Search Documents

By G Sartor, A Rich, D Grimsey, R Forzatti, M White

An in-depth process model was developed for the pyrometallurgical, off-gas systems and water balance of the Kalgoorlie Nickel Smelter. This model was used to assess plant capacity with changing concentrate grades, increased throughput and tighter environmental emissions under a range of potential future operating conditions. Comparison of modelled results allowed for flow sheet optimisation across a range of metrics including sustainability, processing capacity and costs. Process modelling software, METSIM® (ver 2020.06 by METSIM International), was used to simulate the flash furnace, integrated electric slag cleaning furnace, Pierce-Smith converters, matte granulation, waste heat boiler, hot gas handling equipment, wet gas cleaning plant and acid plant. The METSIM® model was divided into three separate, yet interconnected models: metals, off-gas and water balancing. This allowed for improved modelling efficiency and traceability while minimising manual error. The METSIM® model was supported by inputs from other specialised software. Chemical thermodynamics software, FactSage™ (ver 8.2 by GTT Technologies), was used to establish relationships for the flash furnace fluxing strategy and determine the operating temperature. Arena® (ver 16.0 by Rockwell Automation), a discrete event modelling software, was used to simulate material movements within the aisle as well as Pierce-Smith converter operation, allowing for integration with upstream and downstream systems. A dynamic data exchange (DDE) was used to connect the results of each software package, interfacing through Excel® (version 4203 by Microsoft). The integration between models provided a streamlined approach to test capacity, bottlenecks, water consumption and emissions under a range of operating conditions, enabling a more robust process. Further downstream modelling techniques were used to assess mechanical equipment. METSIM® outputs provided key parameters for combustion assessments using computational fluid dynamics and finite element analysis for the furnace mechanical design.

Aug 21, 2024

By A Markham

Stream diversions are a common feature of mine sites worldwide. From an operational perspective, a fundamental requirement of a stream diversion is that it should convey water flows between two points in a safe, controlled and predictable manner. On the other hand, rivers and waterways are naturally dynamic systems, and many of their natural values are achieved through their ability to alter their forms and processes over time in response to flow events - often in a potentially unsafe, uncontrolled and unpredictable manner. In order to ensure that diverted river reaches achieve the dual objectives of short-term operational stability and longer term physical equilibrium with surrounding landscapes, alteration of form and process must somehow be understood and incorporated into the design process. However, performance targets for waterways are not always easy to define and assessing what is good and bad in such variable systems can be difficult. This paper discusses the role of the stream diversion from the operational, environmental and regulatory/relinquishment perspectives, and how stream diversions must achieve physical stability in the short-term, but dynamic equilibrium in the long-term.CITATION:Markham, A, 2012. Mine site stream diversions - A balance of competing objectives, in Proceedings Life-of-Mine 2012 , pp 215-218 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 10, 2012

By Griffiths L, Marshall P

fhis paper describes investigations into drainage of gas from the solid to control outbursts. Initial studies conducted on drainage of shear zones showed that, given enough time, these can be successfully drained. Once drained, they can be intersected and driven through without any activity of outbursts. The results of programme of investigations to determine parameters for drainage from the solid show that gas flow rates from the Bulli Seam on the average are about 2 litres/min/metre length of borehole. But when shear zones are intersected, the flow rates could be as high as 8 litres/min/ metre length of hole. Shear zones can be picked up from pressure measurements 50 - 60 m away and this could give sufficient time to drill through these zones and drain them in advance. Systematic drainage of Bulli Seam at West Cliff Colliery could eliminate or reduce frequency of outbursts considerably. At present drainage holes are being drilled systematically in the seam, with drainage installations on the surface. Gas purity of 80% methane is being delivered at the surface plant.

Jan 1, 1980

A large scale distributed process con-trol system has been successfully applied to the automatic control of aluminium reduction cells at Boyne Smelters. A three stage hierarchy of minicomputers and microcomputers is used to continuously monitor and control conditions in each cell and to manage the data generated during the process.The automation hardware was purchased on the basis of low cost, high reliability, prior use in the aluminium industry and a high level of backup under failure conditions. The hardware has met performance criteria to date.The process control strategies have continually been updated to minimise the energy and raw material consumptions in each cell. A major change to systems software has recently been made to decrease the development time for-future changes. Various low energy potline retrofit alterations are currently being investigated requiring significant changes to the process control strategies.

Jan 1, 1985

Although the flotation cell has been under continuous development over the past 80 years, an understanding of the precise roles of a cell in produc- ing the flotation result had evolved slowly. In fact, detailed studies of cell dynamics began only in the 1940s when flotation practice had almost reached the half-century mark. The earliest generalizations related cell capacity to power intensity (hp/vol- ume) (Rose, 1946), and specific operating features such as aeration and power ' consumption to impeller submergence and operating speed (Read, 1933). In the 1950s hydrodynamic characterization of cells through power coefficients and air flow numbers began (Arbiter and Harris, 1961) and has continued to the present, with increasing industrial use of these concepts (Degner, 1982; Degner and Treweek, 1976). Liquid flow measurements in Wemco cells (Degner, 1982) made liquid flow numbers and turnover frequencies available for more complete under- standing of cell dynamics. The present overview of flotation technology is a critique of cell design. The cell process represents the interactions between cell dynam- ics, cell geometry, and ores, with the latter prepared for that interaction through size reduction and reagent treatment. While previous invest- igations of flotation cells have accepted all cell designs uncrit- ically, the present study considers the physical process components that an effective cell must provide, and then compares a limited number of

Jan 1, 1984

By D Blair, T Scutts, L Fergusson

This paper presents a waste rock treatment and rehabilitation program conducted at a metaliferous mine site in northern New South Wales from 2000–2013. It updates findings from 2005 for Program #1 (which examined acidity, leachable metals and tree growth in a control and three treated areas of waste rock) and includes new results for Program #2 (which examined acidity, plant uptake of metals and trace elements and tree growth in a control and four treated areas compared to undisturbed background levels) and Program?#3 (which examined the treatment and revegetation of submerged mine tailings and an exposed tailings beach).Program #1 showed low soil pH in the control area remained unchanged from years 1–14, and soil pH in the limed and capped areas was initially increased but fell back to starting levels within 12 months and remained low for 14 years. In contrast, soil pH in the Terra B area resulted in soil high pH immediately after treatment and increased in years six and 14 without further treatment. Tree height and density in 2005 and again in 2013 indicated acidity in the control, limed and capped areas suppressed tree height and density; however, in the Terra B area, revegetation in 2013 was comparable to undisturbed forest. Outcomes in the control, biosolids and three Terra B areas in Program #2 were similar to those observed in Program #1.Program #3 showed the submerged and exposed tailings initially had low pH and high concentrations of total and leachable metals before treatment, but these became non-leachable after treatment with Terra B. Revegetation was achieved on the tailings beach, with almost uniform colonisation of bulrush and common reed, along with bottlebrush and golden wattle; a variety of reptiles have also been observed on the revegetated tailings beach, along with migrating ducks, spoonbills and grebes.CITATION:Fergusson, L, Blair, D and Scutts, T, ?2014. Treatment and rehabilitation of acidic waste rock and tailings – a 14-year case study, in Proceedings Life-of-Mine 2014 , pp 247–260 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 16, 2014

By P Breuer, D J. Robinson, A McFarlane, L L. Kuhar

Increasing global demand for commodity metals and capital and the greater operating costs of mining and metal production present significant challenges for the metals mining industry. Current conventional technologies may not be feasible for processing deposits of declining grade, challenging mineralogy or those that occur at increasingly greater depths. To overcome these issues, the development of a step-change technology such as in situ recovery (ISR), which reduces mining and avoids milling costs, may be vital in ensuring future economic metal production. ISR has been used extensively to treat porous soft rock deposits such as the water-soluble salts, sylvite and halite. Although ISR has typically been used for mining conventionally uneconomic uranium ores, it has also been used less frequently for the treatment of other restricted permeability hard rock deposits, such as those containing copper and gold. The reason for the limited uptake of the technology for hard rock mineralisations is primarily due to low natural rock porosity and permeability and hence poor response to available lixiviant. However, additional challenges include solution containment, management of groundwater and regulatory, ecological and societal requirements and expectations. CSIRO has focused on understanding the challenges of hard rock ISR and identifying global capabilities that can contribute to developing the essential enabling technical areas required to realise ISR. Specific focus areas include geochemistry and advanced resource characterisation; drilling and controlled rock-breaking technologies; solution chemistry and environmentally benign lixiviant systems; lixiviant delivery systems and ‘subsurface mixing’; subsurface hydrology and reactive transport mechanisms and models; downstream processing options; legal, social and environmental aspects; and techno-economic modelling. This paper will discuss ISR challenges including industry feedback focused on addressing this issue, gaps preventing ISR from being applied in practice, capabilities to overcome these gaps and the development of a collaborative approach to making hard rock ISR a reality.CITATION:Kuhar, L L, Breuer, P, Robinson, D J and McFarlane, A, 2015. Making hard rock in situ recovery a reality, in Proceedings Third International Future Mining Conference, pp 189–196 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 4, 2015

The discovery since 1990 of four major orebodies in the Mt Isa Inlier - Century Zn-Pb, Osborne Cu-Au, Cannington Pb-Zn and Ernest Henry Cu-Au - only serves to enhance the already high stature of the Inlier in world mining importance. Currently the known mineral resources of the Inlier represent about 11 per cent of the world's Pb-Zn resources, five per cent of the world's Ag resources, and one per cent of the world's Cu resources. More can be expected to be added to these impressive figures given that two-thirds of the Inlier remains obscured by younger cover. Individually, projects such as Century and Cannington may ultimately achieve `world's best' status; Century's proposed production of 450 000 tpa of Zn metal would rank it close to number one with Cominco's expanded Red Dog project in Alaska. Cannington, with projected production of 660 tpa Ag, could become the world's biggest producer of silver. For comparison, Mt Isa produced 170 000 t of zinc metal and 335 t of silver in 1995. The apparent physical diversity of deposits in the Mt Isa Inlier is matched by a great diversity of opinion as to their origins. Because Ernest Henry is hosted by `porphyries', it is described by some as a porphyry copper deposit, despite mineralisation age possibly post-dating volcanic age by 200 Ma. Cannington Pb-Zn could be a Broken Hill-type (BHT) exhalitive deposit, or a late epigenetic replacement `regional skarn'. Mt Isa - Hilton Pb-Zn deposits appear to have experienced all deformational events and he syn-diagenetic in origin, or may have experienced little of the above and be epigenetic replacement deposits formed late in the major Isan orogeny, some 150 Ma after deposition.

Jan 1, 1996

The Australian Mineral Industry's growth in the last two decades is directly related to the skill and experience of its consultants in mining, metallurgy, geology, finance, management, marketing, and engineering. The role of mining consultants needs to be re-examined, so that the quality of the service they deliver will continue to be adequate for the 1990's. One means of this evaluation is by examining Case Studies in the strategies and difficulties of developing contract and entrepreneurial research.

Jan 1, 1986

By Johns D. R

The producers of mineral sands on the East Coast of Australia might be regarded as having a simple task of selling Rutile and Zircon. Such is not the case. Differing quality and grain size requirements plus the dramatic increase in the percentage of mineral sold in a processed form have meant a large increase in the number of different end products handled. The resulting sales control problems are compounded by the need to be able to deliver against a large number of separate contracts which may relate to spot or long term sales in small quantities or in bulk shipments. Methods of helping management control this situation have been devised and incorporated into a suite of computer programs. Experience with the approach has been very satisfactory. The effect of changes to shipping schedules, commitment to new or changed orders, or proposed changes to production can be evaluated as and when necessary with little bother. Confidence in decisions taken is high since the process of data collection has been designed to involve

Jan 1, 1977

By Grieve BL

For a blast to be successful both heave and fragmentation must be satisfactory. Amongst the major factors influencing blasting are rock properties. This paper considers the effect of rock density on fragmentation and heave and how better results can be achieved in dense ore. Patterns which increase the heave and give better fragmentation are examined and the application of theory to the blasting of the Dales Gorge Haematite, density 4.2 - 4.5 t.m.,3 is then discussed. The drilling of staggered patterns instead of square patterns and a shallower 'V' initiation system has given better heave and fragmentation. This practice has re- duced backbreak and improved toe conditions; these factors have resulted in increased load ing rates. There has been an increase in the lump/fine ratio which is consistent with the theory although other factors such as ground conditions could have contributed.

Jan 1, 1978

FOR some years past it has been usual to specify high-grade copper for use for many purposes, but the practice of specifying zinc of a high degree of purity for certain purposes is of comparatively recent origin. It is a practice, however, which is extending ag the effect of the impurities in zinc on products manufactured therefrom becomes widely recognized.The notes hereunder are intended to briefly survey the principal uses to which high-gr.ade zinc is being put, and, wherever possible, to indicate the effect of the impurities normally present in the lower grades of zinc.In the United States zinc is graded into five divisions, known respectively as "High-grade" "Intermediate" "Brass Special" "Selected," and "Prime Western." The maximum amounts of impurities allowed in the various grades are indicated in Table I,which is compiled from data published by the American Society of Testing Materials:In addition, it is specified in an cases that the slabs shall be reasonably free from surface corrosion or adhering foreign matter. Although zinc used in Europe has in many cases been sold on analysis it is only recently that any attempt has been made to grade...

Jan 1, 1923

By Mine F. J, Woods P. H

Waste waters from mine sites may be screened for all constituents of significance as a first step in establishing water quality criteria for protection of aquatic ecosystems. Inductively-coupled plasma mass spectrometry (ICP-MS) offers the capability to screen water samples and digest solutions for virtually all elements in the periodic table. This technique is therefore able to identify elements whose concentrations are elevated in waste waters and may be rarely present in background surface or ground waters. Such elements may be present in waters at only a few ¦g/L. ICP-MS has sufficient sensitivity to detect sub-¦g/L or even ng/L levels of many elements. Waste waters from most mining activities in the Northern Territory have been examined by ICP-MS. The concentration data provide the basis of a contaminant data base. The data can show specific tracers in the ore or mineral itself, subsequently found in waste water. An example is the presence of rhenium in uranium ore. Such trace elements may be present in soluble or insoluble chemical forms and are more useful as indicators when soluble and exemplifying conservative chemical behaviour. The approach described, based on ICP-MS screening of mine site waste waters, together with general physico-chemical variables, provides the most comprehensive means yet available of selecting variables for monitoring programs and ensures that key elements and/or their chemical species are not excluded from monitoring programs.

Jan 1, 1994

By X X. Qiu, T Zhang, B L. Wang, X Qiu, Y H. Du

This paper summarises the information about current state of eco-environmental problems, geological disaster and mining waste causing during the process of limestone mining. By comparing the management experiences of limestone mines in other countries, management problems in China have been discussed and improved management options have been proposed here. These options include: accelerating the process of legislation, promoting and strengthening environmental impact assessment for limestone mine, and increasing compensation requirements according to the local eco-environment conditions.CITATION :Wang, B L, Qiu, X X, Qiu, X, Zhang, T and Du, Y H, 2012. Eco-environmental problems caused by the process of limestone mining and management options, in Proceedings Life-of-Mine 2012 , pp 357-360 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 10, 2012

By J Isarua, R Mabiria

The Ok Tedi copper and gold project, located in the Western Province of Papua New Guinea, commenced operations in 1983. The open cut mine has undergone several significant transformations throughout its project life including changes of ownership, mine life extensions and varying production performance profiles. As of today, the Ok Tedi Mine is a 100 per cent PNG owned company (67 per cent State and 33 per cent Western Province and Communities) and has a life-ofmine plan extending out to about 2032.

May 5, 2022

By A Larsson, K Niiranen

The Palaeoproterozoic Leveäniemi iron oxide apatite (IOA) deposit of the so-called Kiruna type is currently mined by Luossavaara-Kiirunavaara AB (publ.), commonly known as LKAB. The mineralogy of iron oxides, ie magnetite, hematite, maghemite, and goethite is more complicated compared to the neighbouring and more famous IOA deposits of Kiirunavaara and Malmberget. Furthermore, the mineral chemistry of the iron oxides in the Leveäniemi deposit is also slightly different. Especially, the information about the deportment of titanium and vanadium in iron oxides and distribution in the deposit is essential since they can have an impact in the steelmaking process. For this study 50 samples were selected from exploration drill cores and investigated by optical microscopy, FE-SEM-EDS and EPMA at LKAB and the Geological Survey of Finland. Investigations revealed that magnetite is the predominant iron oxide mineral with secondary hematite being the second most abundant mineral. Primary hematite, maghemite, and goethite seem to be less abundant. It should be noted, however, that this investigation focused on magnetite which currently is the only mineral with economic value. Vanadium occurs as a substitution element in the crystal lattice of iron oxide minerals in the Leveäniemi deposit and not as discrete stochiometric vanadium minerals. In the investigated samples vanadium concentration in magnetite ranges from 0.12 to 0.32 wt per cent V2O3 with higher concentration in the southern part of the deposit. Contrary, titanium does not substitute for iron in the crystal lattice of magnetite or secondary hematite (less than 0.018 wt per cent TiO2). It either occurs as tiny inclusions of titanium oxide minerals or as exsolution lamellae of ilmenite in magnetite. The spatial distribution for titanium in the deposit, however, remains unknown. Furthermore, results of this study indicate that alteration of primary magnetite to secondary hematite has had no significant effect on the trace element chemistry of these minerals in the Leveäniemi deposit.

Nov 8, 2021

By E Thomas, L McCallum, G Dale, J Bennett, K Reardon-Smith, S Raine

Sustainable closure of coal mines in Australia to a safe, stable, non-polluting condition remains one of the industry’s biggest environmental and social challenges. A significant proportion of mines in the Bowen Basin of Queensland have dispersive spoil. Based on an estimated area of 20,000ha and a rehabilitation cost of AUD$100,000 to AUD$150,000/ha, the instantaneous rehabilitation liability for the Bowen Basin alone is estimated at AUD$2 to $3 billion.Dispersive spoils present problems in post-mining rehabilitated landforms due to increased potential for surface and tunnel erosion, compromising the ability to achieve fundamental mine closure objectives of a safe, stable, non-polluting and self-sustaining post-mining landform (Minserve, 2004). Dispersion results in clay particles being mobilised and transported in water, even at low flow velocities (So et al., 1998; Minserve, 2004), and blocking of soil pores, resulting in surface sealing, crusting and reduced permeability (DNR, 1997; Vacher et al., 2004) which, in turn, further increases runoff (Dang et al., 2018).CITATION:Dale, G, Reardon-Smith, K, Thomas, E, Bennett, J, McCallum, L and Raine, S, 2018. A process-based approach to mine rehabilitation decision making using Bayesian modelling and risk-based principles for dispersive spoil rehabilitation, in Proceedings Life-of-Mine 2018, pp 106–109 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 25, 2018

By B Ganesia, H Sahupala

PT Freeport Indonesia is a copper-gold mine operation located in West Papua, Indonesia about 3500 km east of Jakarta. Current ore production is about 270 000 tpd, of which 30 000 tpd comes from underground. In the future, the production from underground will be gradually increased to reach a maximum of 115 000 tpd, as the Grasberg open pit production decreases. The current and future challenge for PT Freeport Indonesia is to fill the quota of underground miners, as Indonesia does not have a long culture of underground work. At present, there are only three active underground mines in Indonesia. The lack of underground skilled labour incited the company to develop its own skilled workforce. In the mean time, to overcome the shortage of personnel, the underground management had to find a way to improve the productivity. Since 21 May 1998, PT Freeport Indonesia Underground Mine has operated with the new roster of two rotating shifts a day, 11 hours per shift. The previous schedule consisted of three nine-hour shifts per day, six days a week, for a total of 26 working days in a month. This change was intended to increase the productivity of the miners. With the previous roster, studies determined that the effective working time was only seven hours per shift. The new roster produces an improvement of effective working hours to about nine hours per shift. As a result, total production has increased by 33 per cent and the utilisation of production equipment has increased by 16.5 per cent. This paper describes the background of the decision to change the work schedule, the study carried out to evaluate the benefits and drawbacks of the new shift roster, the challenges, and then compares the results for various parameters between the old schedule and the new one.

Jan 1, 2002

The State of New South Wales is highly favoured in having vast deposits of coal adjacent to and within easy reach of the coastal Ports. Not only is the quality of the fuel generally superior to any found in the other States, but it is greater in extent than in any other part of the Continent. For interesting and reliable details of the history of the discovery of coal, the geology of the coal bearing strata, analysis of the various coals and other valuable data, the readers are referred to the book recently issued by the New South Wales Government, entitled The Mineral Resources of New South Wales, by Edward F. Pittman, A.R.S.M., etc., by the direction of the Hon. T. L. Fegan, Minister for Mines. The mining community is indebted to the Minister for having had published the most valuable condensed record of the mineral resources of the State extant.For the purposes of this paper we will only give such a general description of the coal fields as will make it intelligible in connection with the subject of the coal mining in the State of New South Wales.

Jan 1, 1904

By R R. Lovel, G J. Sparrow

Currently there are large reserves of good quality iron ore near to existing infrastructure that are not being developed because the phosphorous levels are above acceptable market specifications. Since the high phosphorous content is considered to be mainly associated with the goethite fractions of the ore, attempts were made to leach the phosphorous from the ore after a heat treatment to dehydroxylate the goethite. Heating the ore and leaching with 40 g/L NaOH lowered the phosphorous levels from 0.145 wt per cent P to 0.075 wt per cent P or lower, but a heating temperature over 800¦C was required to achieve this reduction in phosphorous levels. However, when sodium hydroxide was added to the iron ore before the heat treatment, similar phosphorous removal was achieved with a heating temperature of 300 - 350¦C. It was considered that dehydroxylation of the goethite in the presence of the hydroxide makes the phosphorous available for removal with a water leach. As well, 50 per cent of the silica and 60 per cent of the alumina in the ore were also removed in the leach, but some sodium remained in the leach product. Further work is required to remove the residual sodium to produce a marketable product.

Jan 1, 2009