opportunities to improve froth pumping capability of mineral froth with challenging (high) Froth Volume Factor while maintaining high efficiency, long wear life and stable pumping performance.CITATION:Loderer, P and Roudnev, A, 2018. A reliable solution for pumping mineral froth with challenging froth volume, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 291–296 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

By G R. Ballantyne, G Lane

Dry milling circuits that include high pressure grinding rolls (HPGR) or vertical roller mills (VRM) and air classification have replaced dry ball milling in cement production, but how do they compare to wet milling and classification circuits in mineral processing plants? Two case studies are presented that compare the energy efficiency, wear, liberation and capital cost of dry and wet milling circuits. In both case studies the VRM and HPGR consume half the energy of a wet tumbling mill for the same duty. However, the dry classification system tends to significantly erode the energy benefits. A number of improvement opportunities are presented that have the potential to improve the energy and capital efficiency of dry milling circuits. These improvement opportunities focus on the dry classification system that consumes significant energy in heating and fan power requirements and requires a large proportion of the footprint.

Aug 24, 2022